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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of Australian Provisional Patent Application No. 2014905148 entitled “A MARKMANSHIP AID” and filed on 19 Dec. 2014, the content of which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present disclosure relates to a device for aiding marksmanship, and a method of use thereof. In a particular form the present disclosure relates to a device for teaching the principle of leading a target.
BACKGROUND
[0003] When shooting a moving target, the shooter must, in order to hit the target, actually shoot at a distance in front of the target that will cause the shot from the firearm to intersect the trajectory of the target at the same instant that the target arrives at that point.
[0004] To hit the target the shooter must apply what is commonly known as lead′; lead is the distance the shooter must shoot ahead of the target to allow for the time it takes for the shot or bullet to travel from a muzzle of the firearm to the point of intersection with the trajectory at the moment that target is at that point, and thus to hit the target.
[0005] New and intermediate shooters have great difficulty estimating how much lead to give a target, as it is very difficult for them to comprehend that one must shoot so far in front of a target to hit it. This fact leads to a situation where a new or intermediate shooter can find it very difficult to hit a moving target. This provides shooters (and coaches) with a great challenge, as they struggle to give greater and greater lead to the target. This is perhaps the biggest challenge in shooting at a moving target, and is probably the biggest cause of shooter frustration.
[0006] Once a shooter is coached to be able to hit a target requiring a long lead, it is difficult for the shooter to be able to reproduce that lead. That is, they hit the target but then cannot do it with consistency. This leads to great confusion and makes it difficult for the coach to be able to keep the shooter on track.
[0007] It is against this background and the problems and difficulties associated therewith that the present disclosure has been developed.
[0008] Certain objects and advantages of the present disclosure will become apparent from the following description, taken in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present disclosure is disclosed.
SUMMARY
[0009] According to a first aspect of the present disclosure, there is provided a device for aiding marksmanship, the device comprising a base securable to a firearm, a compensating sight spaced apart from the base to at least a side of the firearm and positionally adjustable with respect to the base, wherein in use, the compensating sight is so positioned with respect to the base (and thus a muzzle of the firearm in turn) that when the firearm is aimed at a moving target via the compensating sight an appropriate amount of lead is applied to the target.
[0010] The term “target” as used herein is intended to describe any moving object, living or inanimate, at which a shooter is aiming and therefore includes game and clay targets.
[0011] In one form, the base of the device is movable along, and securable with respect to, a barrel of the firearm.
[0012] In one form, the base comprises a frame comprising an aperture for receiving the barrel of the firearm there-through.
[0013] In one form, the base comprises a clamping means for locking a position of the base with respect to the firearm.
[0014] In one form, the base may be interchangeable to accommodate firearms of distinctly different types.
[0015] In one form, the compensating sight is a part of a compensating sight assembly.
[0016] In one form, the compensating sight assembly comprises an adjustment means providing a lateral (i.e. sideways) movement at least, of the compensating sight relative to the barrel of the firearm.
[0017] In one form, the adjustment means further provides a longitudinal (i.e. lengthwise along the barrel) movement of the compensating sight relative to the barrel of the firearm.
[0018] In one form, the compensating sight assembly comprises a further adjustment means providing a normal (i.e. vertical, or up and down) movement of the compensating sight relative to the barrel of the firearm.
[0019] In one form, the compensating sight assembly comprises the base, a carriage depending from the base, a wing mount depending from the carriage, a wing depending from the wing mount, and the compensating sight depending from the wing.
[0020] In one form, the base comprises a normally (relative to the barrel) extending track along which the carriage is positionable. In this way, the above mentioned ‘further adjustment means’ is provided.
[0021] In one form, the wing mount is pivotable with respect to the carriage, and about a longitudinal (relative to the barrel) axis.
[0022] In one form, the wing is pivotable with respect to the wing mount, and about a normal (relative to the barrel) axis. In this way, the above mentioned ‘adjustment means’ is provided.
[0023] In one form, the compensating sight comprises a bead. In one form, in an alternative, the compensating sight may comprise an optical or laser sight.
[0024] In one form, the device comprises a compensating sight assembly to either side of the base.
[0025] According to a second aspect of the present disclosure, there is provided a method for using the above described device to shoot a moving target, the method comprising the steps of setting a position of the compensating sight relative to the base based on characteristics of the target, and following the trajectory of the target while sighting the target via the compensating sight until the target is hit.
[0026] A detailed description of one or more embodiments of the disclosure is provided below along with accompanying figures that illustrate by way of example the principles of the disclosure. While the disclosure is described in connection with such embodiments, it should be understood that the disclosure is not limited to any embodiment. On the contrary, the scope of the disclosure is limited only by the appended claims and the disclosure encompasses numerous alternatives, modifications and equivalents. For the purpose of example, numerous specific details are set forth in the following description in order to provide a thorough understanding of the present disclosure.
[0027] The present disclosure may be practiced according to the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the disclosure has not been described in detail so that the present disclosure is not unnecessarily obscured.
BRIEF DESCRIPTION OF DRAWINGS
[0028] Embodiments of the present disclosure will be discussed with reference to the accompanying drawings wherein:
[0029] FIG. 1 is a perspective view of a device for aiding marksmanship according to a first embodiment of the present disclosure;
[0030] FIG. 2 is a perspective view of a base from the device of FIG. 1 ;
[0031] FIG. 3 is a plan view of the base of FIG. 2 ;
[0032] FIG. 4 is a side view of the base of FIG. 2 ;
[0033] FIG. 5 is a perspective view of a pair of carriages (comprising a left hand side carriage, and a right hand side carriage) from the device of FIG. 1 ;
[0034] FIG. 6 is a front view of the carriages of FIG. 5 ;
[0035] FIG. 7 is a plan view of the carriages of FIG. 6 ;
[0036] FIG. 8A is a perspective view of a left hand side wing mount from the device of FIG. 1 ;
[0037] FIG. 8B is a perspective view of an alternative embodiment of a left hand side wing mount from the device of FIG. 1 ;
[0038] FIG. 9A is a perspective view of a right hand side wing mount from the device of FIG. 1 ;
[0039] FIG. 9B is a perspective view of an alternative embodiment of a right hand side wing mount from the device of FIG. 1 ;
[0040] FIG. 10 is an end view of the left hand side wing mount of FIG. 9 ;
[0041] FIG. 11 is a side view of the left hand side wing mount of FIG. 8 ;
[0042] FIG. 12 is an underside view of the right hand side wing mount of FIG. 9 ;
[0043] FIG. 13 is a perspective view of a left hand side wing from the device of FIG. 1 ;
[0044] FIG. 14A is a plan view of a dial face from the wing of FIG. 13 ;
[0045] FIG. 14B is a plan view of an information panel comprising a dial face from FIG. 14A with additional information;
[0046] FIG. 15 is a perspective view of a right hand side wing from the device of FIG. 1 ;
[0047] FIG. 16A is a plan view of a dial face from the wing of FIG. 15 ;
[0048] FIG. 16B is a plan view of an information panel comprising a dial face from FIG. 16A with additional information;
[0049] FIG. 17 is an underside view of the wing of FIG. 15 ;
[0050] FIG. 18 is a side view of the wing of FIG. 15 ;
[0051] FIG. 19A is a perspective view of a clamp base from the device of FIG. 1 ;
[0052] FIG. 19B is an alternative perspective view of a clamp base from the device of FIG. 1 ;
[0053] FIG. 20 is a perspective view of a clamping screw from the device of FIG. 1 ;
[0054] FIG. 21A is a perspective view of a movable jaw from the device of FIG. 1 ;
[0055] FIG. 21B is an alternative perspective view of a movable jaw from the device of FIG. 1 ;
[0056] FIGS. 22 through 25 illustrate the device in use for shooting a moving target;
[0057] FIGS. 26 and 27 illustrate the device in different positions along the barrel;
[0058] FIG. 28 is a perspective view of a device for aiding marksmanship according to a second embodiment of the present disclosure;
[0059] FIG. 29 is a perspective view of a base from the device of FIG. 28 ;
[0060] FIG. 30 is a plan view of the base of FIG. 29 ;
[0061] FIG. 31 is a side view of the base of FIG. 29 ;
[0062] FIG. 32 is a perspective view of a pair of carriages (comprising a left hand side carriage, and a right hand side carriage) from the device of FIG. 28 ;
[0063] FIG. 33 is a front view of the carriages of FIG. 32 ;
[0064] FIG. 34 is a plan view of the carriages of FIG. 32 ;
[0065] FIG. 35 is a perspective view of a left hand side wing mount from the device of FIG. 28 ;
[0066] FIG. 36 is a plan view of the left hand side wing mount of FIG. 35 ;
[0067] FIG. 37 is a perspective view of a right hand side wing mount from the device of FIG. 28 ;
[0068] FIG. 38 is an end view of the left hand side wing mount of FIG. 35 ;
[0069] FIG. 39 is a side view of the left hand side wing mount of FIG. 35 ;
[0070] FIG. 40 is an underside view of the left hand side wing mount of FIG. 35 ;
[0071] FIG. 41 is a perspective underside view of a left hand side wing mount of FIG. 35 ;
[0072] FIG. 42 is a perspective view of a left hand side wing from the device of FIG. 28 ;
[0073] FIG. 43 is a plan view of an information panel from the wing of FIG. 42 ;
[0074] FIG. 44 is a plan view of a dial face from the information panel of FIG. 43 ;
[0075] FIG. 45 is an underside view of the wing of FIG. 42 ;
[0076] FIG. 46 is a side view of the wing of FIG. 42 ;
[0077] FIG. 47 is a perspective view of a right hand side wing from the device of FIG. 28 ;
[0078] FIG. 48 is a plan view of an information panel from the wing of FIG. 47 ;
[0079] FIG. 49A is a perspective view of a clamp base from the device of FIG. 28 ;
[0080] FIG. 49B is an alternative perspective view of a clamp base from the device of FIG. 28 ;
[0081] FIG. 50 is a perspective view of a clamping screw from the device of FIG. 28 ;
[0082] FIG. 51A is a perspective view of a movable jaw from the device of FIG. 28 ; and
[0083] FIG. 51B is an alternative perspective view of a movable jaw from the device of FIG. 28 .
[0084] In the following description, like reference characters designate like or corresponding parts throughout the figures.
DESCRIPTION OF EMBODIMENTS
[0085] Referring now to FIG. 1 , there is shown a first embodiment of a device 1 for aiding marksmanship, the device comprising a base 2 which is securable to a firearm 100 , by way of the base 2 comprising a frame 4 surrounding an aperture 6 for receiving a barrel 102 of the firearm 100 there-through.
[0086] The base 2 is configured for use with a barrel 102 of an over and under type shotgun 100 . It should be appreciated that the device 1 could be fitted to a rifle, or configured for use with a side by side type shotgun, or any other firearm type, by use of a base shaped for fitment to that particular firearm type.
[0087] With reference to FIGS. 1 through 4 , it can be seen that the base 2 is an assembly comprising a clamping means 7 for clamping the device 1 to the barrel 102 of the firearm 100 . This clamping means 7 comprises a clamp base 10 (see FIGS. 19A and 19B ) which comprises a tooth portion 101 which slidably engages with a channel 11 in the frame 4 and is secured (by way of snap fit in this case) to the frame 4 , a clamping screw 12 with a handle 13 (see FIG. 20 ) threaded through the clamping base 10 , and a movable jaw 14 (see FIGS. 21A and 21B ) secured to an end of the clamping screw 12 so as to be driven to provide clamping force to the barrel 102 with clockwise rotation of the clamping screw 12 , and outwards with counter-clockwise rotation of the clamping screw 12 to release the barrel 102 . Alignment pins 141 insert into guide holes 108 (shown in FIG. 19A ) to guide movement of the movable jaw 14 relative to the clamping base 10 .
[0088] The open U-shape of the frame 4 allows for it to be installed on the barrel 102 of the firearm 100 by sliding each side 16 over either side of the barrel 102 and then installing the clamping means 7 to clamp the device 1 to the barrel 102 . The device 1 can thereby be easily attached to a barrel 102 without sliding the assembled device 1 over a front sight.
[0089] The frame 4 comprises a pair of spaced apart and parallel sides 16 , a top portion 161 with a centre guide 162 , wherein in use, one side 16 extends to either side of the barrel. Outwardly, each frame side 16 comprises a track 18 , and a gear rack 19 extending along the track 18 , along which a carriage 30 of a compensating sight assembly 20 will run, to enable what will, in use, be mainly a normal (or mainly vertical) adjustment in the position of the compensating sight assembly 20 relative to the base 2 .
[0090] Each compensating sight assembly 20 comprises a carriage 30 , a wing mount 40 depending from the carriage 30 , a wing 50 depending from the wing mount 40 , and a compensating sight 54 depending from the wing 50 .
[0091] With reference to FIGS. 5 through 7 , it can be seen that each carriage 30 comprises a body comprising a slot 32 for receiving the track 18 of the frame 4 , and defining a socket 34 with two cantilever teeth 38 , the purpose of which will be discussed below.
[0092] From a floor of the slot 32 there depends a cantilever tooth 37 having a tip which will run against the gear rack 19 on the frame 4 , to provide a detent for mechanically resisting unintended movement of the carriage 30 , and for dividing this movement into discrete increments.
[0093] The wing mount 40 (see FIGS. 8A through 12 ), is pivotably mounted to the carriage 30 by pivot pins 36 provided in the socket 34 of the carriage 30 . The pivot pins engage with a snap fit in pivot mounts 42 , for rotation about an axis parallel to a longitudinal axis of the barrel 102 , so that the wing 50 may be swung up and down.
[0094] With reference to FIGS. 8A through 12 , it can be seen that each wing mount 40 comprises a circular platform 44 having an upper side 442 , and an underside 444 , and further comprising a pair of gear segments 46 extending from the underside 444 of the platform 44 for insertion into the carriage socket 34 .
[0095] Each gear segment 46 comprises a plurality of gear teeth 462 which will, in use, run against a tip of a cantilever tooth 38 which depends from the carriage 30 and is located in the socket 34 , to provide a detent for mechanically resisting unintended rotation of the wing mount 40 , and dividing this rotation into discrete increments. In alternative embodiments, the carriage 30 comprises a single cantilever tooth or more than one cantilever tooth.
[0096] From each wing mount 40 there depends a wing 50 (see FIGS. 13 through 18 ), which is generally elongate, with opposing first and second ends 511 and 512 , an upper surface 513 and a lower surface 514 . From the proximal underside of the wing 50 (i.e. near first end 511 on the lower surface 514 ) there depends a pivot pin 52 for insertion with a snap-fit in a pivot mount 48 provided in an upper side of the wing mount 40 to enable what will, in use, be a rotation of the wing 50 about a normal axis. From the distal upper side of the wing (i.e. near second end 512 on the upper surface 513 ) there depends the compensating sight 54 in the form of a bead (hereinafter ‘the compensating bead’).
[0097] From the medial underside of the wing 50 (i.e. in the lower surface 514 ) further depends a cantilever tooth 56 having a tip which will run against a gear rack 49 provided in the underside of platform 44 of the wing mount 40 , and which extends concentrically around the pivot mount 48 , to provide a detent for mechanically resisting unintended rotation of the wing 50 , and dividing this rotation into discrete increments.
[0098] Carried on the proximal upper side of each wing (i.e. near first end 511 on the upper surface 513 ) there is an indicating dial 60 (shown in FIGS. 14A and 16A for the left and right wing, respectively), which will, in use, indicate the angle of the wing 50 relative to the wing mount 40 . In some embodiments, a central axis of indicating dial 60 is substantially in line with a central axis of the pivot pin 52 . FIG. 14B shows left wing information panel 601 comprising an indicating dial 60 from FIG. 14A . FIG. 16B shows right wing information panel 602 comprising an indicating dial 60 from FIG. 16A . The information panel 601 provides information about the “standard” settings for a target that is 30 metres away from the shooter and travelling at approximately 72-78 kilometres per hour (kph), where the compensating bead 54 should be 33 mm from the centre of the gun sight. The information panel 602 provides information about the settings for targets travelling at different angles relative to the shooter and for fast moving targets. In the illustrated embodiment, information is provided for targets with an approach angle of 30, 60 or 90 degrees. For example, an angle of 90 degrees indicates that the target is travelling perpendicular to the shooter (i.e. perpendicular relative to the path of the bullet with the intersection at the point of impact) as shown in FIG. 22 which is described below, whereas if the the approach angle was 30 degrees (i.e. relative to the path of the bullet with the intersection at the point of impact) it would indicate that the target was approaching the shooter from behind and moving away from them as the target passed by.
[0099] Referring now to FIGS. 28 through 51B , there is shown a second embodiment of device 1 for aiding marksmanship. The device of the second embodiment is structurally and functionally similar to the device of the first embodiment, unless otherwise indicated in the description or apparent from the drawings.
[0100] Outwardly, each frame side 16 comprises a track 18 , and a gear rack 19 extending along the track 18 , along which a carriage 30 of a compensating sight assembly 20 will run. The device of the second embodiment differs from the first embodiment in that the gear rack 19 is of a greater length to provide greater adjustment of the carriage 30 . Outwardly, each frame side 16 comprises a stud 9 , which may provide a stop to the movement of the carriage 30 along the track 18 .
[0101] Alignment pins 141 on moveable jaw 14 (shown in FIGS. 51A and 51B ) insert into guide holes 108 in clamping base 10 (shown in FIG. 49A ) to guide movement of the movable jaw 14 relative to the clamping base 10 .
[0102] Carried on the proximal upper side of the left wing is information panel 6010 and on the right wing is information panel 6020 (shown in FIGS. 43 and 48 , respectively), each information panel comprises an indicating dial 60 (shown in FIG. 44 for the left wing only), which will, in use, indicate the angle of the wing 50 relative to the wing mount 40 . The information panel 6010 provides similar information to information panel 601 about the “standard” settings for a target that is 30 metres away from the shooter and travelling at approximately 72-78 kilometres per hour (kph), with the difference being that compensating bead 54 should be 36 mm from the centre of the gun sight. The information panel 6020 provides similar information to information panel 602 about the settings for targets travelling at different angles relative to the shooter or for fast moving targets, with the differences being the listed distances that the compensating bead will be from the centre of the gun sight for a given target. These differences in the distance of the compensating bead from the centre of the gun sight between the first and second embodiments are detailed further below.
[0103] The slidable movement of the carriage 30 relative to the frame 4 , the pivotable movement of the wing mount 40 relative to the carriage 30 and the pivotable movement of the wing 50 relative to the wing mount 40 allow the shooter to adjust the lead to account for variables such as the distance from the target, the speed of the target and the trajectory of the target. To assist with setting the device 1 to account for a target, the frame 4 comprises markings 21 on each side 16 as a reference for the position of the carriage 30 , each carriage 30 comprises markings 22 as a reference for the angle of the wing mount 40 and wing 50 , and finally each wing mount 40 comprises pointers 232 and 233 and a quadrant of graduations 234 which align with a quadrant of graduations 242 and 243 and pointer 244 , respectively, as a reference for the distance of the compensating bead 54 from the centre of the gun sight.
[0104] The markings 21 on the frame 4 provide guidance as to the appropriate adjustment of the carriage 30 relative to the frame 4 for a target with a 15 degree fall 212 , a level target 213 , a 15 degree rise 214 , a 30 degree rise 215 and a 44 degree rise 216 . The frame 4 of the second embodiment also comprises marking 211 to provide adjustment for a target with a 30 degree fall. In alternative embodiments, the frame 4 provides adjustment for targets with greater degrees of either one or both of rise and fall. The gear rack 19 comprises gears 191 which provide for fine adjustment between the markings 21 . The markings 22 on the carriage 30 provide guidance as to the appropriate adjustment of the wing mount 40 relative to the carriage 30 for a target with a 15 degree fall 222 , a level target 223 , a 15 degree rise 224 , a 30 degree rise 225 and a 44 degree rise 226 . The carriage 30 of the second embodiment also comprises marking 221 to provide adjustment for a target with a 30 degree fall. In alternative embodiments, the carriage provides adjustment for targets with greater degrees of either one or both of rise and fall. In other non-illustrated embodiments, the markings 22 are through holes and an indicator on the wing mount 40 is visible through the appropriate hole according to the adjustment of the wing mount, for example, through hole 222 appears coloured or illuminated when selected.
[0105] The pointers and graduations on each indicating dial 60 and on each wing mount 40 indicate the distance of the compensating bead 54 from the centre of the gun sight. The graduations are in degrees and indicate the distance in millimetres (mm). Due to the structural differences between the first embodiment shown in FIGS. 1 to 21B and the second embodiment shown in FIGS. 28 to 51B , the distance of the compensating bead 54 from the centre of the gun sight will be different in order to provide the appropriate lead for the same target. However, the similarities between the pointers and graduations mean that in use the first and second embodiments are functionally equivalent and corresponding reference characters will be used. For 30 or 15 degree falling target, a level target or a 15 degree rising target, a pointer 232 on the wing mount aligns within a quadrant of graduations 242 on the indicating dial 60 . For the first embodiment, alignment of the pointer 232 with the graduation 611 places the compensating bead 11 mm from the centre of the gun sight and the other graduations have the following meaning: 612 (22 mm), 613 (33 mm), 614 (44 mm), 615 (55 mm). For the second embodiment, alignment of the pointer 232 with the graduation 611 places the compensating bead 12 mm from the centre of the gun sight and the other graduations have the following meaning: 612 (24 mm), 613 (36 mm), 614 (48 mm), 615 (60 mm). Use of graduation 613 may be particularly suitable for a target that is 30 metres away from the shooter and travelling at approximately 72-78 kilometres per hour (kph). Adjustments can be made to the device to account for variations in the distance of the target from the shooter and for targets travelling at different speeds or different angles relative to the shooter, as appropriate. The wing may also be adjusted relative to the wing mount at finer increments than indicated by graduations 611 , 612 , 613 , 614 and 615 (or any other graduations), which is provided by cantilever tooth 56 running against gear rack 49 . In alternative embodiments, the wing provides adjustment for placing the compensating bead greater than 55 mm for the first embodiment or 60 mm for the second embodiment from the centre of the gun sight to account for a fast moving target.
[0106] For the first embodiment, for a 30 degree rising target, the pointer 233 on the wing mount aligns within the quadrant of graduations 243 on the indicating dial 60 and the graduations have the following meaning: 711 (11 mm), 712 (22 mm), 713 (33 mm), 714 (44 mm), 715 (55 mm). For the second embodiment, for a 30 degree rising target, the pointer 233 on the wing mount aligns within the quadrant of graduations 243 on the indicating dial 60 and the graduations have the following meaning: 711 (12 mm), 712 (24 mm), 713 (36 mm), 714 (48 mm), 715 (60 mm).
[0107] For the first embodiment, for a 44 degree rising target, the pointer 244 on the indicating dial 60 aligns within the quadrant of graduations 234 on the wing mount and the graduations have the following meaning: 811 (11 mm), 812 (22 mm), 813 (33 mm), 814 (44 mm), 815 (55 mm). For the second embodiment, for a 44 degree rising target, the pointer 244 on the indicating dial 60 aligns within the quadrant of graduations 234 on the wing mount and the graduations have the following meaning: 811 (12 mm), 812 (24 mm), 813 (36 mm), 814 (48 mm), 815 (60 mm).
[0108] The pointers 232 , 233 , 244 and graduation 813 may be any suitable shape that indicates the position of the wing relative to the wing mount, for example, triangular, as shown in FIGS. 35 to 37 or rectangular, as shown in FIGS. 8A and 9A .
[0109] In use, each of the carriage 30 , the wing mount 40 and the wing 50 are adjusted together to account for the distance, speed and trajectory of the target. The markings may be colour coded, where a colour indicates which settings are appropriate for the particular target. For example, each of markings 212 , 222 , pointer 232 and quadrant of graduations 242 may be the colour red. When in use, for a 15 degree falling target, the carriage 30 is set (i.e. slid) to align indicator 301 with marking 212 on the frame 4 , the wing mount is set (i.e. tilted) in line with an imaginary line drawn between marking 220 and marking 222 on the carriage 30 , and the wing 50 is adjusted (i.e. rotated) so that the pointer 232 on the wing mount aligns within the quadrant of graduations 242 on the indicating dial 60 . The wing 50 may then be rotated relative to the wing mount 40 to align the pointer 232 to the appropriate graduation within the quadrant of graduations 242 according to the nature of the target. For example, for a target with an approach angle of 30 degrees, the pointer 232 aligns with graduation 611 which places the compensating bead 12 mm from the centre of the gun sight. For a target with greater approach angle (i.e. 60 or 90 degrees) or a faster moving target, the wing would be pivoted to place the compensating bead 54 further from the centre of the gun sight.
[0110] For a level target, markings 213 and 223 are selected and the wing 50 is adjusted so that the pointer 232 on the wing mount aligns within the quadrant of graduations 242 on the indicating dial 60 . The wing 50 may then be rotated relative to the wing mount 40 to align the pointer 232 to the appropriate graduation within the quadrant of graduations 242 according to the nature of the target.
[0111] For a 15 degree rising target, markings 214 and 224 are selected and the wing 50 is adjusted so that the pointer 232 on the wing mount aligns within the quadrant of graduations 242 on the indicating dial 60 . The wing 50 may then be rotated relative to the wing mount 40 to align the pointer 232 to the appropriate graduation within the quadrant of graduations 242 according to the nature of the target.
[0112] For a 30 degree rising target, markings 215 and 225 are selected and the wing 50 is adjusted so that the pointer 233 on the wing mount aligns within the quadrant of graduations 243 on the indicating dial 60 . The wing 50 may then be rotated relative to the wing mount 40 to align the pointer 233 to the appropriate graduation within the quadrant of graduations 243 according to the nature of the target.
[0113] For a 44 degree rising target, markings 216 and 226 are selected and the wing 50 is adjusted so that the pointer 244 on the indicating dial 60 aligns within the quadrant of graduations 234 on the wing mount. The wing 50 may then be rotated relative to the wing mount 50 to align the pointer 244 to the appropriate graduation within the quadrant of graduations 234 according to the nature of the target.
[0114] Using the device of the second embodiment, for a 30 degree falling target, markings 211 and 221 are selected and the wing 50 is adjusted so that the pointer 232 on the wing mount aligns within the quadrant of graduations 242 on the indicating dial 60 . The wing 50 may then be rotated relative to the wing mount 40 to align the pointer 232 to the appropriate graduation within the quadrant of graduations 242 according to the nature of the target.
[0115] Referring now to FIG. 22 , where, in use, the device 1 fits over the end of the barrel 102 of a firearm 100 , and is secured in a position close to a muzzle M using the clamping means. The wings 50 on each side of the barrel(s) 102 allow the shooter or the coach to establish the correct lead at any given distance/target speed combination by creating a ‘sight picture’ that shows the shooter the correct amount and type of lead (i.e. how far in front and how far above or below the target the muzzle M of the firearm 100 must be when the shooter pulls the trigger—and of course follows through).
[0116] The adjustability of each compensating sight assembly 20 means the shooter or coach can ‘set the lead’, by setting the position of the compensating bead 54 . That is, provide a visual cue as to the amount and type of lead that the shooter needs to apply to place his or her shot so it intersects the trajectory of the particular target T. For example, the coach can instruct the shooter and provide a cue to shoot “to the left of a target” as shown in FIG. 22 .
[0117] Further adjustment can be achieved by moving the device 1 along the barrel(s) 102 of the firearm 100 as shown in FIGS. 26 and 27 . More particularly, by increasing the distance of the device 1 from the muzzle M, greater amounts of lead can be applied. In some embodiments, the device is placed between about 300 mm and about 1300 mm from the eye of the shooter, for example, approximately 700 mm.
[0118] With reference to FIG. 22 , it can be seen that the device 1 has been set for the maximum lead on a crossing target. This setting would provide 2.5 m lead at 30 m. The wing 50 has been fully extended to the right (i.e. the pointer 232 aligns with graduation 615 to place the compensating bead 60 mm from the centre of the gun sight), the carriage 30 is set to marking 213 and the wing mount 40 is set to marking 223 which provide a level or horizontal shooting plane.
[0119] This target presentation is a difficult one for a beginning shooter, because the beginning shooter is being asked to shoot so far in front of the target T. Coaches often find themselves instructing the beginning shooter to, “miss in front and follow through on the trajectory of the target”. The device 1 provides a visual cue or guide for the shooter to do this.
[0120] By adjusting the wing 50 the compensating bead 54 can be moved closer to the barrel 102 of the firearm, which will produce a setting for a quartering target or a target that is slower and or closer. In these situations less lead is required and the device 1 is able to be adjusted to provide the shooter with a visual cue to the amount of lead required, no matter what the target T trajectory or speed.
[0121] In FIG. 23 , the device 1 is set to provide lead to a falling and crossing target T, again the instruction to the shooter is to place the target T above the compensating bead 54 and while moving the firearm 100 pull the trigger and then follow through on the trajectory of the target T. By doing this the shooter will be applying a ‘collapsing lead’ where the target ‘collapses’ or falls down toward the muzzle of the firearm 100 . The device is set with the wing fully extended to the right (i.e. the pointer 232 aligns with graduation 615 to place the compensating bead 60 mm from the centre of the gun sight), the carriage 30 is set to marking 212 and the wing mount 40 is set to marking 222 , which provide for a crossing target and a 15 degree fall.
[0122] In FIG. 24 , the device has been set to indicate the lead necessary in the case of a target T that is only just moving and commencing to fall, such as a chondel or high incoming target. Very little lead is necessary as the target T is stalling in the vertical plane and only just starting to fall but still has some (in this case) right to left movement. This target T can be at long range (over 40 m) which often induces in the shooter the strong inclination to see a bigger lead than is really needed. This presentation is often ‘over shot’, i.e. given much too much lead. The instruction to the shooter is to ‘shoot just under and just to the left of the target’. This is achieved by setting the device with the wing close to the barrel (i.e. the pointer 232 aligns around graduation 611 or 612 to place the compensating bead approximately 12 to 24 mm from the centre of the gun sight) the carriage 30 is set to marking 212 (alternatively marking 213 ) and the wing mount is set to marking 222 (alternatively marking 223 ).
[0123] In FIG. 25 , the target T presented is climbing and quartering slightly right to left (quartering springer). The shooter needs to shoot above and to the left of the target T. The coach has set the carriage 30 at its lowest setting (i.e. marking 216 ), has rotated the wing mount 40 downwards (i.e. marking 226 ) and the wing is set so that the pointer 244 aligns around graduation 813 , to produce an extreme setting that will place the shot above and to the left of the target T. Again the instruction to the shooter will be to place the target T above the compensating bead 54 , pull the trigger and follow through on the trajectory of the target. At any given distance/target speed combination, the correct lead can be established by moving the firearm 100 so that the target T can be seen above the compensating bead 54 and then firing and following through on the trajectory of the target T, thus keeping the target T above compensating bead 54 until the target T is hit.
[0124] A shooter who is unsure of the amount of lead that should be applied to a given target T can experiment with the device 1 until they find the correct lead. The shooter can make a first estimate of lead and adjust the wing 50 to provide that lead. If the target is missed, then the shooter can increase or decrease the lead by adjusting the wing 50 . Without the device 1 , the shooter in this situation can only guess about how much more or less lead they are actually applying. The device 1 allows them to see whether or not they are actually applying more or less lead as it provides them with a constant point of reference. Once the shooter is able to consistently hit the target, the device 1 can be removed.
[0125] A shooting coach can employ the device 1 to instruct a student. Before going onto the range the coach is able to set various ‘lead pictures’ for the student. Once the device 1 is fitted to the students firearm and the ‘lead picture’ is set, the coach can use a laser pointer to simulate a moving target and have the student execute their shooting movement; in so doing the student is able to see a simulated lead that enables them to become aware of just how far in front of a target T they need to be to break it. This cuts down the time and cost of acquiring the knowledge necessary to break a moving target T.
[0126] When shooting in the field, the coach can fit the device 1 to the shooter's firearm 100 and adjust the wing 50 and carriage 30 to provide a lead picture for the student. This is particularly useful when the student is tackling a new type of target trajectory or if they ‘lose’ a sight picture and start to miss a target T they have previously been hitting. This greatly speeds up the coaching process.
[0127] It should be apparent from all of the above therefore, that the device 1 according to the present disclosure accelerates the process of training a shooter to lead a moving target T, reducing the cost associated with coaching time and ammunition, and reducing shooter frustration.
[0128] Throughout the specification and the claims that follow, unless the context requires otherwise, the words “comprise” and “include” and variations such as “comprising” and “including” will be understood to imply the inclusion of a stated integer or group of integers, but not the exclusion of any other integer or group of integers.
[0129] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement of any form of suggestion that such prior art forms part of the common general knowledge.
[0130] It will be appreciated by those skilled in the art that the disclosure is not restricted in its use to the particular application described. Neither is the present disclosure restricted in its preferred embodiment with regard to the particular elements and/or features described or depicted herein. It will be appreciated that the disclosure is not limited to the embodiment or embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the disclosure as set forth and defined by the following claims.
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The present disclosure relates to a device for aiding marksmanship and a method of use thereof. In a particular form the present disclosure relates to a device for teaching the principle of leading a target. According to one aspect, the device comprises a base securable to a firearm, a compensating sight spaced apart from the base to at least a side of the firearm and positionally adjustable with respect to the base, wherein in use, the compensating sight is so positioned with respect to the base that when the firearm is aimed at a moving target via the compensating sight an appropriate amount of lead is applied to the target.
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This is a continuation of co-pending U.S. application Ser. No. 07/677,198 filed on Mar. 28, 1991.
BACKGROUND OF THE INVENTION
This application relates to improvements in rod guides or the like for rotating sucker rods and pumping oil wells and more particularly to rod guides having reduced drag resistance, turbulence and energy demand.
As is well known, sucker rods in pumping oil wells normally extend longitudinally through the well bore or tubing and are reciprocated or rotated therein during the pumping operation. Since most well bores are not straight, and many are purposely drilled at an angle, the rods frequently wear against or engage the walls of the tubing during reciprocation or rotation thereof, which creates detrimental wear on the rods, rod couplings and tubing.
One usual apparatus for pumping well fluids includes a pump connected to the lower end of the tubing which is reciprocated the string of sucker rods. The sucker rods, or rod string, are connected to a reciprocating mechanical lift for alternately pulling the string upward and then allowing the string to move downwardly by gravity.
An alternative apparatus for pumping well fluids includes a progressing cavity pump connected to the lower end of the tubing. A rotor is rotated within a stator of the pump by the string of sucker rods. The sucker rods, or rod string, are connected to a mechanical drive for rotating the string to raise the well fluids.
Since the rotation of the rod string provides the force necessary to move well fluids upwardly through the tubing, if the resistance to rotational movement of the string is excessive, energy is unnecessarily expended. Further, if the rotation of the rods induces large amounts of pressure drop, turbulence or resistance to flow at a point, this localized turbulence can promote excessive wear of the rod and tubing or even induce fracture.
Heretofore, conventional rod guides of the paddle type have been used to avoid unnecessary wear of the rod against the tubing. However, these paddle type rod guides induce excessive resistance to fluid flow and cause greater turbulence and considerable tubing wear where it is mounted on the rotating rod.
In order to avoid this problem, occasionally substantially solid rod guides are employed with progressing cavity pumps in wells. To reduce restriction of fluid flow, the solid guide must leave substantial clearance between the guide and the tubing wall which permits only a reduced erodible volume of material to protect the rod coupling.
SUMMARY OF THE INVENTION
This invention includes an improved sucker rod guide to be fixedly engaged about a sucker rod at a selected location along the length of a rod. The rod guide comprises a substantially cylindrical polymeric body, having a longitudinal axis, a radially inward surface and a radially outward surface. The radially inward surface of the body is adjacent to and in gripping engagement with the rod when the rod guide is fixedly engaged about the rod. Further, the invention contains a single substantially continuous helical vane carried by the body. The vane is disposed about the radially outward surface of the guide body and is axially displaced along a length of the guide body a selected flight distance sufficient for the vane to complete at least one revolution about the axis of the guide body. A revolution of the vane is separated by a selected pitch distance with the vane extending radially away from the guide body and having a radially outside wear surface. The vane has a maximum width at the wear surface between 30-60 percent of the selected pitch distance.
An alternative improved sucker rod guide for fixedly engaging about a sucker rod at a selected location along the length of the rod is disclosed. This rod guide comprises a substantially cylindrical polymeric body having a longitudinal axis, a radially inward surface and a radially outward surface. The radially inward surface of the body is adjacent to and in gripping engagement with the rod when the rod guide is fixedly engaged about the rod. Two substantially continuous helical vanes are carried by the body. Each vane is disposed about the radially outward surface of the guide body and axially displaced along the length of the guide body a selected flight distance sufficient for the vane to substantially complete between 1/2 and 3 revolutions about the axis of the guide body. A revolution of the vane is separated by a selected pitch distance with the vane extending radially away from the guide body and having a radially outside wear surface. The vane has a maximum width at the wear surface between 10-30 percent of the selected pitch distance.
It is an object of the present invention to provide a rod guide for rotating sucker rods of a rod string which will hold the rods in central longitudinal alignment in the tubing while presenting minimal resistance t the axial flow of fluids.
It is another object of the present invention to provide rod guides on the rods which decrease the resistance to fluid flow and turbulence and the internal abrasion of the rod and the excessive tubing wear.
It is yet another object of the present invention to provide a rod guide having a longer wear life with a greater erodible volume of material.
It is yet another object of the present invention to provide a rod guide with reduced resistance to upward flow past the rod guide without sacrificing the erodible volume available for wear.
These and other objects of this invention will become more apparent from the following description.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical view of a well having a rotating rod string provided with rod guides of the present invention;
FIGS. 2a and 2b are side views of one embodiment of a rod guide of the present invention.
FIG. 3 is a cross-sectional view taken along line 3--3 of the rod guide of FIG. 2.
FIG. 4 is an end view in cross-section taken on line 4--4 of FIG. 2a.
FIG. 5 is a side view of another embodiment of the rod guide of the present invention having two vanes and adapted for field installation.
FIG. 6 is an end view of the rod guide of FIG. 5.
DETAILED DESCRIPTION
Referring now to the drawings, a motor apparatus (10) is shown in use pumping fluids from a well (12) through a string of tubing (14) disposed within well casing (16). Connected to the motor (10) is a string of sucker rods (8) which are connected together by typical box and socket couplings (20).
When the motor apparatus rotates the string of rods (18) within the tubing (14) it operates a progressing cavity pump (not shown). A plurality of rod guides (22) of the present invention are fixedly engaged around the sucker rods at selected locations throughout the length of the rod. During this rotational movement of the string of sucker rods, the well fluids are caused to flow upwardly in the tubing relative to the rod guides.
Referring now to FIGS. 2a and 2b, there may be seen a more detailed illustration of one embodiment of rod guide (22). This rod guide is typically composed of a polymer material molded about a selected location along rod (18). In the alternative, an axial slot may be provided for field installation. Although many polymeric materials are suitable, presently in common use are UHMW polyethylene, polyethylene, nylon, and polyphenyl sulfide.
This substantially longitudinal rod guide is substantially coaxial with the rod and has a substantially cylindrical polymeric body (24) molded about the rod which carries a single, substantially continuous helical vane (28) integrally molded with the body (24) and disposed about the radially outward surface of the guide body. This helical vane (28) extends substantially the entire length of the guide body and extends radially away from the guide body to provide a radially outside wear surface (32) for frictional engagement with the tubing (14) This helical vane is axially displaced along the length of the guide body a selected flight distance (F) sufficient for the vane to complete between about one and three revolutions about the axis of the guide body. If desired, the guide body may include a tapered end (36) for even lower resistance to fluid flow around the rod guide.
Referring now to FIG. 3, there may be seen a side view in cross-section of the guide of FIG. 2a. It may be seen that the helix formed by the vane has a selected pitch distance (P) and the vane, at its point of maximum thickness, has an axial thickness, or width (W). A selected pitch distance (P) between 1-2 inches is preferred, with 1.4-1.6 inches more preferred. Although it is preferred that the vane have a substantially equal width throughout its length, it may be desirable to have its thickness vary from its midpoint to the terminal ends of the vane.
Referring now to FIG. 4, there may be seen a cross-sectional view of the guide of FIGS. 2 and 3 along line 4--4. The rod guide is molded about the rod (18) and is fixedly engaged about the rod by the shrink fit of the polymer body about the rod at the inward surface (46) of the guide. Referring to FIGS. 3 and 4, the thickness of the guide body is determined by the outer diameter (d) of the guide body about the rod. For manufacturing convenience, it has been found desirable to allow the outer diameter of the body to remain substantially constant even though the diameter of the rod (18) may vary. Accordingly, the thickness of the body on the rod may vary from rod size to rod size.
It is a feature of the present invention that the maximum width (W) of the vane is maintained at a thickness which permits convenient passage of fluids about the guide yet provides adequate erodible volume for wear life. Accordingly, it has been found that a maximum width of the vane, measured axially at the wear surface, should be between 30-60 percent of the selected pitch distance if a single vane is used. A maximum width of 45-55% is more preferred. In practice a width of about 0.5 to 0.7 inches is acceptable for a pitch distance of 11/2" used on a nominal 21/2" guide. The flight (F) of the helical vane is preferred to be a selected distance sufficient for the vane to complete between one and three revolutions about the axis of the guide body, although between one and two revolutions is more preferred.
Referring to FIGS. 3 and 4, it may be seen that the wear surface (32) of the vane establishes a diameter (D). It may also be noted that the base portion (50) of the vane adjacent the rod body is wider than the vane at the outside wear surface. This feature permits manufacturing convenience.
It is a feature of the present invention to provide a rod guide having a reduced rotational drag force while at the same time not sacrificing erodible volume. Erodible volume is that volume of polymer on the guide which lies between the outer diameter (D) and the diameter (56) of the coupling to be protected. The diameter of the coupling (20) may vary depending upon the style of coupling and the diameter of the rod. Typically, a 5/8" rod is coupled with a coupling having an outer diameter of about 1.5 inches. A 3/4" rod is coupled with a 15/8" coupling, a 7/8" rod with a 1-13/16" coupling, and a 1" rod with a 2-3/16" coupling.
Another important concept is the by-pass area. This is that area between the guide body and the tubing wall which is available for the flow of fluid. Naturally, if the by-pass area is small, each rod guide serves as a restriction point, which unnecessarily increases the amount of energy required to pass fluids along the length of the tubing. It can be seen, therefore, that by-pass area and erodible volume may tend to oppose each other. Accordingly, the space between each revolution of the vane establishes a fluid passage way for axial flow of the well fluid along the tubing string when the rod string is rotated. Naturally, the direction of the spiral of the vane should be selected based upon the direction of rotation of the rod and the desired axial flow of the well fluids. Conventionally the rod is rotated clockwise when viewed from the top. In this case the helix of the rod guide should have a right hand lead or thread.
Referring now to FIGS. 2a and 4, it may be seen that at each end of the substantially continuous vane there is a brief transition portion (38) as the vane extends radially away from the guide body to wear surface (32). For convenience, it has been elected to define the flight distance (F) to be the axial distance from the beginning (34) of wear surface (32) to the end (40) of wear surface (32). Likewise, the pitch distance (P) is defined as the axial distance required for the midline of the vane to make a single revolution about the axis.
Referring now to FIGS. 5 and 6, there may be seen a top and side view of an alternative embodiment of the present invention having a borehole (54) and an axial slot formed throughout the length of the guide to permit the guide to be field installed. Although the slot (42) passes through the axial length of the vanes and guide body, each vane is still considered substantially continuous. A divergent tapered slot (42) may be preferred, but in some situations a parallel or even convergent slot may be desired. The borehole (54) is slightly smaller than the rod to be gripped to provide a firm engagement about the rod.
Further, this alternative embodiment illustrates the placement of two vanes (28,28'), with each of the vanes having a maximum axial width (w) of 10-30% of the selected pitch distance (P), with 20-25% more preferred. In practice an axial width of 0.8 to 1.5 inches is acceptable for a pitch distance of 5 inches. A pitch distance of 2-6 inches is more preferred, with a pitch of 2.5-3.5 most preferred. It should be noted that with a two vane guide, each vane need only have sufficient flight distance to complete 0.5-3 revolutions about the guide body, with 0.75-1 revolution being more preferred. Accordingly, a two vane guide with each vane completing 0.75 revolutions about a pitch distance of 5 inches and having an axial width of 1.25 inches produces a P/w ratio of 0.25. Likewise, a two vane guide with each vane completing 1.5 revolutions about a pitch distance of 3 inches and having an axial width of 0.75 inches also produces a P/w ratio of 0.25. In the embodiment of FIG. 5, each vane completes only about 0.75 revolutions therefore, the pitch distance is greater than the flight distance (F).
While this invention has been described in detail for the purpose of illustration, it is not construed as limited thereby but is intended to cover all changes and modifications within its spirit and scope.
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A rod guide for use with a rotating progressing cavity pump rod string which minimizes the resistance offered thereby to the axial flow of well fluids. This rod guide decreases turbulence and thereby reduces internal abrasion of the rod and tubing wear together with energy demand. The helical guide may employ either one or two lead vanes.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to microprocessors and, more particularly, to emulation of complex instructions by microcode, and still more particularly, to caching of memory used during such emulation.
[0003] 2. Description of the Related Art
[0004] While it is desirable for microprocessors to maintain compatibility with a complex instruction set computer (CISC) architecture, other architectures offer improved execution speed and performance. Microprocessor designers have attempted to achieve both CISC compatibility and high performance by emulating CISC instructions. For example, superscalar, reduced instruction set computer (RISC) architectures may include microcode that performs CISC instruction emulation. During the emulation process, microcode makes use of a scratchpad memory for saving intermediate values. To maintain high performance, it is desirable for a microprocessor's microcode to be able to access the emulation memory as quickly as possible.
[0005] In addition, microprocessors commonly include multiple memory caches, arranged hierarchically and shared by multiple cores or execution units. A variety of caching architectures are used and include various combinations of on-chip cache and off-chip cache. Memory operations that read data from cache or memory may be referred to more succinctly herein as “loads”. Memory operations that write data to cache or memory may be referred to more succinctly herein as “stores”. A load or a store may target a particular cache line (or portion of a cache line) and include an address identifying the targeted line as well as including data to be loaded from or stored within the cache line. Since cache accesses are faster than memory accesses, various caching techniques are used to increase the likelihood that data is located in a cache when a core or execution unit needs to access it, thereby improving execution speed. Consequently caching the microcode emulation memory offers the performance advantage of the relatively faster access time of cache memory compared to system memory. The shortest access times are generally those associated with the lowest level of the cache hierarchy, commonly referred to as L1-cache, or simply L1. Therefore, it is desirable to cache the microcode emulation memory in L1. Such performance advantages have often been reinforced by the permanent allocation of a portion of L1 for microcode emulation memory.
[0006] Of course, the performance advantages of using the L1-cache would benefit other processes as well. Consequently, it is desirable to make the L1-cache as large as possible to increase the availability of L1-cache space for any process. However, increasing the size of L1 increases the cost and complexity of the microprocessor. Also, if the microcode emulation memory is permanently allocated in L1, this portion of L1 is not available to other processes. In order to address the above concerns, what is needed is a way to improve availability of space in a given size L1-cache to all processes while maintaining the advantages of caching the microcode emulation memory.
SUMMARY OF THE INVENTION
[0007] Various embodiments of a processor, a computer system, and methods are disclosed. The processor includes a cache hierarchy including at least a first level-1 cache and a higher-level cache. The processor is configured to map a first portion of a physical memory space to a first portion of the higher-level cache, execute instructions, at least some of which comprise microcode, allow microcode to access the first portion of the higher-level cache, and prevent instructions that do not comprise microcode from accessing the first portion of the higher-level cache. In one embodiment, the higher-level cache is a level-2 cache. In another embodiment, the first portion of the physical memory space is permanently allocated for use by microcode.
[0008] In a further embodiment, the processor is configured to move one or more cache lines of the first portion of the higher-level cache from the higher-level cache to a first portion of the first level-1 cache. The processor is further configured to allow microcode to access the first portion of the first level-1 cache and prevent instructions that do not comprise microcode from accessing the first portion of the first level-1 cache.
[0009] In a still further embodiment, the processor is configured to detect a microcode access signal. The processor is further configured to prevent instructions from accessing the first portion of the physical memory space if the microcode access signal is not asserted and allow instructions to access the first portion of the physical memory space if the microcode access signal is asserted.
[0010] In a still further embodiment, the processor includes a translation lookaside buffer (TLB), wherein to prevent instructions that do not comprise microcode from accessing the first portion of the physical memory space the processor is further configured to disallow TLB refills to the first portion of the physical memory space.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a generalized block diagram of one embodiment of a computer system.
[0012] FIG. 2 illustrates one embodiment of a virtual memory and cache architecture.
[0013] FIG. 3 illustrates one embodiment of a process for accessing a memory hierarchy including microcode emulation memory.
[0014] FIG. 4 illustrates one embodiment of a process for accessing microcode emulation memory in a level-1 cache.
[0015] FIG. 5 is a block diagram of one embodiment of a computer system including a L2 data cache and microcode emulation memory coupled to a variety of system components.
[0016] While the invention is susceptible to various modifications and alternative forms, specific embodiments are shown by way of example in the drawings and are herein described in detail. It should be understood, however, that drawings and detailed descriptions thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION
[0017] FIG. 1 is a generalized block diagram of one embodiment of a computer system 100 . In the illustrated embodiment, processor 110 is shown coupled to a memory 150 . Memory 150 may include SDRAM, SRAM, ROM, DRAM and/or other conventional memory devices. Processor 110 includes a core 120 , an L2 data cache 130 , and an L2 translation lookaside buffer (TLB) 140 . Core 120 includes an execution unit 122 , a load/store unit 124 , an L1 data cache 126 , and an L1 TLB 128 . L2 data cache 130 includes a microcode emulation memory 135 . In alternative embodiments, processor 110 may include more than one core, each core including a level-1 data cache and each core sharing a single level-2 data cache. In one alternative embodiment, L1 data cache 126 may be separate from core 120 . In other alternative embodiments, additional cache levels may be included in computer system 100 , such as a level-3 cache, either included in processor 110 or separate from processor 110 . In these and other alternative embodiments, microcode emulation memory 135 may be included in any cache level above level-1. A variety of other embodiments are also contemplated. However, for ease of understanding, the examples that follow will assume that space is permanently allocated in a level-2 data cache for microcode emulation memory 135 .
[0018] During operation, execution unit 122 may receive the data portion of loads to be executed from load/store unit 124 via link 161 and convey the data portion of stores to load/store unit 124 via link 162 . Load/store unit 124 may receive the data portion of loads to be executed from L1 data cache 126 via link 163 and convey the data portion of stores to L1 data cache 126 via link 164 . L1 data cache 126 may receive the data portion of loads from L2 data cache 130 via link 165 and convey the data portion of stores to L2 data cache 130 via link 166 . L2 data cache 130 may receive the data portion of loads from and convey the data portion of stores to memory 150 via link 167 . L1 TLB 128 is shown coupled to L1 data cache 126 via link 171 , to L2 data cache 130 via link 172 , and to L2 TLB 140 via link 173 . L2 TLB 140 is also shown coupled to L2 data cache 130 via link 174 .
[0019] L1 data cache 126 , L1 TLB 128 , L2 data cache 130 , and L2 TLB 140 may perform conventional address translation and caching functions. For example, L1 TLB 128 may cache mappings of virtual addresses to physical addresses. When a memory access request occurs, L1 TLB 128 may be checked to see if a mapping of the desired virtual address to a physical address is cached. Mappings cached in L1 TLB 128 may be used to determine if a desired cache line is present in L1 data cache 126 . If a desired cache line is not present in L1 data cache 126 , i.e., there is an L1 cache miss, L2 TLB 140 may be checked to see if a mapping of the desired virtual address to a physical address is cached. Mappings cached in L2 TLB 140 may be used to determine if a desired cache line is present in L2 data cache 130 . When a cache miss occurs in L1 data cache 126 , in order to make room for a new entry, a cache line may be evicted from L1 data cache 126 to L2 data cache 130 . A corresponding entry in L1 TLB 128 may be moved to L2 TLB 140 . In order to make room for a new entry in L2 data cache 130 , it may be necessary to evict a cache line from L2 data cache 130 to memory 150 . A new address translation may be performed for the desired cache line and the result cached in L1 TLB 128 , a process that may be referred to as a TLB refill. Further details of the operation of data caches 126 and 130 and TLBs 128 and 140 that account for and avoid corruption of microcode emulation memory 135 are presented below.
[0020] FIG. 2 illustrates one embodiment of a virtual memory and cache architecture that may be used with processor 110 . In the illustration, a virtual memory space 210 is shown, portions of which are mapped to a physical memory address space 220 . Portions of physical memory address space 220 are shown mapped to L2 cache space 230 , portions of which are in turn mapped to L1 cache space 240 . Each application that executes on processor 110 may employ a separate virtual memory address space. Virtual memory address space 210 , as shown in FIG. 2 , includes blocks 211 - 215 that represent the portions of virtual memory that are mapped to physical memory address space 220 and are available to be accessed by an application at a given point in time. Similarly, physical memory address space 220 includes blocks 221 - 224 that represent the portions of physical memory that are cached in L2 cache space 230 . Likewise, L2 cache space 230 includes blocks 231 - 233 that represent the portions of L2 cache that are cached in L1 cache space 240 . More particularly, blocks 231 , 232 , and 233 of L2 cache space 230 are mapped to blocks 242 , 243 , and 241 of L1 cache space 240 , respectively. In various embodiments, each block described above may represent one of a set of cache lines, blocks of a uniform size, a group of cache lines or blocks, or blocks of varying sizes. In alternative embodiments, any of virtual memory address space 210 , physical memory address space 220 , L2 cache space 230 , and L1 cache space 240 may include more or fewer blocks than the number shown in FIG. 2 .
[0021] In one embodiment, block 221 may be reserved in physical memory space 220 as microcode emulation memory. Further, block 231 of L2 cache space 230 may be permanently reserved for caching the contents of microcode emulation memory. During operation, when processor 110 desires to access microcode emulation memory, block 231 may be cached in level 1 cache, such as in block 242 , as shown in FIG. 2 . However, block 242 may not be permanently reserved for the use of microcode emulation memory, as is block 231 . The blocks that are cached in L1 may change from time to time, depending on program execution. Accordingly, microcode emulation memory may be evicted from L1 to L2, where block 231 is reserved for its use. In one embodiment, access to microcode emulation memory by applications or processes other than microcode may be prevented by disallowing L1 TLB refills involving block 221 of physical memory space.
[0022] FIG. 3 illustrates one embodiment of a process 300 for accessing a memory hierarchy including microcode emulation memory. A memory access may begin with a check for the presence of a microcode access signal (not shown) associated with each instruction decoded by an execution unit (decision block 310 ). For example, in one embodiment, a bit of each decoded instruction may be used as a microcode access signal. In an alternative embodiment, microcode instructions may have a special opcode that serves as a microcode access signal and by which they may be identified as microcode. Any of a variety of alternative microcode access signals may be conveyed from an execution unit to a cache controller to indicate whether or not an instruction is a microcode instruction. If a microcode access signal is detected, then access to the microcode emulation memory may be allowed (block 320 ) and the access is completed.
[0023] If the microcode access signal is not detected, process 300 may proceed as follows. One or more TLBs may be searched to find an entry matching the cache line targeted by the access (block 330 ). If a matching entry is found in an L1 TLB (decision block 340 ), then the targeted cache line may be accessed (block 390 ) and the access is completed. If a matching entry is not found in an L1 TLB but is found in an L2 TLB (decision block 350 ), then the targeted cache line may be moved from the L2 cache to the L1 cache (block 360 ), the targeted cache line may be accessed (block 390 ), and the access is completed. If a matching entry is not found in either L1 or L2 cache, then an address translation may be performed (block 370 ). If the result of the address translation produces a target address that is located in the microcode emulation memory (decision block 380 ), then the access may be prevented (block 384 ) ending the access attempt. If the result of the address translation produces a target address that is not located in the microcode emulation memory (decision block 380 ), then a TLB refill may be performed (block 382 ), the targeted cache line may be accessed (block 390 ), and the access is completed.
[0024] FIG. 4 illustrates one embodiment of a process 400 for accessing microcode emulation memory in a level-1 cache. An access request targeted to microcode emulation memory may begin with a check to see if the targeted cache line is cached in an L1 cache (decision block 410 ). If so, access to the targeted cache line may be allowed (block 420 ) and the access is completed. If the targeted cache line is not cached in an L1 cache, then the reserved location of the targeted cache line in L2 cache may be obtained (block 430 ) The targeted cache line may then be moved from L2 cache to L1 cache (block 440 ). Once the target cache line is moved to L1 cache, access may be allowed (block 420 ) and the access is completed.
[0025] Turning now to FIG. 5 a block diagram of one embodiment of a computer system 500 including L2 data cache 560 and microcode emulation memory 135 coupled to a variety of system components is shown. In the depicted system, processor 510 is shown coupled to peripherals 520 and to a memory 530 . Peripherals 520 may include any of a variety of devices such as network interfaces, timing circuits, storage media, input/output devices, etc. that may be found in a conventional computer system. Memory 530 may include SDRAM, SRAM, ROM, DRAM and/or other conventional memory devices. Processor 510 includes cores 540 A and 540 B, write coalescing cache 550 , level-2 data cache 560 , and I/O interface 570 . I/O interface 570 may couple each of cores 540 to peripherals 520 . Elements referred to herein by a reference numeral followed by a letter may be collectively referred to by the reference numeral alone. For example, cores 540 A and 540 B may be referred to as cores 540 and an unspecified one of cores 540 may be referred to as a core 540 .
[0026] Each of cores 540 includes a level-1 data cache 542 , a store logic unit 544 , and a load/store pipeline 546 . Store logic unit 544 (alternately referred to as “store unit”) may represent a portion of a load/store unit, a separate logic unit, or a combination thereof. Store logic 544 is coupled to both level-1 data cache 542 and write coalescing cache 550 to enable core 540 to write to either cache level. More specifically, store logic 544 may convey stores 584 to level-1 data cache 542 and stores 582 to write coalescing cache 550 . Write coalescing cache 550 may be further coupled to level-2 data cache 560 via fills 564 and evicts 566 . Write coalescing cache 550 may coalesce stores 582 with fills 564 to produce a reduced number of evicts 566 . Level-2 data cache 560 may be further coupled to each level-1 data cache 542 . More specifically, level-2 data cache 560 may convey fills 562 to level-1 data cache 542 . Level-2 data cache 560 may also be bi-directionally coupled to memory 530 .
[0027] During operation, core 540 may execute a stream of instructions that, when decoded, cause loads 586 from L1 data cache 542 to load/store pipeline 546 and/or stores 580 from load/store pipeline 546 to store logic 544 . The instructions executed by core 540 may include execution of microcode. When microcode execution requires access to a cache line in microcode emulation memory 135 , the targeted cache line may be accessed and, if necessary, moved from L2 data cache 560 to L1 data cache 542 using the process described in FIG. 4 above. Once the targeted cache line is moved to L1 data cache 542 , it may be accessed via loads 586 and/or stores 580 and 584 .
[0028] Although system 500 , as shown, include two cores, in alternative embodiments more than two cores may be included and/or each core may represent a cluster of execution units. Additional level-2 caches may also be included in further alternative embodiments in which more than two cores are included. Further, although level-2 data cache 560 is shown coupled directly to memory 530 and memory 530 is shown as off-processor memory, processor 510 may include a memory controller and/or on-processor memory. Alternatively, an off-processor memory controller may couple level-2 data cache 560 to memory 530 . A variety of processor core and memory configurations will be apparent to one of ordinary skill in the art.
[0029] It is noted that the above-described embodiments may comprise software. In such an embodiment, the program instructions that implement the methods and/or mechanisms may be conveyed or stored on a computer accessible medium. Numerous types of media which are configured to store program instructions are available and include hard disks, floppy disks, CD-ROM, DVD, flash memory, Programmable ROMs (PROM), random access memory (RAM), and various other forms of volatile or non-volatile storage. Still other forms of media configured to convey program instructions for access by a computing device include terrestrial and non-terrestrial communication links such as network, wireless, and satellite links on which electrical, electromagnetic, optical, or digital signals may be conveyed. Thus, various embodiments may further include receiving, sending or storing instructions and/or data implemented in accordance with the foregoing description upon a computer accessible medium.
[0030] Although the embodiments above have been described in considerable detail, numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications.
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A processor includes a cache hierarchy including a level-1 cache and a higher-level cache. The processor maps a portion of physical memory space to a portion of the higher-level cache, executes instructions, at least some of which comprise microcode, allows microcode to access the portion of the higher-level cache, and prevents instructions that do not comprise microcode from accessing the portion of the higher-level cache. The first portion of the physical memory space can be permanently allocated for use by microcode. The processor can move one or more cache lines of the first portion of the higher-level cache from the higher-level cache to a first portion of the level-1 cache, allow microcode to access the first portion of the first level-1 cache, and prevent instructions that do not comprise microcode from accessing the first portion of the first level-1 cache.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a multi-layer packaging material for food, having at least one metal barrier—especially aluminum—layer and paper layer, to a unit piece comprising such a packaging material, to a packaging produced therefrom, and to roll material, in accordance with the preambles of patent claims 1 , 6 , 7 and 8 .
[0003] 2. Description of the Related Art
[0004] Such packaging material is usually printed, the printing being carried out on the aluminum layer or, preferably, on the paper layer. In the case of somewhat more costly packagings, the printed paper layer is additionally surface-coated, externally laminated and/or sealed in order to make it substantially resistant to smudging and scratching.
[0005] When packagings produced from known packaging materials are stacked on top of one another or inside one another for the purpose of transportation, there is a risk that the printing will be transferred from the, usually, outside of the packaging onto the inside of the packaging, which comes into contact with food. Such transfer can present food hygiene problems and should be prevented as far as possible. It is accordingly important to prevent such transfer. This can be accomplished—as already mentioned—by means of costly sealing of the printed surface or by avoiding the use of printing ink as far as possible, which does however entail the disadvantage that such printing-ink-free packagings can only be marked by extremely costly means, for example with the aid of stickers.
SUMMARY OF THE INVENTION
[0006] The problem underlying the present invention is to provide a packaging material of the kind mentioned at the beginning, especially also in the form of roll material and pre-cut material, which is cheap to produce and mark, that is to say to print as desired, without using printing ink. A further problem is to make available unit pieces produced from such a packaging material for producing ready-to-use packagings, and also such packagings themselves.
[0007] The problem in respect of the packaging material is solved by the characterising features of claim 1 .
[0008] The problem according to the invention is solved especially by a multi-layer packaging material, especially a laminate, for food, having at least one metal barrier—especially aluminum—layer, and at least one paper layer, the paper layer being laser-marked with predetermined intensity at least portion-wise through its entire cross-section, and optionally the aluminum layer on its surface side.
[0009] A core aspect of the present invention accordingly lies in the fact that the printing is performed by means of a laser, or laser beam, the paper layer, which in the finished packaging defines the outer layer and/or inner layer, being—in accordance with the invention—laser-marked with predetermined intensity right through, that is to say at least portion-wise through its entire cross-section, and optionally the underlying aluminum layer on its surface side.
[0010] In this case, the packaging material, namely especially primarily the paper layer, is irradiated using at least one, preferably focussed, laser beam of predetermined intensity, so that the paper layer becomes oxidatively perforated, especially “burnt through”, whilst the underlying aluminum layer optionally becomes marked, for example discolored, to a greater or lesser degree as a result of the laser irradiation, as desired, depending on the intensity of the laser.
[0011] Depending on the focussing of the laser beam(s) it is possible, in accordance with the invention, to produce in the paper layer a channel-like perforation having substantially parallel, tapering or curved side walls, the fibrous materials of the paper layer consisting advantageously of 100% cellulose having a fineness of 30° SR.
[0012] Preference is moreover given to using paper having a weight of about 50 to 140 g/m 2 .
[0013] In accordance with an embodiment of the invention, the paper layer contains amounts of micronized and/or fibrous plastic(s), especially linear aromatic polyesters and/or linear polyarylenes, and also, optionally, colored pigments, preferably light-sensitive pigments, the amount(s) thereof being in each case in the range between about 0.001 and 15% by weight, preferably in the range between about 0.008 and 5.3% by weight and especially in the range between about 0.05 and 0.09% by weight, based on the weight of the paper.
[0014] Insofar as such laser-radiation-absorbing plastics and/or carbon sources and also, optionally, colored pigments and also light-sensitive pigments are admixed with the paper of the paper layer, a printed image produced by means of laser marking can be obtained with the substantially entire color spectrum, if the particle size of the absorbents and carbon sources and also pigments, as provided in accordance with the invention, is about 0.005 to 150 μ, preferably about 0.05 to 150 μ.
[0015] Polycarbonate, polyethylene terephthalate, polyvinyl sulfide and/or a polyarylene ether are preferably used as plastics.
[0016] As a result of using plastics as a constituent of the paper layer it is advantageously possible to produce rounded-off and also, depending on the amount of plastics, fused perforation rims and edges.
[0017] In the case of a preferred embodiment having, for the paper layer, normal paper with a weight of 80 g/m 2 , the paper and aluminum layers are laser-marked by means of a CO 2 , solid-state or, especially, YAG laser having an energy density in the range from 0.3 mJ/cm 2 to 50 J/cm 2 , especially about 0.5 mJ/cm 2 to 15 J/cm 2 , or by means of a pulsed laser having a pulse frequency in the range from 0.1 to 10000 Hz, especially from 1 to 1000 Hz, and a pulse length in the range from 0.1 to 1000 ns, especially 1 to 100 ns, in each case in an atmospheric environment. The intensity of the laser, which usually has a power of about 0.1 W to 100 W, preferably 1 W to 55 W, and especially 5 W to 30 W, ultimately depends on the selected paper quality and also on the quality of the aluminum layer.
[0018] This kind of printing is extremely simple. It can be carried out in an atmospheric environment, the use of conventional lasers being sufficient to produce the packaging material according to the invention. For obtaining monochrome color effects and also a color palette in the range from light-yellow through brownish tones to virtually black, the paper layer can be produced from normal paper.
[0019] The present invention relates also to a unit piece of packaging material of the aforementioned kind for producing packagings, especially so-called “paper cones” for holding food, especially for holding complementarily shaped wafers to be filled with ice-cream at a later stage. When the laser marking is carried out on the outside of the paper cone, no ink can pass from that laser-marked outside to the inside of a paper cone, which comes into contact with the food, when the paper cones are stacked up inside one another, because the laser marking does not transfer. The same applies in the case of re-stacking paper cones into which empty (i.e. not yet filled with ice-cream) wafers have already been introduced. In accordance with the invention it is moreover also possible for printing to be provided on the inside of the paper cone.
[0020] The invention relates especially also to finished packagings made from a packaging material of the aforementioned kind, especially to paper cones, and also to roll material, especially for producing a paper cone for holding food, preferably for holding wafers to be filled with ice-cream, and especially also for producing a packaging for hygiene products, electronic products and animal feed, having at least one metal barrier—especially aluminum—layer and at least one paper layer, the paper layer being laser-marked with predetermined intensity at least portion-wise through its entire cross-section, and optionally the metal barrier —especially aluminum—layer on its surface side.
[0021] It should also be mentioned that the packaging material can comprise the following layers:
oriented polypropylene (OPP)/color/aluminum/paper; or polyethylene terephthalate (PET)/color/aluminum/paper; or oriented polypropylene (OPP)/paper/aluminum/paper; or surface-coating/color/aluminum/paper; or paper/aluminum/paper; or paper/aluminum (simplest embodiment).
[0028] It has been pointed out hereinbefore that the paper layer can include absorbents and carbon sources. For these there are preferably used micronized plastics consisting of linear aromatic polyesters and/or linear polyarylenes having a particle size as mentioned hereinbefore.
[0029] Another aspect of the invention relates to a method of producing a packaging unit, comprising obtaining the multi-layer packaging material as described hereinabove and forming the material into a packaging unit. Either the inside and/or outside of the packaging unit is laser-marked. The packaging unit can be adapted for holding food, such as a paper cone for holding an ice-cream cone. Thus, a paper cone is one example of the packaging units that can be formed from the multi-layer packaging material that is described. This packaging material can also be rolled to form a roll.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] A preferred embodiment of a packaging material according to the invention and a packaging produced therefrom (paper cone) will be explained in greater detail hereinbelow with reference to the accompanying drawings, in which
[0031] FIG. 1 is a section, to an enlarged scale, through a laser-marked packaging material consisting of paper/aluminum/paper;
[0032] FIG. 2 is a section, to an enlarged scale, through a laser-marked packaging material consisting of paper/aluminum; and
[0033] FIG. 3 is a perspective view of a paper cone produced from a packaging material according to FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] FIG. 1 shows, in an enlarged cross-section, part of a packaging material formed in accordance with the invention. This packaging material consists of three layers, namely an outer and an inner paper layer 11 , 12 and a central aluminum layer 10 . The outer paper layer 11 is laser-marked, these markings being indicated by reference numeral 14 . It can be seen that, as a result of the laser marking, the outer paper layer 11 has been “burnt through” and the central aluminum layer 10 is laser-marked, that is to say exposed, only on its surface side. Depending on the intensity of the laser, especially the perforation edge of the paper layer is discolored to a greater or less extent, from light-yellow through gold to dark-brown, and is smoothly formed—to a greater extent in the case of greater laser beam intensity and focussing density and to a lesser extent in the case of lower laser beam intensity and focussing density. The color of the “printing” obtained by the laser marking that appears to the observer results from light reflection and light refraction at the edges of the perforation, on the one hand, and the aluminum foil or layer, on the other hand, and an overlayering of these effects.
[0035] If required, the opposite side of the packaging material can also, as previously mentioned, be laser-marked. Laser marking on both sides of the multi-layer packaging material is then obtained.
[0036] FIG. 2 shows a section through a laser-marked packaging material corresponding to FIG. 1 with the difference that, according to FIG. 2 , only one paper layer 11 is provided on the aluminum layer 10 , in which laser markings 14 in the form of continuous or interrupted perforations are introduced. The packaging material according to FIG. 2 is accordingly, in contrast to the packaging material according to FIG. 1 , suitable not for two-sided but rather for one-sided marking, that is to say “printing”.
[0037] In FIG. 3 , a so-called “paper cone” 13 has been produced from a packaging material according to the invention in accordance with FIG. 1 . The cone is laser-marked (see reference numeral 14 ) both on the inside and on the outside. The packaging material consists of three layers, with the layer sequence paper/aluminum/paper, as can be seen from the portion 15 of paper cone material in FIG. 3 . Having regard to the thickness of the packaging material, it should be noted that the individual layers have been exaggeratedly shown in FIG. 3 . The overall thickness of the three-layer material for the paper cone 13 is max. about 0.08 to 0.5 mm. The thickness of each individual layer 10 , 11 , 12 is between 0.005 to max. 0.3 mm.
[0038] In the region of overlapping longitudinal edges 16 of the packaging material unit piece from which the paper cone according to FIG. 3 has been formed there is provided, on the outside, a gripping tab 17 , by means of which the paper cone can be ripped open and removed from the contents of the packaging.
[0039] When paper cones 13 of the kind shown in FIG. 3 are stacked inside one another, especially for the purpose of transportation or also for the purpose of being made available for filling, there is no longer a risk that printing ink will be transferred from the outside of the paper cone onto the inside of the next paper cone placed on top of it or inside it.
[0040] For producing a paper cone according to FIG. 3 , the unit piece of packaging material is approximately triangular, with the side which defines the circumferential edge of the paper cone defining an outwardly extending arc of a circle.
[0041] At the bottom end of the gripping tab 17 there is also formed a notch 18 , which defines the start of an intended tear line extending around the circumference. When the gripping tab 17 is gripped and pulled away around the circumference of the paper cone, the upper part of the paper cone, that is to say the part extending above the notch 18 , can be ripped off from the lower part.
[0042] In principle it should also be mentioned that, in the case of a packaging material of (overprint) surface-coating/color/aluminum/paper, the laser marking can also be carried out on the color side in order, by that means, to modify the color or to add additional “printing” produced by laser marking. Preferably, however, it is the paper side, which is usually free from conventional printing inks, that is laser-marked.
[0043] All features disclosed in the application documents are claimed as being important to the invention insofar as they are novel on their own or in combination compared with the prior art.
REFERENCE NUMERALS
[0000]
10 aluminum layer
11 paper layer
12 paper layer
13 paper cone
14 packaging material portion of paper cone 13
16 longitudinal edges
17 gripping tab
18 notch
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Multi-layer packaging material, especially laminate, preferably for food, hygiene products and electronic products, having at least one metal barrier—especially aluminum—layer and at least one paper layer, and also roll material. The paper layer is laser-marked with predetermined intensity at least portion-wise through its entire cross-section, and optionally the metal layer on its surface side.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional application of, and claims priority to U.S. application Ser. No. 11/924,334 U.S. Pat. No. 7,818,064, issued on Oct. 19, 2010, filed on Oct. 25, 2007 for Fitting of Brightness in a Visual Prostheses, which is a division of U.S. application Ser. No. 11/357,680 U.S. Pat. No. 7,738,962, issued on Jun. 15, 2010 filed Feb. 16, 2006, for Fitting of Brightness in a Visual Prosthesis, which claims priority to U.S. Provisional Patent Application 60/653,674, filed Feb. 16, 2005, for A Method of Determining the Electrical Current Amplitude Required to Produce a Percept. This application is related to and incorporates herein by reference, U.S. Pat. No. 7,483,751, issued on Jan. 27, 2009, for Automatic Fitting for a Visual Prosthesis.
GOVERNMENT RIGHTS NOTICE
This invention was made with government support under grant No. R24EY12893-01, awarded by the National Institutes of Health. The government has certain rights in the invention.
FIELD OF THE INVENTION
The present invention is generally directed to neural stimulation and more specifically to an improved method of Optimizing neural stimulation levels for artificial vision.
BACKGROUND OF THE INVENTION
In 1755 LeRoy passed the discharge of a Leyden jar through the orbit of a man who was blind from cataract and the patient saw “flames passing rapidly downwards.” Ever since, there has been a fascination with electrically elicited visual perception. The general concept of electrical stimulation of retinal cells to produce these flashes of light or phosphenes has been known for quite some time. Based on these general principles, some early attempts at devising a prosthesis for aiding the visually impaired have included attaching electrodes to the head or eyelids of patients. While some of these early attempts met with some limited success, these early prosthetic devices were large, bulky and could not produce adequate simulated vision to truly aid the visually impaired.
In the early 1930's, Foerster investigated the effect of electrically stimulating the exposed occipital pole of one cerebral hemisphere. He found that, when a point at the extreme occipital pole was stimulated, the patient perceived a small spot of light directly in front and motionless (a phosphene). Subsequently, Brindley and Lewin (1968) thoroughly studied electrical stimulation of the human occipital (visual) cortex. By varying the stimulation parameters, these investigators described in detail the location of the phosphenes produced relative to the specific region of the occipital cortex stimulated. These experiments demonstrated: (1) the consistent shape and position of phosphenes; (2) that increased stimulation pulse duration made phosphenes brighter; and (3) that there was no detectable interaction between neighboring electrodes which were as close as 2.4 mm apart.
As intraocular surgical techniques have advanced, it has become possible to apply stimulation on small groups and even on individual retinal cells to generate focused phosphenes through devices implanted within the eye itself. This has sparked renewed interest in developing methods and apparatuses to aid the visually impaired. Specifically, great effort has been expended in the area of intraocular retinal prosthesis devices in an effort to restore vision in cases where blindness is caused by photoreceptor degenerative retinal diseases such as retinitis pigmentosa and age related macular degeneration which affect millions of people worldwide.
Neural tissue can be artificially stimulated and activated by prosthetic devices that pass pulses of electrical current through electrodes on such a device. The passage of current causes changes in electrical potentials across visual neuronal membranes, which can initiate visual neuron action potentials, which are the means of information transfer in the nervous system.
Based on this mechanism, it is possible to input information into the nervous system by coding the information as a sequence of electrical pulses which are relayed to the nervous system via the prosthetic device. In this way, it is possible to provide artificial sensations including vision.
One typical application of neural tissue stimulation is in the rehabilitation of the blind. Some forms of blindness involve selective loss of the light sensitive transducers of the retina. Other retinal neurons remain viable, however, and may be activated in the manner described above by placement of a prosthetic electrode device on the inner (toward the vitreous) retinal surface (epiretial). This placement must be mechanically stable, minimize the distance between the device electrodes and the visual neurons, and avoid undue compression of the visual neurons.
In 1986, Bullara (U.S. Pat. No. 4,573,481) patented an electrode assembly for surgical implantation on a nerve. The matrix was silicone with embedded iridium electrodes. The assembly fit around a nerve to stimulate it.
Dawson and Radtke stimulated cat's retina by direct electrical stimulation of the retinal ganglion cell layer. These experimenters placed nine and then fourteen electrodes upon the inner retinal layer (i.e., primarily the ganglion cell layer) of two cats. Their experiments suggested that electrical stimulation of the retina with 30 to 100 uA current resulted in visual cortical responses. These experiments were carried out with needle-shaped electrodes that penetrated the surface of the retina (see also U.S. Pat. No. 4,628,933 to Michelson).
The Michelson '933 apparatus includes an array of photosensitive devices on its surface that are connected to a plurality of electrodes positioned on the opposite surface of the device to stimulate the retina. These electrodes are disposed to form an array similar to a “bed of nails” having conductors which impinge directly on the retina to stimulate the retinal cells. U.S. Pat. No. 4,837,049 to Byers describes spike electrodes for neural stimulation. Each spike electrode pierces neural tissue for better electrical contact. U.S. Pat. No. 5,215,088 to Norman describes an array of spike electrodes for cortical stimulation. Each spike pierces cortical tissue for better electrical contact.
The art of implanting an intraocular prosthetic device to electrically stimulate the retina was advanced with the introduction of retinal tacks in retinal surgery. De Juan, et al. at Duke University Eye Center inserted retinal tacks into retinas in an effort to reattach retinas that had detached from the underlying choroid, which is the source of blood supply for the outer retina and thus the photoreceptors. See, e.g., E. de Juan, et al., 99 Am. J. Opthalmol. 272 (1985). These retinal tacks have proved to be biocompatible and remain embedded in the retina, and choroid/sclera, effectively pinning the retina against the choroid and the posterior aspects of the globe. Retinal tacks are one way to attach a retinal array to the retina. U.S. Pat. No. 5,109,844 to de Juan describes a flat electrode array placed against the retina for visual stimulation. U.S. Pat. No. 5,935,155 to Humayun describes a retinal prosthesis for use with the flat retinal array described in de Juan.
In addition to the electrode arrays described above, there are several methods of mapping a high resolution camera image to a lower resolution electrode array. U.S. Pat. No. 6,400,989 to Eckmiller describes spatio-temporal filters for controlling patterns of stimulation in an array of electrodes. The assignee of the present applications has three related U.S. patent applications: U.S. Ser. No. 09/515,373, filed Feb. 29, 2000 and abandoned, entitled Retinal Color Prosthesis for Color Sight Restoration; Ser. No. 09/851,268, filed May 7, 2001 and issued as U.S. Pat. No. 6,920,358 on May 19, 2005, entitled Method, Apparatus and System for Improved Electronic Acuity and Perceived Resolution Using Eye Jitter Like Motion; and Ser. No. 10/355,791, filed Jan. 31, 2003 and issued as U.S. Pat. No. 7,574,263 on Aug. 11, 2009, entitled Pixel Re-Mapping for a Visual Prosthesis. All three applications are incorporated herein by reference.
Each person's response to neural stimulation differs. In the case of retinal stimulation, a person's response varies from one region of the retina to another. In general, the retina is more sensitive closer to the fovea. Any stimulation, with magnitude less than the threshold of perception, is ineffective. Stimulation beyond a maximum level will be painful and possibly dangerous to the patient. It is therefore, important to map any video image to a range between the minimum and maximum for each individual electrode. With a simple retinal prosthesis, it is possible to adjust the stimulation manually by stimulating and questioning the patient. As resolution increases, it is tedious or impossible to adjust each electrode by stimulating and eliciting a patient response.
A manual method of fitting or adjusting the stimulation levels of an auditory prosthesis is described in U.S. Pat. No. 4,577,642, Hochmair et al. Hochmair adjusts the auditory prosthesis by having a user compare a received signal with a visual representation of that signal.
A more automated system of adjusting an auditory prosthesis using middle ear reflex and evoked potentials is described in U.S. Pat. No. 6,157,861, Faltys et al. An alternate method of adjusting an auditory prosthesis using the stapedius muscle is described in U.S. Pat. No. 6,205,360, Carter et al. A third alternative using myogenic evoked response is disclosed in U.S. Pat. No. 6,415,185, Maltan.
U.S. Pat. No. 6,208,894, Schulman describes a network of neural stimulators and recorders implanted throughout the body communicating wirelessly with a central control unit. U.S. Pat. No. 6,522,928, Whitehurst, describes an improvement on the system described in Schulman using function electro stimulation also know as adaptive delta modulation to communicate between the implanted devices and the central control unit.
The greatest dynamic range is achieved by setting the minimum stimulation at the threshold of perception and the maximum stimulation level approaching the pain threshold. It is unpleasant for a patient to first concentrate to detect the minimum perception and then be subjected to stimulation near the threshold of pain.
The human retina includes about four million individual photoreceptors. An effective visual prosthesis may include thousands of electrodes. An automated system is needed to adjust individual electrodes in a visual prosthesis for maximum benefit without the need for patient interaction in a long and difficult process.
SUMMARY OF THE INVENTION
The invention is a method of automatically adjusting an electrode array to the neural characteristics of an individual patient. The response to electrical neural stimulation varies from patient to patient and the relationship between current and perceived brightness is often non-linear. It is necessary to determine this relationship to fit the prosthesis settings for each patient. It is advantageous to map the perceptual responses to stimuli. The method of mapping of the present invention is to provide a plurality of stimuli that vary in current, voltage, pulse duration, frequency, or some other dimension; measuring and recording the perceptual response to those stimuli; deriving a formula or equation describing the map from the individual points; storing the formula; and using that formula to map future stimulation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the implanted portion of the preferred retinal prosthesis.
FIG. 2 a - d are graphs showing typical current vs. brightness response.
FIG. 3 is a flowchart show the brightness mapping method.
FIG. 4 is a flow chart showing an alternate process of auto fitting an electrode array.
FIG. 5 depicts a block diagram of the retinal prosthesis electronic control unit.
FIG. 6 is a graph depicting a typical neural response to electrical input.
FIG. 7 depicts an alternate fitting process using cortical recording.
FIG. 8 depicts an alternate fitting process using iris recording.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description is of the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the invention. The scope of the invention should be determined with reference to the claims.
FIG. 1 shows a perspective view of the implanted portion of the preferred retinal prosthesis. A flexible circuit 1 includes a flexible circuit electrode array 10 which is mounted by a retinal tack (not shown) or similar means to the epiretinal surface. The flexible circuit electrode array 10 is electrically coupled by a flexible circuit cable 12 , which pierces the sclera and is electrically coupled to an electronics package 14 , external to the sclera.
The electronics package 14 is electrically coupled to a secondary inductive coil 16 . Preferably the secondary inductive coil 16 is made from wound wire. Alternatively, the secondary inductive coil 16 may be made from a flexible circuit polymer sandwich with wire traces deposited between layers of flexible circuit polymer. The electronics package 14 and secondary inductive coil 16 are held together by a molded body 18 . The molded body 18 may also include suture tabs 20 . The molded body 18 narrows to form a strap 22 which surrounds the sclera and holds the molded body 18 , secondary inductive coil 16 , and electronics package 14 in place. The molded body 18 , suture tabs 20 and strap 22 are preferably an integrated unit made of silicone elastomer. Silicone elastomer can be formed in a pre-curved shape to match the curvature of a typical sclera. However, silicone remains flexible enough to accommodate implantation and to adapt to variations in the curvature of an individual sclera. The secondary inductive coil 16 and molded body 18 are preferably oval shaped. A strap 22 can better support an oval shaped coil.
The preferred prosthesis includes an external portion (not shown) which includes a camera, video processing circuitry and an external coil for sending power and stimulation data to the implanted portion.
FIGS. 2 a - d show typical perceptual responses collected from four patients. The perceptual responses differ in both the amplitude of the response curve and the shape of the response curve. All four patient perceptual responses, however, can be fitted by the function B=aI b where B is brightness, I is current amplitude, and a and b are parameters to be estimated from fitting the empirical data. Three data points will adequately define the function. Numerous statistical tools are available for automatically fitting the function to the three data points.
In this example the x axis represent the amplitude of stimulation using a single pulse. The y axis represents the patient's subjective rating of brightness where a stimulus rated as “10” is twice as bright as a stimulus rated as “5”.
FIG. 3 shows a flow chart of the fitting procedure. In this case, we are using patient's ratings of subjective brightness but a measure of neural actively such a neural recording or pupil response (described below) could be used in an analogous fashion. First the fitting system must determine the perceptual brightness response to current relationship. This is accomplished by stimulating and measuring the subject reported brightness response rating at three points. It should be noted that the response is near linear in most cases. Hence, two points can be used to approximate the response, but three points will yield a more accurate fit. First, a stimulus is presented 23 . If there is no response 24 , the stimulus is increase 25 and stimulation is presented again 23 . If there is a response to stimulus 24 and the response is pain 26 , the stimulation is reduced 27 and stimulation is presented again 23 . If there is a non-painful response it is recorded 28 in in non-volatile memory of the prosthesis device. Recording the response may include subjective response, neural recording or other physiological response. This process is repeated to get the required number of recorded responses, usually 3. If there are three recorded responses 29 , an equation or formula is derived to describe the relationship between current and brightness relationship 30 . The formula may be saved as an actual equation to be applied to the input value, or as a table of input and output values. It should also be noted that there must be a maximum charge limit sent in a visual prosthesis for safety reasons. Hence, the current variations must be limited by the preprogrammed maximum change. In the preferred embodiment, current is mapped to brightness. It should be noted that other a factors which may affect brightness, such as voltage, pulse width or frequency, may be mapped by the same method.
After the formula is established, input is received by the camera 31 ; the formula is applied to input data 32 ; and an output value is used to stimulate neural tissue 33 .
FIG. 4 is a flow chart of an automatic fitting sequence which may be employed to gain the three points needed for the method described in FIG. 3 , or may be used as an alternative fitting procedure. In the flow chart, the value N is the selected electrode, X is the neutral activity recorded, and L is the level of stimulation (current amplitude). First N is set to 0 40 and then incremented 42 . The first electrode, electrode N, is addressed 44 . The stimulation level is set to zero 46 , and then incremented 48 . The neural tissue is stimulated at the minimum level 50 . The stimulation is immediately followed by a recording of activity in the neural tissue 52 . Alternatively, recording can be done simultaneously by an adjacent electrode. If recording is done simultaneously, one must distinguish between neural activity and electrical charge from the stimulating electrode. The neural response follows stimulation (see FIG. 6 ). Simultaneous stimulation and recording requires that the recording phase be longer than the stimulation phase. If so, the stimulation and neural response can be separated digitally. If the recorded neural activity is less than a predetermined level 54 , the stimulation level is increased and steps 48 - 54 are repeated.
In most cases, the preset minimum level is any measurable neural activity. However, perception by the patient is the determining factor. If neural activity is detected and the patient reports no perception, the minimum level must be set higher. Once minimum neural activity is recorded, the stimulation level is saved in memory 56 . The level is then further increased 58 and stimulation is repeated 60 . Again stimulation is immediately followed by recording neural activity 62 . If a predetermined maximum level has not been reached, steps 58 - 64 are repeated until the predetermined maximum stimulation level is obtained. Once the predetermined maximum stimulation level is obtained, steps 42 - 64 are repeated for the next electrode. The process is continued until a minimum and maximum stimulation level is determined for each electrode 66 .
To obtain the subjective brightness or neural response for the necessary three points, one first finds the stimulus amplitude (the intensity of the stimulus can also be varied along other dimensions) which is barely detectable by the patient or provokes a minimally detectable neural response. One then presents the stimulus at that value (e.g. the amplitude value V=42) repeatedly until one has an accurate measurement of the subjective brightness or neural response at that stimulus intensity. One then finds the stimulus amplitude that is just under the safety limit or pain threshold, and measures the apparent brightness or neural response at that stimulus intensity. Finally one finds apparent brightness or neural response for a stimulus whose amplitude is halfway (or intermediate) between those two points. If additional data points are desired, equal distant points such as 25% and 75% should be used.
The range of intensities used for stimulation during operation of the device will fall within the range that is measured during the fitting procedure. Very low or high intensity values may not be used in normal function.
The maximum stimulation level borders on discomfort for the patient. Because the automatic fitting process is automated, high levels of stimulation are only applied for a few microseconds. This significantly decreases the level of discomfort for the patient compared with stimulating long enough to elicit a response from the patient.
The fitting process is described above as an incremental process. The fitting process may be expedited by more efficient patterns. For example changes may be made in large steps if it the detected response is significantly below the desired response, followed by increasingly small steps as the desired response draws near. The system can jump above and below the desired response dividing the change by half with each step.
Often, neural response in a retina is based, in part, on geographical closeness. That is, neurons closer to the fovea require less stimulation than neurons farther from the fovea. Hence once a stimulation is level is set for an electrode, one can presume that the level will be similar for an adjacent electrode. The fitting process may be expedited by starting at a level near the level set for a previously fit adjacent electrode.
Automating the fitting process has many advantages. It greatly expedites the process reducing the efforts of the patient and clinician. Further, the automated process based on measured neural responses is objective. Patient perceptual responses are subjective and may change over time due to fatigue. In some cases, a patent may not be able to provide the required responses due to age, disposition, and/or limited metal ability.
FIG. 5 depicts a block diagram of the control unit. The block diagram is a functional diagram. Many of the functional units would be implemented in a microprocessor. A control unit 80 sets and increments a counter 82 to control the stimulation level of the stimulator 84 . The stimulation signal is multiplexed in MUX 86 to address individual electrodes 88 . After each stimulation, the addressed electrode returns a neural activity signal to a recorder 90 . The signal is compared to the stored minimum or maximum level (stored in a memory 92 ) in a comparator 94 . After programming, a signal from a video source 96 , or other neural stimulation source, is adjusted in a mapping unit 98 , in accordance with the minimum and maximum levels stored in the memory 92 . The adjusted signal is sent to the stimulator 84 , which in synchronization with MUX 86 applies the signal to the electrodes 88 . The electronics for the control unit could be external or within the implanted prosthesis.
FIG. 6 is a graphical representation of the neural response to electrical stimulus. This figure is derived from actual recordings of a frog retina. Response in a human retina will be similar and can be measured by a retinal electrode, implanted cortical electrode, or external cortical electrode commonly known as a visual evoked response or VEP. The vertical axis is current while the horizontal axis is time. Four curves 100 - 106 show the response at varying input current levels. An input pulse 108 , is followed by a brief delay 110 , and a neural response 112 . Hence, it is important to properly time the detecting function. Either the stimulating electrode must be switched to a detecting electrode during the brief delay or detecting must occur on another electrode and continue long enough to record the neural response. It should also be noted that the delay period 110 becomes shorter with increased stimulation current. Hence, the system must switch faster from stimulation mode to detecting mode with increased current. The change in delay time may also be used as an additional indication of neural response. That is, the minimum and maximum may be determined by matching predetermined delay times rather than predetermined output levels. As stimulation increases, it becomes more useful to employ an alternate recording means as described in the following alternate embodiments.
In a first alternate embodiment, the recording electrode may be cortical electrode mounted on or near the visual cortex. Temporary external electrodes placed on the scalp proximate to the visual cortex may record neural activity in the visual cortex. This allows the system to account for any variations in neural processing between the retina and the visual cortex. It, however, requires electrodes either implanted in the visual cortex or placed temporarily near the visual cortex. This alternate embodiment may be combined with the preferred embodiment by first using cortical electrodes to perform an initial fitting of the prosthesis in a clinic. Thereafter, retinal recording may be used to readjust the prosthesis for any changes over time.
FIG. 7 shows the first alternate retinal prosthesis. A stimulating electrode array 150 is placed against the outer surface of a retina 152 (epiretinally). A cable 154 pierces a sclera 156 and attaches to an electronic control unit 158 . A return electrode 160 may be placed distant from the retina 152 . The stimulating electrode array 150 is a plurality of tiny electrodes. One or more recording electrodes 162 are placed in near the visual cortex. The recording electrodes may be temporary external electrodes, implanted electrodes under the scalp, or electrode implanted within the visual cortex.
In a second alternate embodiment, the recording electrode may be either implanted in the iris, or placed externally near the iris. The iris contracts when increasing light levels enter the eye. Electrical stimulation of the retina also causes the iris to contract, because the body perceives an increase in light entering the eye. Conversely, the iris expands in response to a decrease in electrical stimulation. While the response of the iris is relatively slow, the neurological signals initiating a change in the iris respond quickly. Measuring these signals may provide alternate feed back as to the body's response to the electrical stimulus. Alternatively, an optical device aimed at the eye may detect the diameter of the iris.
FIG. 8 shows the second alternate retinal prosthesis. A stimulating electrode array 210 is placed against the outer surface of a retina 212 (epiretinally). A cable 214 pierces a sclera 216 and attaches to an electronic control unit 218 . A return electrode 220 may be placed distant from the retina 212 . The stimulating electrode array 210 is a plurality of tiny electrodes. A recording electrode 224 is place in the periphery of the iris sensing electrical stimulus to the iris.
In a third alternate device, electroluminescent pigments may be applied to the retina. Electroluminescent pigments cause an individual cell to glow when it fires an action potential. A camera of the type used for retinal photos may detect neural response by detecting the electroluminescent glow of the applied pigment.
Accordingly, what has been shown is an improved method of stimulating neural tissue for improved response to brightness. While the invention has been described by means of specific embodiments and applications thereof, it is understood that numerous modifications and variations could be made thereto by those skilled in the art without departing from the spirit and scope of the invention. It is therefore to be understood that within the scope of the claims, the invention may be practiced otherwise than as specifically described herein.
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The invention is a method of automatically adjusting an electrode array to the neural characteristics of an individual patient. The perceptual response to electrical neural stimulation varies from patient to patient and The response to electrical neural stimulation varies from patient to patient and the relationship between current and perceived brightness is often non-linear. It is necessary to determine this relationship to fit the prosthesis settings for each patient. It is advantageous to map the perceptual responses to stimuli. The method of mapping of the present invention is to provide a plurality of stimuli that vary in current, voltage, pulse duration, frequency, or some other dimension; measuring and recording the response to those stimuli; deriving a formula or equation describing the map from the individual points; storing the formula; and using that formula to map future stimulation.
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BACKGROUND OF THE INVENTION
In the field of plumbing fixtures and the like, it is well known to provide pop-up drain fittings which selectively seal drain fittings for tubs, sinks, and the like. Generally speaking, such pop-up drain fittings are disposed within a cylindrical drain body, and are secured to the drain body by means of a spider extending diametrically across the lower opening of the drain body. More specifically, the pop-up drain fitting generally includes a central post having a lower threaded end which is received in a medially disposed threaded hole in the spider of the drain body.
It is common practice to employ the pop-up drain fitting by depressing the upper cover of the mechanism to cause a rubber seal to close the upper opening of the drain body. To release this valve, it is necessary only to depress a button on the upper portion of the fitting, or to depress a particular side edge portion of the cover to effect release of the mechanism and opening of the drain.
However, recent experience has shown that it is also common practice for vandals and others to completely remove the pop-up mechanism from drain by unthreading the mechanism from the spider. There is no pop-up drain mechanism known in the prior art which is designed to resist or withstand such tampering or vandalism.
SUMMARY OF THE PRESENT INVENTION
In a pop-up drain fitting threadedly secured to a spider at the lower end of the drain body, the improvement comprising a detent member pivotally joined to the lower end of the pop-up drain fitting. A stop member is disposed adjacent to the detent member to permit the detent member rotation in only one direction. The detent member depends downwardly by gravitational force to extend through the spider. Clockwise threading motion of the pop-up fitting into the drain body is permitted by the detent arm; counterclockwise rotation of the pop-up fitting causes the spider to impinge upon the detent arm and drive it into the stop member, thereby preventing removal of the pop-up fitting.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an exploded view of one embodiment of the tamper-proof pop-up drain mechanism of the present invention.
FIG. 2 is a bottom view of the embodiment of the present invention as depicted in FIG. 1.
FIG. 3 is a partial cross-sectional elevation of the embodiment of the present invention as depicted in FIGS. 1 and 2.
FIG. 4 is a cross-sectional elevation of the embodiment depicted in FIGS. 1-3.
FIG. 5 is a cross-sectional elevation of a further embodiment of the tamper-proof pop-up drain mechanism.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention generally comprises an improved pop-up drain mechanism which is designed to resist tampering with or removal of the pop-up mechanism from the drain body. A pop-up drain assembly, including the pop-up mechanism and the drain body, generally includes a tubular body member 11 which is provided with external threads 12. The body member 11 includes an axially disposed bore 14 and a radially outwardly extending flange 13 extending from the upper end of the body member. At the lower end of the body member 11 there is secured a spider 16 which supports an axially disposed ring 17. The ring 17 is provided with a concentrically disposed threaded hole 20, as shown for example in FIG. 4.
The pop-up drain mechanism includes a generally rectangular post 19 which is provided with a lower threaded end 18 adapted to be secured in the threaded hole 20 of the ring 17. One vertical surface 25 of the rectangular post 19 is provided with a laterally extending detent slot 21. The same vertical surface is also provided with a ramped camming surface 22 extending from the upper lip of the slot 21 upwardly and obliquely inwardly as shown in FIG. 1.
The vertical surface 30 of the rectangular post, which is opposed to the vertical surface 25, is provided with a radially extending hole 23. Disposed in the hole 23 is a helical compression spring 24, and a flat head biasing member 40 having a short shank extending inwardly therefrom is received in the hole 23 and within the coils of the spring 24. The spring 24 biases the member 40 radially outwardly, for reasons which will be explained in the following description. Extending from the upper end of the surface 30 is a lip 29. As shown in FIGS. 1 and 3-5, the lip 29 extends laterally outwardly only from the surface 30.
Disposed in the top of the rectangular post 19 is a center bore 27. Seated in the bore 27 is a helical compression spring 28, which extends upwardly from the rectangular post. The function of the spring 28 will also be made apparent in the following description.
The pop-up drain mechanism also includes a generally disk-like drain cover 31. Extending downwardly from the drain cover and disposed concentrically with the axis thereof is tubular member 33. The tubular member 33 is provided with a reduced diameter annulus 35. An annular sealing gasket 32 is resiliently secured in the annulus 35, with the peripheral portion thereof angled slightly downwardly with respect to the cover 31. The outer diameter of the gasket 32 is greater than the diameter of the bore 14 of the drain body member, and the peripheral edge of the gasket is adapted to impinge on the flange 13 in sealing fashion to prevent any flow through the bore of the drain.
As shown in the Figures, the chamber 34 within the tubular member 33 receives the rectangular post 19. The width of the post from side 25 to side 30 is less than the diameter of the chamber 34, and the tubular portion 33 is disposed parallel to the post 19 and laterally offset therefrom. The lip 29 extending from the side 30 of the post maintains the lateral offset of the tubular portion 33, and the spring biased member 40 maintains the tubular portion in generally parallel alignment with the post 19. It may be appreciated, however, that the cover member 31 may be rocked or pivotted about the lip 29, the member 40 being urged against the spring force of spring 24 into the hole 23.
A latch pin 36 is also provided in the lower end of the tubular member 33, extending along a chord through the chamber 34. The latch pin 36 is disposed adjacent to the camming surface 22, and is adapted to be retained in the detent slot 21, as shown in FIGS. 4 and 5.
The pop-up drain mechanism described herein is known in the prior art, and is described in greater detail in U.S. Pat. No. 4,144,599, issued Mar. 20, 1978, and U.S. Pat. No. 4,103,372, issued Feb. 28, 1977, both patents being issued to Casper Cuschera. These patents are incorporated herein by reference.
It may be understood that the compression of the spring 28 biases the cover 31 upwardly, so that the gasket 32 clears the flange 13 of the drain body by a substantial margin. In this configuration, there is free flow through the gap defined by the gasket 32 and the flange 13. The pop-up mechanism may be closed by manually urging the cover 31 downwardly. As the cover is depressed, the latch pin 36 rides the camming surface 22 and is received in the detent slot 21 to maintain the cover in the closed position. In this position, the peripheral rim of the gasket 32 impinges upon the flange 13 to prevent any water outflow through the bore 14. The pop-up mechanism is opened by depressing an edge portion of the cover to release the latch pin 36 from the slot 21. In other forms of pop-up mechanisms, a push-button extending upwardly from the cover may be provided to effect release of the mechanism and opening of the valve.
The present invention is an improvement over prior art pop-up mechanisms, the improvement being specifically directed toward preventing vandalism of and tampering with such pop-up mechanisms. With reference to FIGS. 1-4, the present invention includes a lug 41 extending radially outwardly from the lower end portion of the post 19. The lug 41 is disposed directly superjacently of the threaded lower end 18 of the post. Joined to the distal end of the lug 41 is a housing 42. The housing 42 is provided with a generally arcuate cross-sectional elevational configuration, as shown in FIG. 4, and includes a slot opening 43 therein which generally defines a segment of a circle. A detent arm 44 includes an upper portion 46 which is received within the slot opening 43 of the housing 42, with a pivot pin 48 extending through the housing and the arm 44. The housing 42 also includes a stop member 47 which limits rotational movement of the upper end 46 of the arm 44 to a substantially vertical disposition, as shown in FIG. 4. However, the arm 44 is generally free to pivot in the counter-clockwise direction. It may be noted that the lower distal end of the arm 44 is provided with a blended curved terminus 49.
When the pop-up mechanism is initially installed in the drain body 11, the lower end 18 is threaded into the threaded hole 20 of the drain spider. The arm 44 depends downwardly by gravital force and the pop-up mechanism is rotated clockwise, as viewed from above, to engage the threaded end 18. During this procedure, the arm 44 is caused to repeatedly traverse the arms 16 of the drain body spider. However, due to the fact that the arm 44 may rotate freely in the direction necessary to clear the arms 16 of the spider, installation of the pop-up mechanism in the drain body is not impaired in any way.
However, once the pop-up mechanism is installed, removal of the pop-up mechanism requires rotation of the post 19 and its associated mechanism in the counterclockwise direction to unthread the end 18. This motion causes the spider arms 16 to impinge upon the detent arm 44 and drive the upper end 46 thereof to impinge upon the stop member 47. Thus the arm 44 cannot rotate to clear the spider arms 16, and the pop-up mechanism is prevented from rotating to effect removal thereof. Thus tampering and vandalism of the pop-up mechanism is also prevented. It may be appreciated that the drain cover prevents manual intervention with the arm 44, due to the restricted clearance thereby.
In a further embodiment of the present invention, depicted in FIG. 5, the pop-up mechanism and its assembly to the drain body is substantially as described in the preceding embodiment. However, rather than the boss and housing arrangement of the preceding embodiment, the present embodiment includes a hole 51 extending radially through the post 19 and disposed directly superjacently of the threaded end 18. A latch arm 52 includes a lower portion which depends gravitally through the plane of the spider arms 16, and an upper dog leg portion 53 extending at right angles to the portion 52 and received in rotatable fashion within the hole 51. Disposed directly adjacent to the hole 51 and slightly therebelow is a stop pin 54 extending radially outwardly from a hole provided in the post 19. It may be appreciated that the lower portion of the arm 52 is adapted to rotate from its generally downwardly extending disposition, through a counterclockwise angular excursion, to the disposition shown in phantom line in FIG. 5. However, the stop pin 54 prevents rotation of the lower end 52 from the downwardly extending disposition through any clockwise angular excursion.
As in the previous embodiment, the arm 52 may pivot freely upon impingement with the spider arms 16 when the pop-up mechanism is being threaded in clockwise fashion into the hole 20 of the spider portion. However, the stop pin 54 prevents the member 52 from pivotting in the direction necessary to clear the spider arm 16 when the pop-up mechanism is being rotated in a counterclockwise direction to remove the pop-up mechanism. Thus the embodiment depicted in FIG. 5 functions in substantially the same way to prevent tampering and vandalism of the pop-up drain fitting.
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In a pop-up drain fitting threadedly secured to a spider at the lower end of the drain body, the improvement comprising a detent member pivotally joined to the lower end of the pop-up drain fitting. A stop member is disposed adjacent to the detent member to permit the detent member rotation in only one direction. The detent member depends downwardly by gravitational force to extend through the spider. Clockwise threading motion of the pop-up fitting into the drain body is permitted by the detent arm; counterclockwise rotation of the pop-up fitting causes the spider to impinge upon the detent arm and drive it into the stop member, thereby preventing removal of the pop-up fitting.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to a central vacuum cleaner apparatus, and more particularly, to an adaptable twist lock intake system for use with a canister commonly included in a built-in vacuum cleaner frequently found in a building such as a house and useful for vacuuming floors, carpets, drapes, upholstery, etc. in the house.
BACKGROUND OF THE INVENTION
[0002] A first known type of central vacuum cleaning apparatus traditionally has one main vacuum (suction) intake on one side of the canister unit and a utility vacuum (suction) intake on the front of the canister unit. The main suction intake is used for connecting the network of piping in the house to the canister unit, and the utility suction intake is used when the homeowner wants to use the vacuum in a location that is relatively close to the canister unit. Typically, only one of these intakes is used at a time.
[0003] A second type of central vacuum cleaning apparatus has a dual intake configuration, wherein two vacuum (suction) intakes are located on diametrically opposite of each other on the wall of the canister unit. When one of these two vacuum intakes is used for connecting the piping network in the house, the other is either capped off or utilized as a utility vacuum intake with the result that only one of the suction intakes is used at a time.
[0004] In view of the foregoing, it is desirable for an installer of a central vacuum cleaning apparatus to have an option to use a main vacuum intake located on either the left or the right side of the canister unit and to be able to utilize a simple intake coupling assembly. Additionally, it is further desirable for the homeowner to have a cleaning apparatus provided with a usable front-located utility vacuum intake.
SUMMARY OF THE INVENTION
[0005] The present invention is an improved system for adapting the intake configuration of a central vacuum cleaning system. The present invention provides not only a custom vacuum intake connection arrangement for an installer, but also the convenience of a front-located utility vacuum intake for a homeowner. In general, the canister of the central vacuum cleaning system of the present invention is provided with at least two vacuum intake openings from which the installer can choose, depending upon which is in the most convenient location. The installer attaches the intake coupler of the present invention at the selected intake opening and a cap of the present invention at the non-selected opening(s) to close or cap them off.
[0006] Attachment of the intake coupler and cap of the present invention is achieved by use of a novel “twist-to-lock” interface between the canister unit openings and the coupler and cap. The intake coupler of the present invention comprises a unitary tube having a central flange with two locking tabs. The intake openings of the canister are circular holes with notches that are complementary to the locking tabs. Installation of the intake coupler into the intake opening is accomplished without the need for glue, clamps, tools or any other equipment by inserting the coupler into the desired intake opening so that the flange meets the canister wall surrounding the opening. A gasket is positioned within the interface to provide an adequate seal. Partial rotation of the intake coupler relative to the canister wall causes the tabs to engage their respective intake opening notches.
[0007] The cap of the present invention is constructed and arranged similarly to the intake coupler. The cap is provided with the same basic flange, tabs and gasket; however, when it is installed, the body of the cap extends mostly into the interior of the canister unit from the flange. The cap is provided with a diametrical wall to permit hand rotation at its external end.
[0008] Accordingly, it is an aspect of the present invention to provide a means for an installer of a central vacuum cleaning apparatus to have an option to use a main vacuum intake located on either side of the canister unit for connecting the apparatus to the vacuum piping network installed in the house.
[0009] It is another aspect of the present invention not only to provide a means for an installer of a central vacuum cleaning apparatus to have an option to use a main vacuum intake located on either side of the canister unit, but also for the homeowner to have a cleaning apparatus provided with a usable front-located utility vacuum intake.
[0010] It is yet another aspect of the present invention to provide an intake coupler means having a unitary construction that is simpler and less costly to manufacture and install than conventional, multi-piece coupler means.
[0011] It is a further aspect of the present invention to provide an intake coupler means that requires the use of no installation paraphernalia and no extra pipe pieces.
[0012] It is yet another aspect of the present invention to provide an intake closure means that, along with the intake coupler means of the present invention, can be readily installed, removed and relocated to any other intake opening of the canister unit at any time during the lifetime of the cleaning apparatus.
[0013] These and other aspects of the present invention will become evident by reference to the accompanying drawings and detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a perspective view of an intake coupler of the intake system of the present invention;
[0015] [0015]FIG. 2 is a side elevation view of the coupler shown in FIG. 1;
[0016] [0016]FIG. 3 is a cross-sectional view of the coupler shown in FIG. 1, taken along the line 3 - 3 shown in FIG. 2;
[0017] [0017]FIG. 4 is a cross-sectional view of the coupler shown in FIG. 1, taken along the line 4 - 4 shown in 3 ;
[0018] [0018]FIG. 5 is a partial side elevation view of the intake coupler shown in FIG. 1, taken in the flange and tab region of the coupler;
[0019] [0019]FIG. 6 is side view of a lug provided on the intake coupler shown in FIG. 1;
[0020] [0020]FIG. 7 is an end view of the lug shown in FIG. 6;
[0021] [0021]FIG. 8 is a perspective view of an intake closure of the intake system of the present invention;
[0022] [0022]FIG. 9 is a side elevation view of the intake closure shown in FIG. 8;
[0023] [0023]FIG. 10 is a bottom view of the intake closure shown in FIG. 8;
[0024] [0024]FIG. 1I is a side cross-sectional view of the intake closure shown in FIG. 8, taken along the line 11 - 11 shown in FIG. 10;
[0025] [0025]FIG. 12 is a plan view of a gasket used with the intake coupler shown in FIG. 1 and with the intake closure means shown in FIG. 8;
[0026] [0026]FIG. 13 is a side cross-sectional view of the gasket shown in FIG. 12 and taken along the line 13 - 13 therein;
[0027] [0027]FIG. 14 shows an exploded perspective view of the coupler shown in FIG. 1 and the gasket shown in FIG. 12 relative to a wall portion of a canister of a central vacuum cleaning apparatus, that defines a canister intake opening used with the intake system of the present invention;
[0028] [0028]FIG. 15 shows an exploded perspective view of the closure shown in FIG. 8 and the gasket shown in FIG. 12 relative to another wall portion of the canister shown in FIG. 14, that defines a canister intake opening similar to that shown in FIG. 12 and that is also used with the intake system of the present invention; and
[0029] [0029]FIG. 16 shows a side elevation view of a portion of a canister of a central vacuum cleaning apparatus, having the intake coupler shown in FIG. 1 and the intake closure means shown in FIG. 8 installed in intake openings provided in the canister wall.
DETAILED DESCRIPTION OF THE INVENTION
[0030] An intake coupler means 10 included in the intake system of the present invention is shown in FIGS. 1 - 7 . The coupler 10 generally comprises a unitary, conduit-like main body 12 having a first end (outlet) section 12 a , a second end (inlet) section 12 b and a mid-section 12 c that lies between the first and second end sections 12 a and 12 b . The section 12 a has a central, longitudinally extending axis A, the section 12 b has a central longitudinally extending axis B, and the section 12 c has a central longitudinally extending axis C. As most clearly shown in FIG. 3, the axes A and C intersect at a point lying on a plane oriented perpendicularly to the axes A and C and passing through the first angular bend 12 d and the first arcuate bend 12 e where the sections 12 a and 12 c join one another. The axes A and C intersect one another at an obtuse angle a ac that preferably will be 135° Similarly, the axes B and C intersect at a point lying on a plane oriented perpendicularly to the axes B and C and passing through the second angular bend 12 f and the second arcuate bend 12 g where the sections 12 b and 12 c join one another. The axes B and C intersect one another at an acute angle a bc that preferably will be 22.5°.
[0031] The sections 12 a , 12 b and 12 c of the body 12 collectively form a winding, inner passageway 14 that extends between a first circular opening 12 a , defined by the first end section 12 a of the main body 12 and a second circular opening 12 b , defined by the second end section 12 b of the main body 12 . The diameter of the passageway 14 at the second circular opening 12 b , is marginally larger than the diameter at the first circular opening 12 a 1 . This is the case because the second end section 12 b of the body 12 includes a radially extending flange portion 12 b 2 and an axially extending sleeve portion 12 b 3 that cooperatively define a widened neck region 14 a of the passageway 14 .
[0032] A lug 16 projects radially outward from and axially along the sleeve portion 12 b 3 of the second end section 12 b . As indicated by FIGS. 2, 3, 6 and 7 , the lug 16 comprises a first side wall 16 a , a second side wall 16 b , and an outer wall 16 c . The first and second side walls 16 a and 16 b are parallel to one another and extend radially away from and axially along the outer surface of the portion 12 b 3 . The outer wall 16 c , which is spaced radially away from and extends axially parallel relative to the portion 12 b 3 , is joined at its opposing axially extending edges to the radially outermost ends of the first and second side walls 16 a and 16 b . The inner faces of the first side wall 16 a , the second side wall 16 b , and the outer wall 16 c form a channel 17 . The channel 17 openly communicates at first opening 17 a with the neck region 14 a of the passageway 14 , at second opening 17 b with the second circular opening 12 b , and at third opening 17 c with the region exterior to the axially extending sleeve portion 12 b 3 of the second end (inlet) section 12 b . The channel 17 is also provided with first and second orifices 17 d and 17 e that respectively extend through the first and second side walls 16 a and 16 b of the lug 16 . A bolt 11 extends through the orifices 17 d and 17 e . A nut 13 secures the bolt 11 . The nut 13 and bolt 11 are used to adjust the circumference of the axially extending sleeve portion 12 b 3 of the second end (inlet) section 12 b for clamping the intake coupler 10 to a clamping flange of a vacuum piping network.
[0033] The mid-section 12 c of the coupler 10 includes a flange 18 and a pair of flange tabs 19 . The flange 18 is integrally joined at its radially innermost curved edge to the outer surface of the mid-section 12 c and has a first annular face 18 a , a second annular face 18 b and a radially outer curved edge 18 c . The first annular face 18 a is generally oriented toward the inlet end of the coupler 10 , and the second annular face 18 b , which is parallel to the face 18 a , is oppositely oriented toward the outlet end of the coupler 10 .
[0034] The pair of flange tabs 19 includes a first flange tab 19 a and a second flange tab 19 b . The flange tabs 19 a and 19 b are integrated transversely with the flange 18 at the second annular face 8 b and circumferentially with the mid-section 12 c at the outer surface thereof. The flange tabs 19 a and 19 b are positioned on the second annular face 18 b and the outer face of the mid-section 12 c so that they are diametrically opposite one another. The flange tabs 19 a and 19 b are structurally identical in all respects; therefore, a description of the structure of only one of them, the flange tab 19 a , will be provided here, and it will be recognized that whatever structural description is provided for the tab 19 a will be equally applicable to the other tab 19 b.
[0035] The flange tab 19 a is comprised of three integrated segments: an arcuate first end segment 19 a 1 , a straight middle segment 19 a 2 and a straight second end segment 19 a 3 . The arcuate first end segment 19 a , serves, among other things, as a means to join the tab 19 a to the flange 18 . The straight middle segment 19 a 2 extends in a plane that is perpendicular to the central longitudinal axis C of the mid-section 12 c of the main body 12 . The second end segment 19 a 3 adjoins the straight middle segment 19 a 2 and is angled away from the second annular face 8 b of the flange 18 and toward the straight middle segment 19 a 2 of the tab 19 a . The second annular face 18 b of the flange 18 , the outer surface of the mid-section 12 c and the surfaces 19 a 1 ′, 19 a 2 ′ and 19 a 3 ′ of the tab 19 a cooperate to define a circumferentially extending slot 15 a between the flange 18 and the tab 19 a . The purpose of the circumferentially extending slot 15 a along with a corresponding slot 15 b formed between the flange 18 and the tab 19 b will be explained later.
[0036] An intake closure means 20 included in the intake system of the present invention is shown in FIGS. 8 - 11 . The intake closure means 20 is a stopper-like structure molded from a plastic substance and having a substantially radially extending, disc-like base portion 22 , a substantially axially extending, cylindrical main body portion 24 and a substantially radially extending, annular flange portion 26 . The closure means 20 also has a radially and axially extending partition portion 28 that, along with the disc-like base portion 22 and the cylindrical main body 24 , defines a pair of recesses 27 and 29 that are situated on opposite sides of the partition 28 and are dimensionally the same in all respects. The partition portion 28 allows for hand grasping and manipulating the closure means 20 in a manner as will be hereinafter discussed.
[0037] The intake closure means 20 also has a pair of closure means flange portion tabs 23 that are diametrically located relative to each other. The pair of closure means flange portion tabs includes a closure means flange portion first tab 23 a and a closure means flange portion second tab 23 b . The first and second tabs 23 a and 23 b are structurally and dimensionally the same as the flange tabs 19 a and 19 b provided on the intake coupler means 12 . The tabs 23 a and 23 b are integrated transversely with the flange 26 at an annular face 26 a that is oriented toward the base portion 22 of the closure means 20 . The tabs 23 a and 23 b are also integrated circumferentially with the cylindrical main body portion 24 at the outer surface thereof. In a manner not unlike that described above in connection with the tabs 19 a and 19 b , the tabs 23 a and 23 b , the flange 26 and main body portion 24 cooperatively define a pair of circumferentially extending slots 25 a and 25 b . The slots 25 a and 25 b have the same purpose as the slots 15 a and 15 b provided on the intake coupler means 12 , which purpose will be hereinafter explained. Projections 21 project from the base portion 22 to form opposed and offset engagement surfaces 21 a . The projections 21 can be, for example, molded as a part of the closure 20 in an A-shaped configuration. The engagement surfaces 21 a are arranged so that a lever, such as a wrench or screwdriver can be inserted between the surfaces. A force can then be applied to the lever to rotate the intake closure 20 to facilitate installation and removal.
[0038] [0038]FIGS. 12 and 13 show a gasket 30 included with the intake system of the present invention. The gasket 30 is made of a resilient solid substance such as Santoprene® rubber, or any other substance having suitably similar properties. The gasket 30 is used with the intake coupler means 10 and with the intake closure means 20 in a way that will hereinafter be explained. The gasket 30 is comprised of a pair of first and second axially disposed, parallel faces 32 and 34 and a pair of first and second radially disposed, concentric edges 36 and 38 . The first edge 38 has a diameter that is greater than the diameter of the radially curved outer edge 18 c of the flange 18 of the coupler means 10 and the diameter of the radially curved outer edge 26 a of the flange 26 of the closure means 20 . Adjacent the first edge 38 , the gasket is thicker to form an axial flange 39 . The diameter of the second edge 36 of the gasket 30 is smaller than the diameter of the radially curved outer edge 18 c of the flange 18 of the coupler means 10 and the diameter of the radially curved outer edge 26 b of the flange 26 of the closure means 20 . The second edge 36 defines a central void 37 in the gasket 30 . The edge 36 further defines a pair of first and second notches 31 and 33 . The notches 31 and 33 have longitudinally extending central axes 31 ′ and 33 ′ that are equidistantly offset by a distance “d” relative to a transverse axis D that extends through the center of the gasket 30 . The notches 31 and 33 are shaped to have arcuate first ends 31 a and 33 a , straight parallel sides 31 b and 31 c and 33 b and 33 c , and open second ends 31 d and 33 d . The notches 31 and 33 are configured to permit the gasket 30 to be applied to the coupler means 10 and the closure means 20 in a manner that will now be described.
[0039] In the case of the coupler means 10 , the central void 37 receives the first end (outlet) section 12 a of the conduit-like main body 12 . The flange 39 of the gasket 30 faces away from the flange 18 of the coupler 10 . The edge 36 is then slid axially along the outer surface of the first end (outlet) section 12 a and thereafter along the outer surface of the mid section 12 c of the conduit-like main body 12 until the gasket 30 abuts the first flange tab 19 a and the second flange tab 19 b . The gasket 30 is then gently stretched in the radial direction over the tabs 19 a and 19 b and, if necessary, rotated clockwise or counter-clockwise so that the notches 31 and 33 receive first curved end segments of the tabs 19 a and 19 b and either of the axially disposed, parallel faces 32 and 34 contacts the second annular face 18 b of the flange 18 .
[0040] In the case of the closure means 20 , the central void 37 receives the disc-like base portion 22 and the cylindrical main body portion 24 of the closure means 20 . The edge 36 is then slid axially along the outer surface of the main body portion 24 until the gasket abuts the first flange tab 23 a and the second flange tab 23 b . The gasket 30 is then gently stretched in the radial direction over the tabs 23 a and 23 b and, if necessary, rotated clockwise or counter-clockwise so that the notches 31 and 33 receive first curved end segments of the tabs 23 a and 23 b and either of the axially disposed, parallel faces 32 and 34 contacts the second annular face 23 c of the flange 18 . With the gasket 30 assembled to the coupler means 10 and the closure means 20 in the manner just described, the coupler means 10 and the closure means 20 are ready for use with the canister unit 40 .
[0041] [0041]FIGS. 14 and 15 show a portion of a cylindrical, preferably metal, canister unit 40 that is adapted for use with the intake system of the present invention. The portion of the canister unit 40 includes a canister wall segment 42 and a portal structure 44 . The portal structure 44 is preferably formed in the wall segment 42 by a known stamping process. The portal structure 44 projects radially outward from the wall 42 and defines a canister intake opening 46 of the present invention. The portal structure 44 comprises a first gusset-like portion 44 a , a second gusset-like portion 44 b and a ring-like plate portion 44 c . The curved edges 44 a , and 44 b , of the first and second gusset-like portions 44 a and 44 b lay in a plane that is tangent to the wall 42 at the canister intake opening 46 and cooperate with adjoining portions of the canister wall 42 to define the periphery of the ring-like plate portion 44 c.
[0042] The canister intake opening 46 includes a flange shaped to receive and co-act equally well with either the first and second flange tabs 19 a and 19 b included on the flange 18 of the mid-section 12 c of the intake coupler means 10 or the first and second tabs 23 a and 23 b included on the annular flange portion 26 of the closure means 20 to form a mounting structure for mounting the intake couler to the suction intake. The canister intake opening 46 is defined by the first and second arcuate edges 46 a and 46 b , by the third and fourth arcuate edges 46 c and 46 d , by the first and second straight edges 46 e and 46 f , and by the third and fourth edges 46 g and 46 h . The first and second straight edges 46 e and 46 f respectively join terminal points of the first and third arcuate edges 46 a and 46 c and of the second and fourth arcuate edges 46 b and 46 d to form the sharp notches 47 , and the third and fourth edges 46 g and 46 h respectively join terminal points of the second and third arcuate edges 46 b and 46 c and of the first and fourth arcuate edges 46 a and 46 d to form the blunt notches 48 . The tabs 19 a and 19 b or 23 a and 23 b are received by the opening 46 so that either the annular face 18 b of the flange 18 of the coupler 10 or the annular face of the flange 26 of the closure means 20 abuts the ring-like plate portion 44 c of the portal 44 and either the free end of the straight second end segment 19 a 3 of the tab 19 a (or segment 19 b 3 of the tab 19 b ) or the comparable free end of the straight end segment of the tab 23 a (or the tab 23 b ) is received by one of the sharp notches 47 , i.e., the free end of the tabs 19 or 23 is spaced arcuately counter-clockwise relative to and axially inward from either the first straight edge 46 e or the second straight edge 46 f of the opening 46 . With the free end of the tabs 19 a and 19 b or 23 a and 23 b received in the manner just described, the coupler means 10 or the closure means 20 , along with the gasket 30 assembled thereto in the manner explained hereinabove, can simply and expeditiously be rotated clockwise by hand in the opening 46 until the arcuate first end segment 19 a 1 of the tab 19 a (or segment 19 b 1 of the tab 19 b ) abuts one or the other of the straight edges 46 e or 46 f or until the comparable arcuate first end segment of the tab 23 a (or the tab 23 b ) similarly abuts one or the other of the straight edges 46 e or 46 f . Once the coupler means 10 or the closure means 20 has been rotated in the opening 46 in the described manner, portions of plate 44 c that define the third and fourth edges 46 c and 46 d of the opening 46 are received in the circumferentially extending slots 15 a and 15 b of the coupler means 10 or in the comparable circumferentially extending slots of the closure means 20 with the gasket 30 being situated between the inside face of the plate 44 c and the tabs 19 a and 19 b or 23 a and 23 b . The portions of plate 44 c that define the third and fourth edges 46 c and 46 d of the opening 46 preferably are gently indented gently inward toward the center of canister unit 40 . Inward indentation of the third and fourth edges 46 c and 46 d causes the flange 18 and of the coupler means 10 or the flange 23 of the closure means 20 to be drawn slightly inward as either of them is rotated in the opening 46 which in turn causes the gasket 30 to be compressed and to thus establish an air-tight seal between the coupler means 10 and the canister unit 40 or between the closure means and the canister unit 40 and to thus restrict axial movement of the coupler means 10 or the closure means 20 relative to the ring-like plate 44 c.
[0043] In view of the foregoing, it should be evident that the intake coupling system of the present invention makes it possible for an installer to select one or the other of the two portal structures 44 for receiving the intake coupler 10 based on which of the structures 44 is most convenient for making a connection with an end of the vacuum piping network installed in the house and to effectively seal off the non-selected portal structure 44 with the closure means 20 . It should further be evident that the intake coupling system of the present invention makes it possible for the intake coupler means 10 and the closure means 20 to be installed into and removed from the portal structures 44 simply by twisting them by hand and without the need for any tools or application of sealant substances such a glue or cement.
[0044] Although a detailed description of a preferred embodiment of this invention has been shown and described hereinabove, it will be understood that various modifications and rearrangements of the parts and their respective features may be resorted to without departing from the scope of the invention as disclosed and claimed herein.
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An improved system for adapting the intake configuration of a central vacuum cleaning system is disclosed. The canister of the central vacuum cleaning system is provided with at least two vacuum intake openings from which an installer can choose to insert an intake coupler means and at least one intake closure means or cap of the present invention. Insertion and attachment of the intake coupler means and the cap(s) is achieved by use of a novel twist-to-lock interface provided between the vacuum intake openings and the coupler and cap(s). Attachment of the coupler and the cap(s) is accomplished easily and quickly by hand and without the need for glue, clamps, tools, or any other equipment.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to application Ser. No. 10/286,690.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a locking device which may be electrically operated in conjunction with a remote transmitter, while also having the capability of independent manual operation.
[0003] Pickup truck owners lack a secure area for storing tools and equipment, and one solution for this problem is a lockable, bed mounted storage box. The drawback of some of these existing boxes is that they do not utilize the electronic locking systems incorporated into most modern vehicles, and they do not permit remote operation. Rather, the owner who wants to permit other workers to access the box must either surrender the key or leave his work to accompany the worker to the box to unlock and relock it.
BRIEF SUMMARY OF THE INVENTION
[0004] An electric lock with manual redundancy for operation in conjunction with a vehicle's electronic locking system, and the method of operation.
BRIEF DESCRIPTION OF THE SEVERAL DRAWINGS
[0005] FIG. 1 is a diagram of the electrical schematics of the device.
[0006] FIG. 2 is a top view of the device.
[0007] FIG. 3 is a perspective view of the front of the device.
[0008] FIG. 4 is a top view of the device in manual open position.
[0009] FIG. 5 is a perspective view of the back of the device in the manual open position.
[0010] FIG. 6 is a top view of the device in the remote position.
[0011] FIG. 7 is a perspective view of the device in the remote position.
[0012] FIG. 8 is a perspective view of the device in the manual locked position.
DETAILED DESCRIPTION
[0013] The device comprises an electric lock for operation with a wireless transmitter with the ability both to lock the device remotely and to set the device remotely for keyless electric opening. Some embodiments of the present invention provide an electrical locking device capable of being operated with a motor vehicle's existing remote keyless entry transmitter system, so an owner need not carry separate transmitters for a vehicle's locks.
[0014] An owner need not surrender his key or wireless transmitter to permit another worker to open the device.
[0015] Some embodiments of the present invention comprise a redundancy feature which allows an owner to use a key to lock the device manually to override any remote operation, and to use a key to manually open the device. A power failure of the wireless transmitter or electric lock mechanism will not prohibit an owner from opening the device. Rather, in the event of failures such as loss of electric power, transmitter system malfunction or electric driver failure, an owner may still operate the lock by using a redundant manual mechanical system.
[0016] The present device comprises a lock mechanism 2 having a key 4 . The key may be inserted and turned in a lock barrel 6 into a manual lock position 94 , a manual open position 12 , and a remote position 8 .
[0017] When the key 4 in either manual lock position 94 or manual open position 12 , the lock mechanism 2 manually locks or unlocks the device respectively.
[0018] When the key 4 is in remote position 8 , the device is ready for remote operation. FIG. 1 is a diagram showing an electrical schematic of the device illustrating its remote operation. A wireless transmitter 32 sends a signal (not shown) to a transmitter receiver 34 . The receiver 34 is electrically connected to a relay 36 . The relay 36 sends an operational signal (not shown) to micro switch 28 . Relay 36 is shown with chassis ground 22 and battery 38 .
[0019] An owner activates the keyless entry system of the vehicle to lock the vehicle's doors thereby sending a non-conditioning signal to relay switch 36 . This prevents any electrical operation of the lock device. However, turning key 4 in lock mechanism 2 to manual open position 12 will trip latch module 14 and open truck box lid 16 . Turning key 4 to the manual lock position 94 will prevent the lock mechanism 2 from opening by preventing latch module 14 from being tripped even if there is a conditioning signal sent to relay switch 36 .
[0020] When the owner activates the keyless entry system to unlock the vehicle's doors, a conditioning signal is sent to relay switch 36 . An operator, either the owner or another person, can open the truck box lid 16 by pushing a pushbutton switch 18 incorporated into switch 28 , completing a circuit 20 between switch 28 and a chassis ground 22 . Switch 28 momentarily provides electrical power to linear actuators 26 and 46 to move return push rods 97 and 98 , to trip latch module 14 and open truck box lid 16 .
[0021] FIGS. 2-6 illustrate the mechanical operation of the some embodiments of the present invention. Key 4 is insertable into a matingly receptive key shaft 40 in barrel lock assembly 2 in the remote position 8 . Key 4 may be rotated counter-clockwise approximately 90 degrees from the remote position 8 to the manual lock position 94 , preventing further key shaft 40 rotation if key 4 is removed. Key 4 can also be rotated approximately 90 degrees clockwise from the remote position 8 to the manual open position 12 .
[0022] A latch activating arm 44 rotates coaxially with rotation of the key 4 .
[0023] When key 4 is in the manual lock position 94 , latch activating arm 44 has been rotated where it cannot engage either manually or electrically with the latch linkage 93 .
[0024] When key 4 is turned to the manual open position 12 , arm 44 has been rotated clockwise coaxially with key 4 . This causes arm 44 to manually drive latch linkage 93 to slide within linkage slide connector 95 to slide linkage 50 such that lock pin 52 is released. Lock pin 52 is fixed to latch stop 53 and projects vertically between latch stop 53 and lock strike 54 when the truck bed lid 16 is closed. Sliding of linkage slide connector 95 turns latch stop 53 causing lock pin 52 to release lock strike 54 , unlocking the truck bed lid.
[0025] With key 4 in the remote position 8 , latch module 14 can be triggered to open electrically. In the remote position key shaft 40 holds latch activating arm 44 in a vertical orientation. When switch 28 is conditioned by a conditioning signal (not shown) from transmitter receiver 34 and push button switch 18 is operated, power is provided to linear actuator 26 and 46 . Linear actuator 26 and 46 overcomes a return spring 96 and retracts pushrods 97 and 98 . Pushrods 97 and 98 retract linkage 50 , thereby pulling linkage slide connector 95 , thus turning lock pin 52 and releasing lock strike 54 . When power is no longer provided to linear actuator 26 and 46 , return spring 96 forces pushrods 97 and 98 back to a extended configuration.
[0026] When key 4 is in remote position 8 but in the absence of the conditioning signal, operation of push button switch 18 cannot provide sufficient current (not shown) or complete circuit 20 . Return spring 96 maintains pushrods 97 and 98 in the extended position and correspondingly, the lock pin 52 remains unrotateable.
[0027] In some embodiments of the present invention, switch 28 provides a pulsed 12 volt signal through solenoid 56 to linear actuator 26 and 46 .
[0028] Lock pin 52 is fixedly attached to latch stop 53 . Latch stop 53 abuts arm 44 when the device is in the remote position 8 on a side 55 of the latch stop. The opposite side 57 of the latch stop 53 abuts interior truck box surface 5 to halt the rotation of lock pin 52 .
[0029] As FIG. 2 , a top view of the device, illustrates, a bracket 58 supports latch stop 53 , which is glidingly attached to linkage slide connector 95 by latch linkage 93 (shown on FIG. 4 ) with connector 50 . The latch actuators 26 and 46 further comprise pushrods 97 and 98 respectively. Latch actuator 26 further comprises return spring 96 . Lock pin 52 and latch activating arm 44 are capable of coaxial rotation, and are mounted with bracket 58 to align with lock strike 54 (not shown) in either the remote position 8 or the manual lock position 94 .
[0030] As FIG. 3 , a perspective view of the front of the device, illustrates, lock barrel 6 is matingly receptive for key 4 (not shown) and the key is capable of rotation between an approximately vertical remote position 8 and manual lock or open positions 94 and 12 at approximately quarter turns counterclockwise and clockwise respectively. As can be seen from this description, some embodiment the present invention may comprise a lock mechanism orientation which places the remote position 8 at an orientation other than vertical and permits relative rotation to the other positions 94 and 12 .
[0031] As FIG. 4 , a top view of the device in manual open position 12 , illustrates, key 4 has been inserted into barrel lock 6 and rotated clockwise from the remote position 8 turning latch activating arm 44 such that it moves latch stop 53 and linkage 95 , while simultaneously turning lock pin 52 , thereby releasing it from lock strike 54 .
[0032] As FIG. 5 , a perspective view of the back of the device in the remote position, illustrates, key shaft 40 places latch activating arm in proximity to switch 8 (seen in FIG. 6 ) which comprises the incorporated push button switch 18 . In this configuration linear actuator 26 and 46 can retract pushrods 97 and 98 causing activating arm 44 to move linkage 50 thereby releasing lock pin 52 .
[0033] FIG. 6 is a top view of the device in the remote position, illustrated without the bracket 58 and without latch stop 53 to show the slidingly mated relationship of the linkage 50 , linkage slide connector 95 , and latch linkage 93 . Latch linkage 93 is capable of pulling on the latch stop 53 causing latch stop 53 to rotate, thereby driving the rotation of lock pin 52 .
[0034] FIG. 7 is a perspective view of the device in the remote position 8 . Latch activating arm 44 is capable of contact with switch 28 .
[0035] FIG. 8 is a perspective view of the device in the manual lock position 94 . Rotation of key 4 to the manual lock position 94 moves the latch activating arm 44 out of range of contact with switch 28 . This prevents electrical operation of the lock and provides manual lock override of the device for additional security.
[0036] In some embodiments of the present invention, latch module 14 is a “slam” latch which is well know in the industry. Substitution of other types of latches compatible with the other components of this invention would be well know to one skilled in the art.
[0037] The terms and expressions which have been employed in the forgoing specification are used therein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding equivalence of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow.
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An electric lock operating in conjunction with a wireless remote transmitter and having redundant manual operation capability. The key lock cylinder has a three way position. In the remote position, the lock is enabled or disabled via a remote wireless transmitter. Operation of the wireless transmitter switch allows electric power to a micro switch that allows electricity to drive open a mechanical latch when a circuit is completed touching a pushbutton switch. In a manual lock position, the electronic function of the lock are disabled by mechanical discontinuity of a circuit preventing the latch from being opened either by electrical or mechanical operation. Turning the key in the lock cylinder to the manual open position will mechanically actuate the latch to open through a linkage system.
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CROSS REFERENCE
[0001] This is a division of application Ser. No. 10/968,369, filed on Oct. 19, 2004, of Zbigniew Tokarz, for TRANSVERSE-FLOW PYROCATALYTIC REACTOR FOR CONVERSION OF WASTE PLASTIC MATERIAL AND SCRAP RUBBER, which claims priority to Polish Application Nos. P364006 filed Dec. 11, 2003 and P 365361 filed Feb. 18, 2004.
FIELD OF THE INVENTION
[0002] The present invention relates to an improvement in a pyrolysis reactor wherein organic waste is catalytically converted into hydrocarbons which are recovered as vapor issuing from a molten lead bath. “Organic waste” or “waste” for brevity, refers herein to a predominantly hydrocarbon synthetic resinous materials, substantially free of halogen-containing resins, referred to herein as “plastics”, and, rubber from scrap tires.
[0003] The plastics or rubber are mixed with a unique catalyst as the mixture is moved along the heated molten lead along the length of the bath, longitudinally from the bath's feed-inlet end to its residue-discharge end, while the bath is heated with a heating medium flowing first in a longitudinal direction, then in a direction transverse to the flow of waste. The reactor is therefore referred to as a “transverse-flow pyrocatalytic” reactor. The transverse direction is referred to herein as the “x”-axis, the longitudinal axis is referred to as the “y”-axis and the vertical direction is referred to as the “z”-axis. Vapors of hydrocarbons generated within the reactor, which vapors are readily condensible in a cold water heat exchanger, are recovered in a conventional recovery system. The recovered, condensed hydrocarbons are preferably further conventionally refined for use as diesel fuel, gasoline and heating oil; and the non-condensible hydrocarbons, along with carbon monoxide and carbon dioxide are preferably recycled as a gaseous recycle stream to provide fuel for burners used to generate hot gases to heat the bath.
BACKGROUND OF THE INVENTION
[0004] The Problem: Molten lead, used as a heating medium to pyrolyze plastics and rubber waste in the prior art, presents unique problems because lead is about 11.5 times heavier than the waste—the waste is quickly forced to the surface preventing contact time with the lead long enough to convert the waste in a reasonable amount of time. Particularly when solid waste includes polyolefins, poly(vinyl aromatic)s, and rubber from worn out tires, it is difficult to provide an economical level of conversion to reusable hydrocarbons within a residence time (in the molten bath) of less than 1 hour, preferably less than 30 min. “Reusable hydrocarbons” refers to both higher molecular weight hydrocarbons which are condensed, and lower molecular weight hydrocarbons which can be recycled as fuel. Reusable hydrocarbons consist of a major proportion by weight of condensible C 5 + hydrocarbons (having at least five carbon atoms) and a minor proportion (relative to the C 5 + hydrocarbons) of non-condensible C 1 -C 4 hydrocarbons, typically less than 20% by weight of the C 5 + hydrocarbons, the components in the vapor phase being in equilibrium with those in the condensate at the temperature and pressure conditions of condensation within the condenser.
[0005] Though a molten lead bath is able to provide a source of heat at a chosen, substantially constant temperature, using molten lead (or “melt”) as a heat transfer medium in a substantially oxygen-free atmosphere in the reactor, presents numerous difficulties. To begin with, a floating layer of organic waste acts as an insulating barrier, preventing pieces of waste within the floating layer from being heated sufficiently to depolymerize. If the waste cannot be adequately contacted with the melt it does not matter how much melt is in the bath. Yet, efficient heat transfer from the melt to the waste, to obtain an economic residence time in the melt, must not interfere with being able to transport the waste longitudinally through the melt. To cope with this problem by providing a high enough bath temperature to effect the pyrolysis in a reasonable amount of time, results in too high a production of hydrocarbons lower than C 4 , appreciable CO and CO 2 . To complicate the problem, when using a solid, particulate, catalyst it is critical that the waste be contacted and mixed with both the catalyst and the melt.
[0006] When such a catalyst is a combination of an aluminum powder and aluminum oxide mineral, whether calcined hydrated alumina, or calcined zeolite, this mixing is difficult to do without using a fluid bed. “Zeolite” refers to a natural or synthetic composition typically having the structure M x/n [(AlO 2 ) x (SiO 2 ) y .zH 2 ) where n is the charge of the metal cation, M n+ , which is usually Na + , K + , or Ca 2+ , x and y are integers, typically having substantially the same value in the range from 2 to 10, and the z is the number of moles of water of hydration.
[0007] Since conversion of scrap rubber generates sulfur and sulfur-containing compounds, the catalyst, most preferably a combination of aluminum powder and calcined bauxite powder, is required to be substantially unreactive with both, the sulfur and sulfur-containing compounds, and chlorine and hydrochloric (HCl) acid gases, if such gases are present in an appreciable amount. In addition, the reactor requires an essentially oxygen-free atmosphere within it; and the high specific gravity of lead precludes using very much of the melt in the bath, for practical cost considerations relating to the structural requirements of a vat or trough in which the molten lead bath is held.
[0008] Moreover, though the housing and other components of the reactor are typically made of acid and heat-resistant sheet steel, e.g. H25N20S2, the steel does not have notably long-term resistance to SO 2 , H 2 SO 3 , chlorine and HCl gases. The reliance on affordable steel and the use of aluminum powder in the catalyst requires feeding plastic substantially free of a halogen-containing synthetic resin, to the reaction zone, if safe, long-term operation of the reactor is sought. By “substantially free of a halogen-containing synthetic resin” is meant that less than 5% by weight of the waste is a polymer containing chlorine, bromine, iodine or fluorine, e.g. poly(vinyl chloride) (“PVC”) scrap, or other halogen-containing synthetic resins, e.g. chlorofluoro-, chlorobromo- and fluorocarbon polymers.
The Prior Art
[0009] Molten metal, particularly lead, has been the heat transfer medium of choice for the thermal conversion of organic matter, generally. The problem of heating organic matter which floated on a molten lead bath was recognized as early as before 1926 when U.S. Pat. No. 1,601,777 disclosed moving crushed shale along the undersurface of a slightly inclined apertured member, beneath the surface of a heated bath. U.S. Pat. No. 2,459,550 addresses the problem by confining wood or coal pieces between two endless screens. U.S. Pat. No. 3,977,960 teaches using angularly inclined screw conveyors to force crushed shale into a molten bath. As recently as 1990, U.S. Pat. No. 4,925,532 teaches moving perforated baskets filled with waste on an endless conveyor; the baskets are hooked to the conveyor to prevent them from floating against guide rails above the baskets. The '532 patent teaches that it is critical that the molten lead bath be maintained above 343° C. (650° F.), ignoring the fact that the melting point of pure lead at atmospheric pressure is just below, i.e. 327.5° C. (621.5° F.). It failed to realize that a catalyst could enhance conversion; and it missed the fact that optimum conversion of polyolefins, polystyrene and scrap from tires, to vapor consisting essentially of a major proportion by weight of C 5 + hydrocarbons occurs only in the narrow range from 450° C.-550° C. (842° F.-1022° F.), a range commencing more than 100° C. above the temperature deemed critical. Most recently, in 1992, U.S. Pat. No. 5,085,738 teaches using a long, upwardly inclined oxygen-free cylindrical chamber filled with molten lead, through which chamber pieces of scrap tires are forced. A ram is used to circumvent the problem of floating rubber, but still relying solely on the thermal pyrolysis of the submerged rubber. The prior art countered the high specific gravity of molten lead by confining the charge in the melt. It ignores the problem of essentially instantly solidifying molten lead on the rubber as it is fed, because of the low heat capacity (and specific heat) of the lead; and, the requirement of timely supplying adequate heat to re-melt the lead.
[0010] It will be evident that the invention disclosed herebelow, for feeding the waste to the reactor, converting the waste in the reactor, removing and disposing of the residue, is based on the use of a unique catalyst in combination with a novel and unexpectedly efficient system of dealing with the numerous problems associated with feeding waste and catalyst to a molten lead bath in a sealed environment, including, for practical operation of the reactor, not submerging the waste in the molten lead. Further, not unexpectedly, the prior art processes and apparatus which rely solely on thermal pyrolysis of plastics and rubber in molten lead, are conspicuously devoid of data showing the effectiveness of the conversions obtained. As will be evident from the data presented below, the conversion of waste to reusable hydrocarbons by pyrolysis in molten lead alone, is only 53% (see Table 1) when the scrap is PE (polyethylene) and PP (polypropylene); and more than 90% when the catalyst used is bauxite/Al=97/3.
[0011] Recognizing the advantage of using an effective catalyst for the conversion of waste polyolefins, polystyrene and the like to hydrocarbons, U.S. Pat. No. 4,851,601 teaches using a fluid bed of zeolite particles, as does Chinese patent application WO95/06682. In each case, hydrocarbons having a wide range of boiling points are collected, but they rely on the efficient heat transfer provided by a fluid bed and the catalytic effect of a zeolite only, and the zeolite, by itself is evidently unaffected by the presence of chlorine in PVC.
SUMMARY OF THE INVENTION
[0012] The conversion of substantially halogen-free waste to desirable hydrocarbons is effected by providing an elongated generally rectangular vat or trough in which molten lead is held within a sealed, essentially oxygen-free housing, and the waste is contacted with a catalyst consisting of a combination of an aluminum oxide mineral powder<2 mm diameter, and essentially pure aluminum powder<0.1 mm diameter, while the waste is being heated with the melt. The catalytic action is evidently provided by the interaction of the pure aluminum and the aluminum oxide molecules. The aluminum mineral oxide powder is preferably calcined to avoid generating water from uncalcined oxide in the melt.
[0013] Waste, preferably compacted and fed unconfined to the inlet of the vat, floats on the melt and is mixed and tossed with a reciprocable steel grating while the waste is urged from one end of the vat to the other, being advanced longitudinally through the vat, without the waste being submerged in the melt. The steel grating moves from a position under the surface of the melt where it is heated, to a position above the melt where the grating transfers the heat to the waste. This feature, utilizing the much higher heat capacity of steel (nearly three times higher than that of lead) overcomes the problem of having molten lead solidify, essentially instantly, on the waste when it is submerged in the melt. Such solidification results because the rate of heat transfer from the melt to the waste is so high. Such waste, with lead solidified on it, must then be transported while being heated to liquefy the melt. Though submerging the waste in the melt will have the same thermal result, in a commercial reactor to which more than 1000 Kg/hr of waste is fed, it is difficult to move so much waste, with solidified lead on it, through the vat; and it is not practical to heat so much waste, with solidified lead on it, at a rate high enough to re-melt the lead on the waste and obtain an economical residence time.
[0014] The waste is intermittently advanced by using at least one, preferably plural, laterally spaced-apart rotatable drums, each provided with radially protruding blades which urge waste on the surface of the molten lead longitudinally along the length of the trough. Simultaneously, the waste is bathed with melt scooped up from near the surface of the bath. Because, as the waste is converted, the amount of floating waste is progressively reduced, the axis of rotation of each drum is lower than the preceding drum, that is, the axis of each successive drum is progressively vertically downwardly spaced-apart.
[0015] The use of the reciprocable mixing grating in cooperation with each drum, except the first near the inlet of the vat, urges waste upwards towards the drum and bathes floating waste with molten lead, thus providing the contact necessary to convert the waste while dealing with solidifying lead; simultaneously, “fingers” on the drum advance the waste through the vat. It is this unique mechanism for urging the floating waste through the molten bath without submerging the waste in the bath, in combination with the catalytic action of the catalyst used, and the essentially constant temperature of the molten lead held in a desired range of temperature, which accounts for the success of this waste-conversion process. High conversions to desirable hydrocarbons, and avoiding the formation of all but a relatively small amount of carbonaceous residue, is effected by choosing the appropriate temperature to match the waste being fed. Depending upon how clean the waste is, the residue will also contain stones, pieces of wire from scrap tires, pieces of stray metal, glass and other solids not decomposed at the temperature of the molten lead. The residue is continuously removed from the reactor with an endless chain conveyor.
[0016] Either crushed calcined bauxite alone, or aluminum powder alone, is insufficiently effective as a catalyst to convert waste, even when >90% (more than 90 percent) of the bauxite particles are <1 mm in diameter, and >90% of the aluminum powder particles are <0.1 mm (at least an order of magnitude smaller than bauxite). “Diameter” refers to the equivalent diameter of a particle. However, when a mixture consisting essentially of a major proportion by weight of the same bauxite is combined with a minor proportion of the same aluminum powder and contacted with both the heated waste and molten lead, the combination catalyst is typically more than 60% effective to convert the waste into reusable hydrocarbons. Unexpectedly, the substantially halogen-free, reactive atmosphere of hydrocarbons within the reactor, boosts the effectiveness of the aluminum powder rather than negating it.
[0017] Contact with molten lead, by waste and catalyst, both of which are much lighter than lead, is ensured by using a combination of successive drums with radially protruding mixing fingers which engage the waste in the floating layer as it is moved upwards by a grating. The grating is part of a U-shaped saddle forming a cooperating mixing and bathing assembly. The grating reciprocates at a slight angle, less than 30° to the vertical, heats the waste by contact with it, and bathes the floating waste with melt scooped from the surface of the bath. This combined action of heating and bathing the waste with melt and also urging it longitudinally along the length of the bath, allows conversion of the waste with a residence time in the molten bath of less than 1 hour, preferably less than 30 min.
[0018] Though lead melts at 327.5° C. (621.5° F.), optimum effectiveness of the catalyst is achieved at a temperature in the narrow range from about 450° C.-550° C. (842° F.-1022° F.); conversions to reusable hydrocarbons drops off at temperatures below 450° C., but above 400° C., and above 550° C. but below 600° C. where conversion to C 5 + hydrocarbons decreases, and to C 4 and lower hydrocarbons increases above 20%, and normally negligible oxidation to CO and CO 2 increases.
[0019] A process for pyrocatalytic conversion of organic waste comprises, feeding waste into a reaction zone of a pyrocatalytic reactor, the waste being essentially free of a halogenated synthetic resinous material; mixing the waste with a minor proportion by weight of a catalyst in a bath of molten lead held at a temperature in the range from 400° C. to 600° C. in an elongated vat; recovering hydrocarbons generated in the reactor; and, removing carbonaceous residue. Thus, though the waste is unconfined, except by the surface of the melt, the waste is thermally and catalytically converted with at least 50% effectiveness into reusable hydrocarbon vapors which are condensed.
[0020] The catalyst consists essentially of a major proportion by weight of bauxite powder, preferably calcined, in combination with a minor proportion of the aluminum powder having a minimum nominal aluminum content of at least 95%, preferably at least 98%, and a Fe content of less than 0.5% and Si less than 0.2%. The amount of the catalyst required is preferably no more than 20% by weight of the waste charged, preferably less than 10%, most preferably less than 5%.
[0021] The system for converting the waste comprises an elongated vat which is confined in an essentially oxygen-free environment of the reactor; the vat has a feed-inlet or “charging” end and a “residue-discharging” or “discharging” end; the length of the vat is sufficient to afford a residence time for the waste of no more than one hour, and the depth of molten lead in the vat is at least 10 cm. The waste on the molten lead is urged along the vat's longitudinal axis and bathed, substantially simultaneously, with melt. The contact of waste with melt is effected by a reciprocable grating moving into and out of the melt. Preferably, the reactor is fed with a feeding mechanism which compacts waste into a feed tube at the inlet of the reactor, forming an air-tight seal; and carbonaceous residue is discharged by being compacted against an inclined plane and an adjustable continuous chain conveyor into a residue-disposing assembly.
BRIEF DESCRIPTION OF THE DRAWING
[0022] The foregoing and additional objects and advantages of the invention will best be understood by reference to the following detailed description, accompanied with schematic illustrations of preferred embodiments of the invention, in which illustrations like reference numerals refer to like elements, and in which:
[0023] FIG. 1 is an overall side elevational view schematically illustrating the main components of the system.
[0024] FIG. 2 is a perspective view illustrating a mixing and bathing assembly used to provide the necessary contact of waste and melt.
[0025] FIG. 2A is a detail of one effective embodiment of a mixing and urging finger welded to the surface of each mixing drum.
[0026] FIG. 3 is a cross-sectional view in the vertical plane 3 - 3 in FIG. 1 , looking in the direction of the arrows, without showing the U-shaped saddle under the drum.
[0027] FIG. 4 is a cross-sectional view of the reactor taken along the vertical plane 4 - 4 in FIG. 1 looking in the direction of the arrows.
[0028] FIG. 5 illustrates an embodiment of a feeding mechanism.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0029] The key feature of the process is contacting the waste with a combination catalyst selected from the group consisting of a particulate calcined hydrated aluminum oxide and a zeolite, mixed with aluminum powder in a molten lead bath. The waste is typically selected from the group consisting of a polyolefin, e.g. PE and PP; a poly(vinyl aromatic), e.g polystyrene; a polyamide, e.g. nylon; a rubber derived from a conjugated diene, the diene having from 4 to 5 carbon atoms, e.g. polybutadiene and polyisoprene, whether natural or synthetic; and, a rubber defined as a polyblock copolymer of a vinylaromatic compound and a conjugated diene, optionally hydrogenated to include a block of a monoolefin, the olefin having from 2 to 4 carbon atoms, e.g. Kraton® styrene-butadiene-styrene or “SBS” rubber. The term “aluminum oxide mineral” refers to minerals which contain a high amount of alumina, for example the hydrated aluminas and the zeolites which are alumino-silicates. This combination catalyst, in which the preferred aluminum oxide mineral is a calcined hydrated alumina, results in a practical residence time of less than 1 hour results from mixing the waste and forcefully urging it from the feed-charging or inlet end of the vat to the residue-discharging end of the vat.
[0030] Aluminum powder consists essentially of microgranules most of which have an equivalent diameter of less than 44 μm, each being essentially pure aluminum (>99.5% Al) coated with a thin skin less than 0.1 μm thick (referred to as a “nanothick skin”). Such powder is preferably made by atomization of molten aluminum through small orifices in an atomizing head immersed in molten aluminum. As molten aluminum flows through the orifices it strikes a stream of compressed air. This forms a spray of aluminum melt which is quenched at rates on the order of 10 2 to 10 8 ° K./sec to form substantially spherical microgranules of pure Al coated with an aluminum oxide skin from 3 to 20 nm thick.
[0031] The most preferred finely divided aluminum oxide mineral is calcined bauxite (and commercially available), though less readily available particulate gibbsite (a trihydrate), boehmite and diaspore (monohydrates), may also be used. When initially starting up the system, to facilitate catalytic conversion of the waste, catalyst is dropped onto freshly molten lead in the vat, from hatches (openings) in the roof of the reactor. Before feeding waste to the reactor it is mixed with a small amount of additional catalyst so that the amount of catalyst in the waste while it is in the reactor is in the range from about 0.5% to 20%.
[0032] The preferred bauxite employed by the process is particulate bauxite, available in Poland as “Boksyt kalcynowany”, in a size range<1 mm having the following analysis: Al 2 O 3 —min 86% (typically 87.2%); Fe 2 O 3 —max 2% (typically max 1.6%); K 2 O+Na 2 O—max 0.25% (typically 0.18%) and SiO 2 —max 6% (typically 5.2%); the sp. gr. is in the range from 2.5-3.2, the bulk density is about 3.1 g/cc the apparent porosity is <10. More than 50% of all particles are in the size range from about 50 μm to 250 μm, less than 10% being smaller than 50 μm, and the remaining being in the range from 250 μm to 0.1 mm.
[0033] Aluminum powder is preferably metallurgical grade available from Benda-Lutz Skawina having the following typical analysis: 99.7% Al; 0.28% Fe; and 0.07 Si. A typical particle size distribution is as follows: 77.6%>0.032 mm; 36.1%>0.063 mm; and 4.0%>0.09 mm. The average particle diameter of the Al powder is in the range from about 25-50 μm. Comparable aluminum powder is available from Alcoa in the Grade 100 and Grade 1200 series, among others.
[0034] A preferred ratio of the aluminum powder to bauxite powder is in the range from about 0.5-20% aluminum powder, preferably in the range from about 1-10% aluminum powder, most preferably less than 5%, there being very little economic improvement in conversion when the amount of aluminum powder exceeds 10%.
[0035] Instead of mixing calcined aluminum oxide mineral, e.g. bauxite with aluminum powder, an alternative method for preparing the catalyst is by spraying a molten stream of aluminum at a temperature above 1200° C. onto a falling stream of bauxite particles in the size range given above. This results in the aluminum powder being adhered to and supported on the particles of bauxite. In one embodiment, this may be achieved by mixing solid particles of aluminum metal into the flame of an oxy-acetylene torch at a temperature in the range from about 2000° C. to 3000° C. and directing the flame at a falling stream of particles of bauxite. The same may be done with any other aluminum oxide mineral, whether zeolite, gibbsite, etc.
[0036] The pyrocatalytic conversion of waste is most effective when the system is fed with waste which is not “mixed” waste, but a particular class of waste, e.g. polyolefins; or polystyrene; or scrap rubber from vulcanized polybutadiene, polyisoprene and natural rubber in automobile, truck and aircraft tires. To a lesser extent, the catalyst is also effective with other poly(vinyl aromatic) resins, nitrile rubber, styrene-conjugated diene-styrene rubber, acrylate rubber and other predominantly hydrocarbon plastics. It is therefore desirable to sort the waste to provide a particular material to be converted under temperature conditions and a ratio of catalyst components specifically chosen for that material.
[0037] Irrespective of the particular waste chosen, its specific gravity is typically about 1 or less, and, when fed into the molten lead, the waste will be forcefully thrust to the surface, forming a waste layer which functions as insulation, minimizing contact of all but the bottom of the layer with the molten lead and catalyst.
[0038] Though any bath containing a predominant amount of lead may be used, a lead bath containing less than 10% by weight of another metal is preferred. Such a bath provides a high heat transfer coefficient, the heat content of the bath is rapidly exhausted as waste is converted, and the heat must be just as rapidly replenished. The limitations this places on the system are magnified by (i) heat conduction occurring primarily in the vertical direction as the source of heat is from below the melt, and (ii) the layer of floating waste effectively insulating the upper portion of the layer from the heat in the melt. Therefore it is critical that, to meet an economic residence time of less than an hour, the floating waste be actively bathed with melt as the waste is urged along longitudinally along the surface of the melt.
[0039] It is not necessary, if the waste is polyolefin film, or small containers thereof, to comminute the waste, but it is desirable to cut up tires into pieces having an average weight in the range from about 50 g-1 Kg, thus avoiding the cost of comminuting the tires into pieces weighing less. Means for cutting up tires are well known and any of these means may be employed with varying degrees of effectiveness, those providing relatively smaller similarly sized pieces being easily fed into and submerged in the molten lead.
[0040] Referring now to FIGS. 1-5 , the system includes a feeding mechanism, referred to generally by reference numeral 90 (see FIG. 5 ), through which waste W is fed to a reactor 10 housed in an insulated housing H (not shown in FIG. 1 , see FIG. 4 ). Waste W is converted to hydrocarbons in an elongated, heated vat 20 in the reactor, leaving a residue R which is discharged first through a residue-discharging mechanism 60 , and thereafter, to a residue-disposing mechanism 80 . The waste W is compacted and fed to the reactor 10 as a dense, tightly-packed mass of W which functions as an effective air-tight seal to prevent entry of air into the inlet end of the reactor. The waste W enters the vat on an inlet-incline 21 functioning as a feed-guide for waste and guiding it to flow beneath a first of at least two, and preferably five urging drums 13 , 14 , 15 , 16 and 17 , each rotatably mounted on axially aligned supporting shafts 18 and 18 ′ (see FIGS. 2 and 3 ), one of which ( 18 ′) is a passive shaft, the other 18 driven by drive means such as an electric motor M 1 ( FIG. 3 ).
[0041] The reactor 10 preferably comprises a box-shaped reinforced steel casing 11 having a roof 12 , front and rear sidewalls 19 and 19 ′ (only rear sidewall 19 ′ is shown) and end walls E 1 , E 2 all of which are insulated to conserve heat within the reactor, and further protected by an outer insulated structure (not shown in FIG. 1 ). The roof 12 is provided with removably sealable covered hatches 12 ′ to allow catalyst to be charged to the vat initially (before commencing operation of the reactor), and to permit servicing the reactor. In the vault above the vat 20 , near the top of rear sidewall 19 ′ are provided several laterally spaced-apart effluent ducts “D” through which hydrocarbon vapors are ducted to a vapor recovery system (not shown).
[0042] Heat to the lead in the vat 20 , resting on an insulated base B, is supplied by a heating system including at least one array of plural, parallel, is heating tubes 22 spaced-apart along the x-axis, and preferably multiple parallel arrays, one disposed above the other, the heating tubes of the one array being staggered relative to the other. The tubes 22 are in open communication with side hot-air manifolds 23 , 23 ′ ( FIG. 3 ) on either side of the vat, through which manifolds and tubes a heating medium is ducted, back-and-forth, until the heating medium leaves the heating system. Preferably the heating medium is provided by hot gases generated by burners fueled by oil or natural gas. The details of the means for heating the lead in the vat are not narrowly critical as long as the heating medium is supplied at a temperature above about 600° C. or 650° C., preferably above 900° C. such temperature being provided by the hot gases. Sufficient lead is loaded into the vat so that when the lead is molten, its level “L” is preferably at least 10 cm above the upper surface of the uppermost array of heating tubes in the bath. The molten lead presents a planar surface extending from the vat's inlet end 24 to its discharge end 25 .
[0043] A convenient size for the internal dimensions of a reactor is about 7.5 m long×1.2 m wide and 2.1 m high, the length of the bottom 26 of the vat corresponding to that of the bottom of the reactor.
[0044] Referring to FIG. 2 , there is shown a hollow, acid-resistant steel drum 14 with its axis of rotation along the x-axis in a mixing and bathing assembly 40 . Drums 15 , 16 , 17 and 18 are similar to drum 14 and are about equidistantly longitudinally spaced-apart from one and another (along the y-axis) inside the reactor. Because the amount of waste under each successive drum 14 - 18 progressively diminishes as W is converted, the height at which each drum 15 - 18 is mounted within the reactor, decreases progressively. Thus, the axis of rotation of drum 14 is lower than that of drum 13 ; the axis of rotation of drum 15 is lower than that of drum 14 ; the axis of rotation of drum 16 is lower than that of drum 15 ; and so forth, drum 17 being mounted for rotation closest to the level L because substantially all the waste has been converted at that point.
[0045] Each drum is independently rotatable and provided with its own mixing and bathing assembly 40 . Drum 13 being positioned near the inlet of the reactor does not have a mixing and bathing assembly as its sole function is to urge the waste under the drum 14 . The height at which drum 13 is mounted depends upon the particular feed, being higher for polyolefin sheet and lower for scrap rubber. In general, the spacing of the lower surface of the drum 13 from the surface of the melt L, is in the range from 25-35 cm, and the spacing of the other drums, successively lower, the spacing of the lower surface of the last drum 17 being in the range from about 10-15 cm above L.
[0046] The length of each drum (along the x-axis) is approximately the same as the width of the vat 20 (along the x-axis), and each end of each drum 14 - 17 has a cam-follower rod 41 , 41 ′ (not shown) secured near the circumference of each drum's end, the rods 41 , 41 ′ projecting parallel to shafts 18 , 18 ′, in the x-axis direction. The circumferential surface 42 of the drum is provided with plural, generally laminar radial projections 43 , 44 , 45 , 46 (not visible) spaced-apart axially, in rows along the surface and staggered in spaced-apart relationship around the circumference. As shown, four rows of projections are staggered at right angles to each other, each pair of rows being positioned at diametrically opposite ends. These projections are referred to as “mixing and urging blades”, more conveniently as “fingers”, because their function is to mix the waste under the drum and urge the waste away from the drum, along the y-axis. Though the shape of each of the fingers is not narrowly critical, it is preferred they be relatively broad at their straight edges 47 , projecting radially, for maximum thrust efficiency. As shown in the schematic detail of a finger in FIG. 2A , a strip 48 is welded at right angles to an arcuate piece 49 which reinforces strip 48 , and both are welded to the surface 42 of the drum. The arrow shows the direction of rotation of the drum. As the drum rotates, the leading edge of the arcuate reinforcing 49 moves through the waste and directs it against the strip 48 .
[0047] A U-shaped saddle 30 having a grating 31 and sides 32 , 33 , is pivotably mounted with generally triangular flanges 34 , 34 ′ (not shown) for oscillation about a pivot rod 35 . The grating 31 is provided with plural parallel, spaced-apart slits 36 . Each side 32 and 33 has a cam-opening 37 , 37 ′ of identical outline cut into each side, so as to allow the respective cam-follower rods 41 , 41 ′ to ride the inside edges of each cam-opening as the drum rotates. The rotation of the drum thus raises and lowers the grating in a slightly angulated, generally vertical direction, between an “up” position above the melt and a “down position under the surface of the melt. This motion simultaneously raises the floating waste while heating it, and scoops up melt coming through the slits 36 so as to bathe the waste with melt. Preferably, the “up” position is about 5 cm above the melt's surface and the “down” position is about 5 cm below the melt's surface.
[0048] To ensure that the waste is efficiently transferred from under one drum to the next, the radial length of the fingers is such that the tips of the fingers in each row sweep past close to the surface of the grating 31 . This action requires that the longest fingers 44 sweep the grating when it is at its nadir (lowest point) in the melt, and that the fingers 46 be shortest when the grating is at its apogee (highest point) above the melt. This is achieved by aligning the cam-follower rods 41 , 41 ′ with the longest fingers when the rods 41 , 41 ′ are welded to the drum.
[0049] As waste W is mixed, bathed with melt and transported through the reactor, the waste is converted into C 1 -C 24 + hydrocarbons, CO and CO 2 which are removed from the reactor through effluent ducts D, leaving a residue R. The R-discharging mechanism 60 and the R-disposing mechanism 80 cooperate to provide an effective air-tight seal at the outlet end of the reactor.
[0050] It is seen that the R-discharging mechanism 60 comprises a discharge-incline 61 the lower edge of which commences at the upper edge of the vat 20 at its outlet end 25 . The upper edge of the incline 61 terminates in a U-shaped saddle 62 in which the inverted apex 63 is V-shaped so as to accommodate the upper portion of a discharge screw of screw conveyor 64 . Above the discharge-incline 61 is proximally mounted an endless chain conveyor 69 , having a drive cylinder 65 on which the chain is drivingly trained, and which chain goes around stationary passive cylinder 66 , the drive cylinder being at the lower end of the conveyor. The vertical position of the drive cylinder 65 is adjustable by movement of a pivot arm 67 that is connected to the drive cylinder with a link 68 so that the angle at which the chain conveyor operates is in the range from 1° to about 20° to the horizontal. In operation, the lower portion of the chain around the passive cylinder 66 is about 5 cm above the upper edge of the discharge incline 61 , and the lower portion of the chain around the drive cylinder is about 15 cm above the lower edge of the discharge incline so that the chain is able to urge residue R up the discharge incline and over its upper edge into the V-shaped saddle 62 . The angle at which the chain conveyor is operated is chosen as a function of the particular type and amount of residue R generated.
[0051] When residue R is dropped into the saddle 62 , the screw conveyor 64 pushes the residue R out of the saddle into the R-disposing mechanism 70 (see FIG. 4 )
[0052] Referring to FIG. 4 there is schematically illustrated the screw conveyor 64 driven by a motor M 1 which drives the screw until it drops residue R into a vented residue collection chamber 71 provided with an overhead recycle duct 72 to recycle gases from the chamber 71 to the environment in the reactor, above the vat 20 . The chamber 71 has mounted therewithin a manually operable (“hand-cranked”) paddle agitator 77 which may be intermittently rotated to mix the residue and prevent it clumping up. The floor of the chamber 71 is provided with a central semi-cylindrical trough extending beyond the chamber as pipe 73 having a discharge outlet 74 . A manually operated screw conveyor 78 is rotatably disposed in the trough and extends into the pipe 73 so that when shaft 75 of the screw conveyor 78 is rotated, residue is conveyed to the discharge outlet 74 which is normally sealed against entry of air with a gasketed sealing plate 75 and cooperating quick-opening and quick-closing clamp 76 .
[0053] Intermittently, a residue-disposing means 80 is locked to the discharge outlet 74 to receive the residue. Preferably a sealable, wheeled cart 81 is used, the cart having an opening 82 in the ceiling of the cart, and another opening 83 in an endwall near the floor of the cart. Each opening is provided with plates and quick-opening and quick-closing clamps which seal the interior of the cart against leakage of gas. Opening 82 is opened and locked to the discharge outlet 74 when the cart is to be loaded with residue R discharged from the collection chamber 71 . When the cart is locked in this position, the screw conveyor 78 is rotated, and residue R is discharged into the opening 82 of the cart.
[0054] Reverting to FIG. 3 , it is seen that drum-supporting shafts 18 and 18 ′ are supported in the sidewalls of structural insulated housing H (see FIG. 4 ) that protects and insulates the reactor 10 . The drum 17 is show with only three fingers in each row, and the U-shaped saddle 30 is not shown so as to minimize confusion. Waste W is forced under the plural drums above the surface of the melt to which heat is supplied, first through longitudinal heating tubes 27 under the melt, and then by plural banks of transversely disposed heating tubes 22 (see FIG. 1 ), the hot gases traveling from one bank to the next through the side manifolds, until ducted away from the reactor. Hydrocarbons are led from ducts D to a condenser where they are condensed to recover mainly some C 4 and essentially all the other components heavier than C 4 . The level of the surface of the melt is monitored by level control LC in one side 19 of the reactor.
[0055] Waste W may be charged to the reactor R with any conventional feeding mechanism 90 such as is illustrated in FIG. 5 , provided the inlet to the reactor is sealed against entry of air. In the mechanism illustrated, waste W is dumped into a feed bin 91 from which it is discharged onto a endless conveyor 92 and into a waste-charging hopper 93 in open communication with a charging lock 94 defined by spaced-apart quick-opening and closing valves 95 , 96 . Valve 96 is positioned above an initial waste-compressing feeder 97 adapted to feed the waste W to a single-stage fluid-actuated press 100 . A plate 98 is pivotably mounted between the feeder 97 and the press 100 for movement from a vertical position (which allows waste to flow past the plate), to a horizontal position, closing the lower opening of the feeder 97 . A fluid-actuated cylinder 99 opens and closes the plate 98 .
[0056] After the waste W is initially compressed in the press 100 , a ram 101 compresses the waste horizontally and forces the W into and through a flanged connector tube 102 which connects the inlet of the reactor in open communication with the press 100 . With this arrangement it is seen that the volume between the connector tube 102 and the inlet to the reactor is so densely packed with waste W that the waste forms an air-tight seal preventing entry of air into the reactor, and exit of gases out of the reactor.
[0057] The invention described herein is further described by the following specific examples that are given by way of illustration and not as a limitation on the scope of the invention.
[0058] The following runs were made with (1) scrap polyolefin waste, mainly PE and PP; (2) scrap rubber obtained by cutting up worn automobile tires; (3) polystyrene; and (4) scrap Kraton® styrene-butadiene-styrene block copolymer, referred to as “SBS”. All runs use a mixture of the calcined bauxite and aluminum powder in various proportions as catalyst. The mixture of waste and catalyst is fed in less than one minute, to a pilot plant scale reactor containing a molten lead bath maintained at about 500° C. In each run, 1 Kg of the waste is mixed with 200 g of catalyst, to ensure maximum conversion. In the following Table 1, “% conversion” refers to the ratio of reusable hydrocarbons to waste fed, and the amounts of bauxite and Al powder are stated in grams. Most of these hydrocarbons, which are recovered in a water-cooled heat exchanger, boil in the range from 40° C.-400° C.; the remaining hydrocarbons, in the range from C 1 -C 4 , are present in an amount less than 20% of the condensed hydrocarbons. The cooling water used in the examples is recycled after being air-cooled, for example in heat exchangers to heat offices in the vicinity of the reactor, and enters the condensenser at 30° C. Colder water will result in more C 5 + components being condensed, it being understood that conditions of pressure and temperature in the condenser are such that predominantly C 5 + components condense in the liquid phase which is in equilibrium with vapors saturated with the components. All runs are completed in less than 30 min, after which the reactor is allowed to cool and the residue recovered.
TABLE 1 Ex. No. Waste Bauxite Al powder % Conv. 1 PE/PP none none 53 2 PE/PP 200 none (100% bauxite) 70 3 PE/PP none 200 (100% Al) 94 4 PE/PP 194 6 (3% Al) 97 5 rubber 200 none (100% bauxite) 40 6 rubber none 200 (100% Al) 55 7 rubber 194 6 (3% Al) 53 8 polystyrene 194 6 (3% Al) 80 9 SBS 194 6 (3% Al) 40
[0059] It is evident from the foregoing data for conversions of bauxite and Al powder, individually, that 97% bauxite and 3% by weight of pure Al powder is more effective than pure Al powder by itself. One would expect (by ratioing yields of PE/PP obtained with bauxite and Al powder, individually) that 3/97 of Al/bauxite would yield 70.81% conversion.
[0060] Ratioing yields of scrap rubber obtained with bauxite and Al powder, individually, it is evident that 3/97 of Al/bauxite would yield 40.45% conversion, not 53%.
[0061] It is evident, that quite unexpectedly for each waste, the combination of Al/bauxite produces a much higher conversion than calculated.
[0062] It is also evident that the same combination produces lower conversions of scrap rubber, polystyrene and SBS rubber, than of PE/PP, but it is economical to process most such waste in the reactor because it yields at least 40% by weight conversion (of the waste fed) to C 5 + hydrocarbons.
EXAMPLE 10
[0000] Molten Lead Bath Temperature: 465° C.-495° C.
[0063] 1 Kg of PE/PP is mixed with 200 g of catalyst containing 97% calcined bauxite and 3% Al powder, and fed to the bath in less than 1 min. The effluent vapors from the reactor were condensed in a water condenser (water temperature about 30° C.). Boiling points of the condensed hydrocarbons range from 210° C.-400° C. The weight of the condensate is 930 g, indicating 93% conversion of PE/PP.
[0064] In an analogous manner, polyester from discarded beverage bottles and polyamide, i.e. nylon scrap is also converted, though with lower conversions.
EXAMPLES 11-13
[0000] Effect of Concentration of Al Powder on Conversion of Scrap Rubber from Vehicle Tires in Various Temperature Ranges:
[0065] 1 Kg of the scrap rubber in pieces each weighing less than 50 g, and with strands of wire still in the rubber, is mixed with 200 g of catalyst containing the stated amounts (in grams) of calcined bauxite and Al powder, and fed to the bath in less than 1 min. The effluent vapors from the reactor were condensed in a water condenser (inlet water temperature about 30° C.). Boiling points of the condensed hydrocarbons range from 235° C.-400° C. In the following Table 2, the weights of bauxite, Al powder and the condensate collected, is given in grams, and also as “% conversion” (% of rubber fed).
TABLE 2 Ex. Al Temp. % No. Bauxite powder % Al ° C. Condensate Conv. 5 200 none 0.0 490-520 400 40 11 197 3 1.5 500-520 400 40 7 194 6 3.0 490-520 530 53 12 190 10 5.0 490-520 520 52 13 185 15 7.5 485-520 550 55 6 none 200 100 490-520 550 55
[0066] It is evident from the foregoing data that maximum conversion of rubber at the stated temperature is obtained with from about 3-10% by weight of Al powder.
[0067] Having thus provided a general discussion, described the overall process and apparatus in detail and illustrated the invention with specific examples of the best mode of carrying out the process, it will be evident that the invention has provided an effective solution to an old and difficult problem. It is therefore to be understood that no undue restrictions are to be imposed by reason of the specific embodiments illustrated and discussed, and particularly that the invention is not restricted to a slavish adherence to the details set forth herein.
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A process for converting organic waste into reusable hydrocarbons and a system for doing so, the system including a feeding mechanism for the waste, a reactor and a residue-disposing mechanism. The waste is to be fed into the reactor in which a molten lead bath is confined in an oxygen-free atmosphere. The system is used to practice a process for the pyrocatalytic conversion of the waste, which process comprises, feeding the waste into a reaction zone of a pyrocatalytic reactor, the waste being essentially free of a halogenated synthetic resinous material, and mixing the waste with a minor proportion by weight of a particulate catalyst in the bath held at a temperature in the range from about 450° C. to 550° C. in an elongated vat. The catalyst consists essentially of a major proportion by weight of particulate bauxite<2 mm, in combination with a minor proportion of aluminum powder<0.1 mm having a minimum nominal aluminum content of at least 95%, preferably at least 98%, and a Fe content of less than 0.5% and Si less than 0.2%. Between the feed-inlet or “charging” end of the vat where waste from the feeding mechanism enters and the “residue-discharging” or “discharging” end of the vat where the residue is delivered to the residue-disposing mechanism, a combination of plural rotating drums with radially protruding fingers in cooperation with gratings, provide the necessary mixing and urging action and contact time. The waste in the molten lead is urged along the vat's longitudinal axis starting near the charging end of the vat. The length of the vat is sufficient to afford a residence time for the waste of no more than one hour in the vat, and the depth of molten lead in it is at least 10 cm, preferably 30 cm above the surfaces of heating tubes disposed in the molten lead. Thus, the waste is thermally and catalytically converted with at least 60% effectiveness into reusable hydrocarbons which are removed as vapor from above the melt in the reaction zone and recovered as reusable hydrocarbons.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority under 35 U.S.C. 119 to Korean Patent Application No. 10-2008-0132721, filed on Dec. 23, 2008, which is hereby incorporated by reference in its entirety.
BACKGROUND
1. Field of the Disclosure
This disclosure relates to a liquid crystal display (LCD) device, and more particularly to an LCD device which can improve reliability of a backlight unit.
2. Description of the Related Art
Recently, a variety of flat panel display devices with reduced weight and volume have been widely used in place of cathode ray tubes (CRTs). The flat panel display devices include liquid crystal display (LCD) devices, field emission display (FED) devices, plasma display panels (PDPs), and light emitting diode (LED) display devices.
Among the display devices, the LCD device displays an image by adjusting the amount of light transmitted from light generated by a rear light source. This involves using each pixel of a liquid crystal display panel as an optical valve. A cathode ray tube (CRT) of the related art controls luminance by adjusting the intensity of an electronic line. By contrast, an LCD device displays the image on a screen by controlling an intensity of light generated by a light source.
LCD devices include a liquid crystal display panel and a timing controller, as well as gate and data drivers driving the liquid crystal display panel using a timing signal provided from the timing controller.
The liquid crystal display panel includes a plurality of gate lines transferring a scan signal, a plurality of data lines formed intersecting the gate lines and transferring image data, a pixel defined by the gate lines and the data lines, and a thin film transistor formed at each intersection of the gate lines and data lines.
The LCD device further includes a backlight unit providing light.
An LCD device of the related art drives the light source of a backlight unit using an internal algorithm backlight dimming control signal and an external algorithm backlight dimming control signal.
However, upon driving the light source of the backlight unit using the internal/external algorithm backlight dimming control signals, the dimming dutycycle of the backlight unit is set below a reference for an allowable dimming dutycycle (approximately 30% or greater of a dimming dutycycle), frequently deteriorating the reliability of the backlight unit.
BRIEF SUMMARY
Accordingly, the present embodiments are directed to an LCD device that substantially obviates one or more of problems due to the limitations and disadvantages of the related art.
An object of the present embodiment is to provide an LCD device that can improve the reliability of a backlight unit.
Additional features and advantages of the embodiments will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the embodiments. The advantages of the embodiments will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
According to one general aspect of the present embodiment, an LCD device includes: a backlight dimming modulating unit configured to modulate an internal algorithm backlight dimming control signal using an external input algorithm backlight dimming control signal and to maintain a dimming duty equal to or wider than an allowable dimming range of a backlight unit; an arithmetic unit configured to multiply the external input algorithm backlight dimming control signal by the modulated internal algorithm backlight dimming control signal and to output a final backlight dimming control signal; and a data modulating unit configured to modulate image data using the external input algorithm backlight dimming control signal corresponding to the modulated final backlight dimming control signal.
Other systems, methods, features and advantages will be, or will become, apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the following claims. Nothing in this section should be taken as a limitation on those claims. Further aspects and advantages are discussed below in conjunction with the embodiments. It is to be understood that both the foregoing general description and the following detailed description of the present disclosure are exemplary and explanatory and are intended to provide further explanation of the disclosure as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the embodiments and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the disclosure. In the drawings:
FIG. 1 is a schematic view showing an LCD device according to an embodiment of the present disclosure; and
FIG. 2 is a view showing backlight dimming modulation and data modulation according to an embodiment of the present disclosure.
DETAILED DESCRIPTION
Reference will now be made in detail to the embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. These embodiments introduced hereinafter are provided as examples in order to convey their spirits to the ordinary skilled person in the art. Therefore, these embodiments might be embodied in a different shape, so are not limited to these embodiments described here. Also, the size and thickness of the device might be expressed to be exaggerated for the sake of convenience in the drawings. Wherever possible, the same reference numbers will be used throughout this disclosure including the drawings to refer to the same or like parts.
In the present disclosure, an LCD device will now be described by way of example only.
FIG. 1 is a schematic view showing an LCD device according to an embodiment of the present disclosure. FIG. 2 is a view showing backlight dimming modulation and data modulation according to an embodiment of the present disclosure.
Referring to FIGS. 1 and 2 , an LCD according to an embodiment of the present disclosure includes a liquid crystal display panel 110 with gate lines GL 1 ˜GLn and data lines DL 1 ˜DLm intersecting each other and a thin film transistor (TFT) driving a liquid crystal cell Clc formed at intersection of the gate lines GL 1 ˜GLn and the data lines DL 1 ˜DLn, a data driver 130 providing a data signal to the data lines DL 1 ˜DLm of the liquid crystal display panel 110 , a gate driver 120 providing a scan signal to the gate lines GL 1 ˜GLn of the liquid crystal display panel 110 , a timing controller 150 controlling the data driver 120 and the data driver 130 , and a backlight unit 170 providing light to the liquid crystal display panel 110 .
The TFT is formed on the liquid crystal display panel 110 such that every liquid cell dutycycles as a switching device. A gate electrode of the TFT is coupled with the gate lines GL 1 ˜GLn, a source electrode thereof is coupled with the data lines DL 1 ˜DLm, and a drain electrode thereof is coupled with a pixel electrode of the liquid crystal cell Clc and one electrode of a storage capacitor Cst. A common voltage Vcom is provided to a common electrode of the liquid crystal cell Clc. When the TFT is turned-on, the storage capacitor Cst charges a data voltage provided from the data lines DL 1 ˜DLn to maintain a constant voltage of the liquid crystal cell Clc.
When a scan pulse is sequentially provided to the gate lines GL 1 ˜GLn, the TFT is turned-on so that a channel is formed between a source electrode and a drain electrode to provide a voltage of the data lines DL 1 ˜DLm to the pixel electrode of the liquid crystal cell Clc. At this time, an arrangement of liquid crystal molecules in the liquid crystal cell Clc changes to modulate incident light.
The gate driver 120 sequentially generates a scan pulse according to a gate drive control signal GCS provided from the timing controller 150 , and provides the generated scan pulse to the gate lines GL 1 ˜GLn. The scan pulse causes the gate lines GL 1 ˜GLn to be enabled in units of one horizontal synchronization signal interval.
In this case, the gate drive control signal GCS provided from the timing controller 150 includes GSP, GSC, GOE, and the like.
The data driver 130 provides a data signal to the data lines DL 1 ˜DLm in response to a data drive control signal DCS provided from the timing controller 150 . Further, the data driver 130 samples and latches image data R, G, and B input from the timing controller 150 . Next, the data driver 130 converts the image data R, G, and B into an analog data voltage capable of expressing gradation in the liquid crystal cell Clc of the liquid crystal display panel 110 based on a gamma reference voltage provided from a gamma voltage generator (not shown), and provides them to the data lines DL 1 ˜DLm.
In this case, the data drive control signal DCS provided from the timing controller 150 includes SSP, SSC, SOE, POL, and the like.
The timing controller 150 generates a gate control signal GCS and a data control signal DCS using a data clock signal DCLK, a horizontal synchronization signal Hsync, a vertical synchronization signal Vsync, a data enable signal DE, and a polarity inversion signal POL provided from an external device (e.g. the graphic module of a computer system or the image demodulation module of a television receiving system), which is not shown.
The backlight unit 170 drives a light source using an internal algorithm backlight dimming control signal I-CS and an external backlight dimming control signal O-CS provided from the timing controller 150 .
The backlight unit 170 modulates the internal algorithm backlight dimming control signal I-CS according to an external backlight dimming control signal O-CS, and drives the light source using the modulated backlight dimming control signal MI-CS and the external backlight dimming control signal O-CS.
In other words, the backlight unit 170 of the present disclosure includes an internal algorithm backlight dimming modulating unit 172 , which modulates an internal algorithm backlight dimming control signal I-CS using the external backlight dimming control signal O-CS, and an internal algorithm backlight dimming range setting unit 171 setting an internal backlight dimming range using the external backlight dimming control signal O-CS.
The internal algorithm backlight dimming range setting unit 171 performs a dutycycle setting the modulation range of an internal backlight dimming dutycycle according to the dimming dutycycle of the external backlight dimming control signal O-CS in order to prevent the internal backlight dimming range from being set below an allowable dimming range (generally 30%) of a final backlight dimming control signal.
Minimum
internal
algorithm
backlightdimming
duty
=
minimum
backlightallowablerange
duty
externalbacklightdimming
duty
×
100
[
Equation
1
]
The internal algorithm backlight dimming range setting unit 171 calculates a minimum internal algorithm backlight dimming dutycycle using equation 1.
The internal algorithm backlight dimming modulating unit 172 modulates an internal algorithm backlight dimming dutycycle based on the minimum internal algorithm backlight dimming duty calculated by the internal algorithm backlight dimming range setting unit 171 to output an internal algorithm backlight dimming modulation signal MI-CS.
An internal algorithm backlight dimming modulation signal MI-CS from the internal algorithm backlight dimming modulating unit 172 is input to an arithmetic unit 160 . In this case, the external backlight dimming control signal O-CS is input to the arithmetic unit 160 .
The arithmetic unit 160 performs multiplication to generate a final backlight dimming control signal driving a light source of the backlight unit 170 .
A method for generating the final backlight dimming control signal in order to drive a light source of the backlight unit 170 according to an embodiment of the present disclosure will now be described.
Assuming that an allowable dimming range of the backlight unit 170 is from 30% to 100%, when an external backlight dimming duty is 60%, the internal backlight dimming duty may be set to a range from 50% to 100%. That is, a final backlight dimming duty output from the arithmetic unit 160 ranges from 30% to 60% in order to maintain the allowable dimming range.
In this case, the LCD device according to the present disclosure further includes a data modulating unit 142 which modulates image data using an external backlight dimming control signal O-CS as well as an internal algorithm data modulation range setting unit 141 which sets the modulation range for the image data modulated by the data modulating unit 142 .
When the internal algorithm backlight dimming dutycycle being modulated is to be reduced or increased, the data modulating unit 142 dutycycles to modulate and compensate the image data. Namely, when the internal algorithm backlight dimming dutycycle is reduced, the data modulating unit 142 modulates the image to a gradation higher than an internal algorithm gradation, thereby preventing deterioration in the image quality. Furthermore, when the internal algorithm backlight dimming dutycycle is increased, the data modulating unit 142 modulates the image to a gradation lower than an internal algorithm gradation, thereby preventing deterioration in the image quality.
The internal algorithm data modulation range setting unit 141 sets a range setting for the image data according to an internal backlight dimming modulation range using the external backlight dimming control signal O-CS. The data modulating unit 142 modulates the image data according to the set data modulation range from the internal algorithm data modulation range setting unit 141 .
In the case that the image data are modulated, when a dimming dutycycle of the external backlight dimming control signal O-CS changes, a data modulation range of the internal algorithm data modulation range setting unit 141 also changes, thereby compensating for an image with a change of a final backlight dimming dutycycle.
In the LCD device according to an embodiment of the present disclosure as described above an internal algorithm backlight dimming dutycycle is modulated according to an external backlight dimming control signal O-CS and image data are also modulated. This is to prevent the dimming range of the backlight unit 170 from being set below a certain level (generally 30% or more than the dimming dutycycle), which deteriorates the reliability of the backlight unit 170 . Thus in the LCD device according to an embodiment of the present disclosure, an image of the same quality as the related art is displayed, and the deterioration of the backlight unit is prevented.
The present disclosure has been limitedly described regarding only an LCD device as a display device. However, the present disclosure is not limited thereto. It is applicable to a variety of flat panel display devices with a backlight unit.
As described above, in the LCD device according to an embodiment of the present disclosure, an internal algorithm backlight dimming dutycycle is modulated according to an external backlight dimming control signal O-CS and image data are also modulated, thereby displaying an image of the same quality as the related art. Therefore, the LCD device can prevent the reliability deterioration in the backlight unit. To rectifying this, the LCD device forces a dimming range of the backlight unit not to be set below an allowable range thereof (generally, 30% or more of a dimming dutycycle), in order to prevent the reliability deterioration in the backlight unit.
Although the present disclosure has been limitedly explained regarding only the embodiments described above, it should be understood by the ordinary skilled person in the art that the present disclosure is not limited to these embodiments, but rather that various changes or modifications thereof are possible without departing from the spirit of the present disclosure. Accordingly, the scope of the present disclosure shall be determined only by the appended claims and their equivalents.
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A liquid crystal display device capable of improving reliability of a backlight unit is disclosed.
The liquid crystal display device includes: a backlight dimming modulating unit configured to modulate an internal algorithm backlight dimming control signal using an external input algorithm backlight dimming control signal and to maintain a dimming duty equal to or wider than an allowable dimming range of a backlight unit; arithmetic unit configured to multiply the external input algorithm backlight dimming control signal by the modulated internal algorithm backlight dimming control signal and to output a final backlight dimming control signal; and a data modulating unit configured to modulate image data using the external input algorithm backlight dimming control signal corresponding to the modulated final backlight dimming control signal.
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This is a continuation of application Ser. No. 645,975 filed Dec. 31, 1975, and now abandoned.
CROSS REFERENCE TO RELATED APPLICATIONS
Ser. No. 537,797 in the name of G. S. Almasi et al, filed Dec. 31, 1974, now U.S. Pat. No. 3,967,002, describes a method for making a high density magnetic bubble domain storage system in which three masking steps are required, one of which requires critical alignment. In that process, magnetic disks of soft magnetic material, such as NiFe, are part of the ion implantation mask and will not interfere with propagation by ion implanted regions. Thus, the magnetic disks define ion implantation masks as well as providing functions such as generation, propagation, reading and annihilation.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a high density bubble domain memory and a method for making it, and in particular to an improved method for making such a memory using only two masking steps, one of which requires critical alignment.
2. Description of the Prior Art
Various systems using magnetic bubble domains are known in the art. For example, self-contained magnetic bubble domain memory chip using a decoder is shown in U.S. Pat. No. 3,701,125. Additionally, a major/minor loop memory configuration is shown in U.S. Pat. No. 3,618,054. In these memory systems, components are required which provide the functions of read, write, bubble domain propagation, transfer between storage elements, and annihilation. That is, bubble domains are generated for representation of information, and these bubble domains are generally propagated in the memory. After propagation, they are read and then annihilated or returned to their storage locations. Furthermore, these memories often require transfer functions where bubble domains are transferred from one propagation path to another, usually by the use of current carrying loops that produce magnetic field gradients for implementing the transfer.
Many components are known in the art for generating magnetic bubble domains and for detecting magnetic bubble domains. For example, a magnetoresistive sensing technique is shown in U.S. Pat. No. 3,691,540. For the function of storage, bubble domains are generally propagated using any of many well known structures. In particular, ion implanted propagation elements having generally curved paths are useful for bubble domain storage, since the line widths of these elements are generally about four bubble diameters, thereby leading to relaxed lithography requirements. Such ion implanted structures are described by R. Wolfe et al in the AIP Conference Proceedings, No. 10, Part 1, p. 339 (1973). These proceedings contain the text of the papers delivered at the 18th Annual Conference on Magnetism and Magnetic Materials, held in Denver, Colo., in 1972. Furthermore, U.S. Pat. No. 3,828,329 describes propagation structures using ion implanted regions.
The processes used for making magnetic bubble domain chips have developed through the years so that single level masking techniques are now described for making bubble domain memories in which the propagation elements are separated from one another (gapped propagation elements). In such techniques, magnetic sensors are deposited using the same mask that is used for depositing the magnetic propagation elements. Also, since the propagation elements are not in contact with one another, conductors can be placed directly over the propagation elements without shorting any electrical currents. This means that the bubble domain chip can be fabricated using only a single critical masking step.
However, with the exception of aforementioned Ser. No. 537,797, (U.S. Pat. No. 3,967,002) the prior art does not address the problem of making high density magnetic bubble domain chips where the propagation elements are contiguous to one another. In such systems it is difficult to place conductors directly on the propagation elements, since electrical shorting may occur. Additionally, several critical masking steps are usually required in order to define the sensors, propagation elements, and conductors used for bubble domain transfer and sensor current. Furthermore, it is usually necessary to provide a "protect" mask to protect the magnetoresistive sensor when the electrical conductors are formed. Because these are critical problems when bubble domain technology is to be used to provide economical memory structures having high density, the present invention seeks to provide an improved bubble domain memory in which all necessary functions are provided, and which can be made by a process using a minimum number (two) of masking steps, only one of which requires critical alignment.
Accordingly, it is a primary object of this invention to provide an improved process for fabricating high density magnetic bubble domain chips in which only one critical masking step is required.
It is another object of this invention to provide a process for fabricating a magnetic bubble domain chip having contiguous propagation elements, requiring a minimum number of masking steps.
It is still another object of the present invention to provide a high density magnetic bubble domain chip having components for generation, reading, propagation, transfer, and annihilation, all of which components do not require a resolution less than about 4d, where d is the bubble domain diameter.
It is a further object of this invention to provide an improved process for fabricating a high density magnetic bubble domain chip using ion implanted propagation elements which are contiguous to one another, magnetic sensors and annihilators, and current carrying lines for generation, sensing, and transfer.
It is another object of this invention to provide a bubble domain memory having improved means for transfer of information from one storage register to another.
BRIEF SUMMARY OF THE INVENTION
This magnetic bubble domain memory system is characterized by the use of metallurgy that serves a dual function and by an improved gate for transferring information from one storage register to another. Furthermore, this memory is characterized by a high density stretcher-replicator-sensor design which is especially useful for reading very small (submicron) magnetic bubble domains.
In a preferred embodiment, the memory is comprised of ion implanted propagation regions which serve to define propagation elements in a major/minor loop memory organization. The conductor metallurgy (typically gold) serves not only conductor functions but also serves as a mask for protecting regions of the underlying bubble domain medium which are not to be ion implanted. Thus, the gold provides current carrying conductor functions and also is an ion implantation mask.
The improved transfer gate is used to transfer information from the major loop into the minor loops, or vice versa. It is comprised of permalloy bridges which provide guides for the transfer of information between the major and minor loops in response to current in a conductor. Because the permalloy bridges aid the transfer operation, the transfer conductors can be defined from a continuous conducting layer using the same mask that is used to define the regions which are to be ion implanted. Because of this, the conductor metallurgy can be provided early in the fabrication process, rather than having to be provided through the use of a critically aligned mask after ion implantation has been completed.
Generally, the bubble domain medium is any magnetic medium which will support bubble domains, and is preferably a material having garnet structure. After this, a continuous layer of the magnetic material used for functions such as sensing and transfer bridging is deposited as a continuous layer over the entire substrate. This layer is typically NiFe which also serves as a conductor plating base. A resist material is used to protect regions of the NiFe layer which are not to have a conductor deposited on them. A conductor (Au) is then plated over the NiFe layer. The Au serves as the current carrying conductors and also as an ion implantation mask.
The bubble domain material is then ion implanted through the gold mask to define propagation elements in the major loop and minor loops. Then, a second masking step is used to define the conductor metallurgy, that is, to define and isolate the separate current carrying conductors from one another. Sputter etching is used to remove the gold and NiFe in order to leave the desired conductors and to remove conducting material from those regions of the magnetic chip where it is not desired. Thus, the magnetoresistive sensor (NiFe), the annihilators, and the magnetic bridges have no conductors deposited on them.
These and other objects, features, and advantages of the present invention will be more apparent from the following more particular description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a magnetic bubble domain memory system organized as a major/minor loop memory, in accordance with the principles of the present invention.
FIGS. 2A-2F are side elevation views illustrating the process used to make the memory of FIG. 1. In particular, FIG. 2F is a side elevation view in cross-section taken along line 2F-2F of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1
FIG. 1 shows a major/minor loop memory organization which can be made using two masking steps. In this embodiment, ion implantation is used to make contiguous propagation elements along which the bubble domains are propagated in response to a magnetic field H which reorients in the plane of magnetic medium 10.
In more detail, a magnetic medium 10 capable of supporting magnetic bubble domains therein has a non-magnetic spacer layer 12 located thereover. Magnetic medium 10 can be comprised of any known bubble material, such as a rare earth iron garnet. Layer 12 is a non-magnetic spacer layer used to prevent etching of the bubble domain material during subsequent processing steps, such as sputter etching. Also, spacer 12 prevents spontaneous nucleation of bubbles in layer 10. A typical thickness of layer 12 is 4,000 Angstroms.
The memory of FIG. 1 provides the functions of write, read, propagate (storage), transfer between storage elements, and annihilation. All portions of magnetic medium 10 which are ion implanted are shown by cross-hatched regions 14. All other regions of magnetic layer 10 are not ion implanted.
Functionally, the write circuit W used to nucleate bubble domains in magnetic layer 10 is comprised of a conductor 16 which returns to ground along a portion 16A thereof. A current pulse I W in conductor 16 will nucleate a bubble domain B1 in the U-shaped portion of this conductor.
The storage area of the memory is comprised of the major loop 18 and the various minor loops 20. Bubble domains B move along the major loop 18 and minor loops 20 in response to the reorientation of a magnetic field H in the plane of magnetic medium 10. These domains B move in contact with the edges of the ion implanted regions of bubble material 10. In FIG. 1, the major loop does not move magnetic domains along a continuous path defining a closed loop, but rather moves the domains from write circuit W to a read circuit generally designated R.
In order to transfer bubble domains B between the major loop 18 and the minor loops 20, a transfer conductor 22 is provided. Conductor 22 overlays a portion of the major loop 18 and then returns to ground along conductor 16A. That is, write conductor 16 and transfer conductor 22 share a common electrical path along portion 16A. Located between major loop 18 and each of the minor loops 20 are magnetic bridges 24. Typically these bridges are comprised of the same material, such as NiFe, that is used for other functions in the memory. In response to a current pulse I T in conductor 22, bubble domains will be transferred between the major loop and the various minor loops. The direction of transfer depends upon the direction of current in conductor 22.
Prior to entering the read circuit R, bubble domains traveling along major loop 18 are stretched to an elongated shape, illustrated by domain B2, in response to a current I ST in stretcher conductor 26. As the elongated domain B2 continues to move toward the right to read circuit R, it will be split into a plurality of bubble domains such as B3, which travel along the edges of ion implanted regions 14 to read circuit R and are then cumulatively sensed to provide an amplified output signal.
Read circuit R is comprised of a plurality of sense elements 28 which are connected in a manner to provide a cumulative output signal representing the combined effects of the bubble domains B3. In a preferred embodiment, sense elements 28 are comprised of a magnetoresistive material such as permalloy (a trademark of Allegheny Ludlum Corp.). Electrical conductor 29 provides a sense current I S through the series connected sense elements 28. Thus, a bubble domain moving to the area of the stretcher line 26 will be elongated and then split to provide a plurality of domains which individually are detected by read circuit R. This provides an amplified output and is therefore suitable for detection of very small magnetic bubble domains, such as submicron magnetic bubble domains.
After being detected, the domains B3 continue to move to the right where they are trapped by the annihilators 30. These annihilators are typically comprised of a soft magnetic material, such as NiFe, which traps the domains. Because this is a destructive read-out memory, the write circuit W is then activated to provide new bubble domain data corresponding to the data just read.
As will be apparent from the fabrication steps illustrated in FIGS. 2A-2F, certain regions of the magnetic bubble domain system will have overlying layers of magnetic material and conductive material, while other areas will not have these overlying layers. In particular, the bridges 24, sense elements 28, and annihilators 30, indicated by speckled regions, will have no conductive layer over them. In a typical embodiment, bridges 24, sense elements 28, and annihilators 30 are comprised of NiFe which is initially deposited as a continuous layer over the entire substrate 12. It should be noted that the cross-hatching for the ion implanted regions 14 extends under the bridges 24, sense elements 28, and annihilators 30. The presence of this ion implantation does not impair the performance of the functions achieved by the bridges 24, sense elements 28, and annihilators 30.
The portion 32 of the major loop 18 (that is, the region of major loop 18 between transfer conductor 22 and stretcher conductor 26) has no overlying magnetic layer and conductive layer in the final memory organization. This is also true in regions 34 and 36. That is, in regions 34 located between stretcher line 26 and sense conductor 30, there is no overlying layer of magnetic material or conductive material. Further, in regions 36 of the propagation elements located between sense conductor 29 and annihilators 30, there is no overlying magnetic or conductive layer.
The bias field H z used to stabilize the size of domains in magnetic medium 10 is provided by the bias field source 38. This could be any of a number of well known components, such as current carrying coils or permanent magnets. The magnetic drive field H used to move domains along the edges of the ion implanted regions is provided by the drive field source 40. Generally this is a combination of X and Y current carrying coils for establishing magnetic fields that reorient in the plane of magnetic medium 10.
The write current I W is produced by a write current source 42, while the transfer current I T is provided by a transfer current source 44. The stretcher current I ST is provided by a stretcher current source 46 while the sense current I S is provided by a sense current source 48. The magnetic field sources 38 and 40, as well as all of the current sources 42, 44, 46, and 48 are activated under control of a circuit 50, which is any type of well known electronic circuitry for providing timing pulses to synchronize the operation of the various current sources. For example, after a bubble domain (or absence of a domain) is sensed by read circuit R, a signal is provided to the write current source 42 to either provide a nucleating current I W in conductor 16, or not, depending upon whether or not a bubble was present at read circuit R.
In operation, data is written into major loop 18 by the presence or absence of the current I W in nucleating write conductor 16. If current I W is present, a domain B1 will be nucleated at the location shown and will move to major loop 18 as field H reorients. The data thus generated propagates to the right in response to the reorientation of field H. When the desired data is written into loop 18, it can be transferred to the minor loops 20 by a current I T in conductor 22. Depending upon the direction of this current, transfer occurs from the major loop 18 to the minor loops 20 or vice versa. Nucleation and transfer between major loop 18 and minor loops 20 can occur at the same time.
When information is to be read from the minor loops 20, a current pulse I T is provided in conductor 22. This transfers the bubble domain pattern to the major loop 18 after which it propagates to the right as field H reorients. When this information reaches the stretcher conductor 26, a current I ST is provided in conductor 26 which elongates any bubble domain in the data pattern. The elongated domain then moves to the right along the edges of ion implanted regions 14 surrounding areas 34. The elongated domain is split into the domains B3 which then pass under the sense elements 28. A signal is produced in an associated sense amplifier (not shown) which indicates whether the data was the presence or absence of a bubble domain. If the data were a bubble domain, the split domains B3 would be transferred along the edges of regions 36 to the annihilators 30 where they would be trapped.
The sense elements 28 can typically be magnetoresistive sense elements electrically connected in series. As is known by referring to U.S. Pat. No. 3,691,540, these elements will undergo a resistance change when the stray magnetic field of a bubble domain is coupled to them. This resistance change can be detected as a voltage change across all of the series connected sense elements, in order to provide an indication of the presence and absence of bubble domains in flux coupling proximity to the sense elements.
Depending upon whether or not the data consists of bubble domains, a signal will be provided by the control circuit 50 to the write current source 42. This signal will activate source 42 if it is desired to nucleate a new bubble domain to take the place of a bubble domain just detected in the output data.
Thus, the major/minor loop memory of FIG. 1 is characterized by the use of conductors 16, 22, 26, and 29 which serve as ion implantation masks in addition to their functions as current carrying elements. This memory is also characterized by the use of magnetic bridges between the major loop 18 and the various minor loops 20. Still further, a stretcher-replicator-sensor arrangement is provided which can be fabricated in a minimum number of masking steps.
FABRICATION PROCESS (FIGS. 2A-2F)
These Figures illustrate typical fabrication steps used to provide the memory of FIG. 1. In particular, FIG. 2F is a side elevational view of the major/minor loop memory of FIG. 1 taken along line 2F--2F.
FIG. 2A shows the magnetic bubble material 10 having a non-magnetic spacer layer 12 thereover. A continuous layer 52 of magnetic material is deposited over the entire underlying layer 12. Layer 52 is a magnetic material such as NiFe. It is used as a conductive plating base and also for the magnetic elements, such as the magnetic bridges 24, sense elements 28, and annihilators 30.
In FIG. 2B, a patterned resist layer 54 is formed on layer 52, in order to protect those areas which are not to be covered by a conductive layer. More specifically, resist 54 protects the magnetic bridges 24, sense elements 28, and annihilators 30, and all areas 14 of the magnetic medium which are to be ion implanted.
In FIG. 2C, an ion implantation mask is provided by plating a metal 56, such as gold, over the underlying magnetic layer 52. The plated gold is the conductors 16, 22, 26, and 29. Thus, layer 52 provides certain device functions and also serves as a plating base when forming the ion implantation mask. The various conductors 16, 22, 26, and 29 are later isolated from one another in an etching step.
In FIG. 2D, resist layer 54 is removed and the magnetic material 10 is ion implanted using masking layer 56. The ion implantation is indicated by the arrows 58. This step can be provided using well known techniques employing protons or boron ions. During ion implantation, regions 14 of magnetic layer 10 will be implanted.
In FIG. 2E, a second masking step is shown. A patterned resist layer 60 is used to electrically isolate the write conductor 16, transfer conductor 22, stretcher conductor 26, and sense conductor 29. Therefore, portions of the magnetic layer 52 and conductive layer 56 are removed in regions 32, 34, and 36 (FIG. 1) in order to electrically isolate and define conductors 22, 26, and 29.
FIG. 2F is a side view of the completed structure. As is apparent, only two masking steps have been used and only the second of these requires any kind of alignment. Thus, a major/minor loop memory having functions of write, read, storage, transfer and annihilation has been provided using contiguous propagation elements by a process involving only two masking steps.
It will be appreciated by those of skill in the art that various alternatives exist in this process and that the order of the processing steps can be interchanged. For instance, the gold layer 56 can be evaporated or sputtered rather than being electroplated. Further, the gold layer can be deposited prior to deposition of the NiFe layer 52. As an example, a layer of gold can be deposited over SiO 2 layer 12, after which the gold layer is etched to form the conductors which are part of the ion implantation mask. The gold is also removed from the areas of the underlying SiO 2 layer where the sensors, magnetic bridges, and annihilators are to be formed. After this, the magnetic medium is ion implanted and a continuous NiFe layer is deposited over the entire substrate. A mask is then formed to define the magnetic bridges, sensors, and annihilators and also to electrically isolate the conductors 16, 22, 26, and 29.
Thus, it will be appreciated that many variations of the basic process can be envisioned by those of skill in the art. Whatever the sequence of the processing steps, the process is characterized in that the conductors are used for both the ion implantation mask and for current carrying functions, and that the transfer means for transferring information between the minor loops 20 and the major loop 18 are comprised of magnetic bridges.
While the principles of the present invention provide advantages which are even more apparent when contiguous propagation elements defined by ion implanted regions are utilized, it should be evident that the propagation elements need not be contiguous with one another in order to practice this invention. Further, the materials used for the various regions of the bubble domain memory can be different than those illustrated, and other geometries can be used for the propagation elements, whether or not they are contiguous.
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A magnetic bubble storage system and a method for making it using only two masking steps, one of which is critical. In a preferred embodiment, the storage regions are comprised of ion implanted propagation elements which can be contiguous with one another. The functions of write, read, storage, transfer between storage elements in different shift registers, and annihilation are provided by the method in which the same mask is used to define ion implanted regions and for formation of conductor metallurgy. Permalloy bridges over ion implanted regions are used to provide transfer of information between one storage element and another. In a preferred embodiment, NiFe is used for sensing, annihilation, and transfer of information, while the storage registers are comprised of ion implanted regions defining contiguous propagation elements of generally circular geometry.
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PRIORITY CLAIM
[0001] This application is a continuation of PCT patent application No. PCT/DE2004/002022, filed Sep. 10, 2004, which claims the benefit of priority to German Patent Application No. DE 10344567.6, filed Sep. 25, 2003, both of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] The invention relates to an immersion lithography method and a device for the exposure of a substrate.
BACKGROUND
[0003] In the production of large scale integrated semiconductor chips, ever more stringent requirements made of the fabrication installations and production processes used for the production of the semiconductor chips occur in particular by virtue of the ever advancing miniaturization of the structures on the semiconductor chip. One problem which occurs with the rising miniaturization of the large scale integrated semiconductor chips is the limitation of the miniaturization by the resolution capability of the lithography technology used which is employed for patterning the semiconductor chips of a wafer.
[0004] As an introduction, a lithography device 600 that can be used for patterning a wafer 601 is illustrated schematically in a simplified manner in FIG. FIG. 6 . The lithography device 600 has an illumination unit 602 and a lens 603 . The wafer 601 is patterned by being exposed using a mask 604 or reticle. For this purpose, a structure formed on the mask is imaged by means of laser light 605 and the illumination unit through the lens 603 onto the wafer 601 , that is to say that the wafer 601 is exposed and a patterning of the wafer is thus possible.
[0005] Various methods for carrying out the lithography are known in the prior art. One is the use of a so-called “stepper”. When using such a stepper, an entire mask used is transferred all at once within a single exposure step onto a first exposure field of the wafer. Afterward, the wafer is moved on and the next exposure field of the wafer is exposed.
[0006] Another method which is used in lithography is one which is carried out by means of a so-called “scanner”. In the case of a scanner, the entire structure of a mask is not imaged onto a first exposure field of the wafer in one step, rather only a narrow strip of the mask is ever imaged all at once onto an exposure field of the wafer. For this purpose, a so-called exposure slot is used, which only ever illuminates a narrow strip of the mask and through which the mask is moved. During the exposure of an exposure field, the entire field gradually moves through the exposure slot. The mask is clearly scanned by means of this exposure slot. During the imaging of the mask onto a field of the wafer, both the mask and the wafer are moved. In this case, the movement of the wafer and of the mask generally takes place in opposite directions. To put it clearly, the mask is scanned by means of the exposure slot. In this case, every point on the mask is exposed during the movement through the movement slot with a plurality of laser flashes (pulses) onto the wafer.
[0007] The resolution of a lithography technology is given by equation (1):
R = k 1 · λ n · sin ( θ )
[0008] where: R is the resolution,
[0009] k 1 is a process-dependent factor,
[0010] λ is the vacuum wavelength of the beam used for the lithography, and
[0011] n·sin(θ) is the so-called numerical aperture, where n is the refractive index of the medium in which the lithography is carried out, and θ is the aperture angle of the lens.
[0012] The process-dependent factor k 1 has a value of greater than 0.25 for physical reasons. Clearly, k 1 is greater than 0.25 in order to ensure that a uniform pattern of lines and interspaces, that is to say an alternation of bright and dark, can be imaged and is still discernible as such a pattern. In lithography, the wavelength is currently still limited to wavelengths of more than approximately 150 nm, since no materials which are transparent to light having a shorter wavelength are known to date.
[0013] It emerges from these boundary conditions that in order to increase the resolution capability, which increase is necessary for a lithography for the patterning of small structures, it is scarcely possible to make a change to k 1 or to λ. Consequently, the only factor that remains is n·sin(θ), the so-called numerical aperture of the device, which is also designated as NA. In this case, it must be taken into consideration that sin(θ)≦1 holds true for mathematical reasons. Clearly, θ specifies the aperture angle at which light can enter into an imaging element (lens) in order that it also leaves the imaging element again without being subjected to total reflection, and is therefore a measure of the light intensity entering into the imaging element and the resolution capability of the lithography device.
[0014] Lithographic methods in semiconductor production have usually been carried out by means of air as the immersion medium, that is to say as the medium situated between the imaging element and the substrate. A refractive index of n≈1 thus results. If the lithographic method is carried out with a medium different than air, that is to say if a so-called immersion lithography is carried out, then the resolution capability can be improved by a factor which is equal to the refractive index of the immersion medium. In the case of such an immersion method, a liquid having a refractive index of n>1 is introduced into an interspace between an imaging element, that is to say e.g. a lens, and a lithography device.
[0015] The use of an immersion medium makes it possible to have the effect that additional light contributes to the light intensity of the imaging element. Light which is incident in the imaging element at an angle which is too large to still contribute to the light intensity of the imaging element given an immersion medium of air, that is to say would be subjected to total reflection, can still contribute to the light intensity given the use of an immersion medium with a higher refractive index than n=1. As a result of this, it is possible to obtain a better resolution, or the depth of focus of the imaging can be increased for the same resolution.
[0016] One disadvantage of immersion lithography, however, is that the immersion medium absorbs part of the light which is used for the exposure of the wafer. The immersion medium is heated as a result of the absorption. The heating of the immersion medium in turn leads to a change in the refractive index of the immersion medium. For water, there are estimations for the change in the refractive index with the temperature T which amount to approximately dn/dT=10 −4 K −1 for a wavelength of λ=193 nm.
[0017] This in turn leads to a slight change in the distance between the imaging element and the wafer, at which distance the best focusing can be obtained, that is to say that the imaging is sharpest or, to put it another way, the resolution takes up the smallest value. The change in the temperature and hence in the refractive index of the liquid also leads to a reduction of the depth of focus (DoF) of the imaging. In a lithography method, the depth of focus of the projected image, that is to say the image of the mask, is thereby reduced, thus resulting in a reduction of a processing window for the lithography method, that is to say which fluctuation range the lithography parameters are permitted to have.
[0018] One approach to solving this problem lies in controlling the temperature of the immersion liquid. That is to say that it is attempted to keep the temperature as far as possible constant and to stabilize it within a small temperature interval. However, this has to be effected very exactly. Such exact temperature control is costly and can only be achieved with difficulty. Focal changes that remain furthermore have an adverse influence on the depth of focus of the imaging and on the resolution of the lithography method.
[0019] In order approximately to specify the order of magnitude of how exactly the temperature is to be complied with and how great the influence is of a change in temperature that remains, this will be estimated on the basis of an example. For a wavelength of λ=193 nm, a refractive index of n=1.47 (deionized water), a sin(θ)=0.75 and a working distance, that is to say a distance between the imaging element and the wafer surface to be patterned, of D=1 mm, δn<6·10 −7 has to be complied with if a change in the distance of sharp imaging of ΔD<1 nm is intended to be complied with, where δn is the change in the refractive index. From δn<6·10 −7 and the estimation of dn/dT=10 −4 K −1 already discussed above, it is possible to calculate on the basis of equation (2)
Δ D = D · δ n n · cos 2 θ
[0020] how exactly the temperature must be controlled and regulated. A required accuracy of 6 mK results. This accuracy of the temperature control can be complied with only with difficulty, as a result of which the use of immersion lithography in the patterning of semiconductor elements is greatly impeded and made greatly difficult.
[0021] U.S. Pat. No. 6,191,429 to Suwa discloses a focusing device which has an objective system for optically producing a workpiece, for forming a desired pattern on a surface of a workpiece or for inspecting a pattern on a workpiece, and which is used to set the focus state between the surface of the workpiece and the objective system.
[0022] U.S. Pat. No. 6,586,160 to Ho, et al. discloses a scanning exposure system which provides light which comprises items of pattern information which are intended to be transferred onto a wafer, and thus patterns a photoresist layer on the semiconductor wafer.
[0023] Japanese Patent No. JP10303114 discloses an immersion lithography device, a working distance between the device and a workpiece satisfying a relation which takes account of the temperature coefficient of the refractive index of the immersion fluid and the temperature.
[0024] U.S. Pat. No.6,509,952 to Govil, et al. discloses that linewidth control parameters vary within a pattern as a consequence of properties of a lithography device, and that these variations can be compensated for by means of linewidth offset coefficients.
SUMMARY
[0025] The invention is based on the problem of solving the abovementioned disadvantages of the prior art and of providing an immersion lithography method for the exposure of a substrate and a device for such a method which reduce the problem of the accurate temperature control during the immersion lithography.
[0026] The problem is solved by means of an immersion lithography method for the exposure of a substrate and a device for carrying out such a method comprising the features in accordance with the independent patent claims.
[0027] An immersion lithography method for the exposure of a substrate is carried out by means of a scanning exposure device having a beam source, which generates a beam, a holder, which accommodates a reticle, a carrier, on which a substrate is arranged, and an imaging element, which is arranged between the reticle and the substrate, in which case, during the exposure of the substrate, an immersion fluid is introduced between the imaging element and the substrate, and in which case, during the method, the beam passes from the radiation source through the reticle, through the imaging element and through the immersion fluid onto a substrate surface to be exposed, the beam scans the reticle in a first direction, the carrier is moved in a second direction during the exposure of the substrate and the depth of focus and/or resolution of the exposure, or, to put it another way, the position of best focus during the exposure, of the surface of the substrate is set by varying during the exposure with the reticle a distance in the beam direction between the reticle and the surface of the substrate along the direction of movement of the carrier.
[0028] A device for carrying out an immersion lithography for the exposure of a substrate has a beam source for emitting a beam, a carrier, on which a substrate can be arranged, a holder for accommodating a reticle, and an imaging element, which is arranged between the holder and the carrier. In the device, the carrier and the holder are set up in such a way that they can be moved in relation to one another, and the arrangement is set up in such a way that an immersion fluid can be introduced between the imaging element and the carrier. Furthermore, the arrangement is set up in such a way that a reticle arranged in the holder and a surface to be exposed of a substrate arranged on the carrier are tilted in relation to one another during the exposure of the surface of the substrate.
[0029] The invention can clearly be seen in the fact that a reduction of the depth of focus and/or an increase in the resolution which as a result of the heating of an immersion liquid, which heating is brought about by a beam, e.g. laser beam, and leads to a shift of the best focus position, is not prevented solely by a control of the temperature of the immersion liquid, but rather by means of a tilted arrangement of the reticle and the carrier, on which a substrate to be patterned is arranged, that is to say a substrate having a surface to be exposed. Clearly, the distance between the reticle and the substrate surface to be exposed increases or decreases in the direction of movement of the carrier. To put it another way, the reticle in the holder and the substrate surface to be exposed are not oriented parallel to one another, but rather are at a relative angle with respect to one another. The arrangement is configured such that it enables the change in the position of the best focus to be compensated for by means of the varying distance between the reticle and the substrate surface to be exposed which results from said relative angle. That is to say that the ΔD from equation (2) which results for a given rise in temperature is not prevented by controlling the temperature, but rather is compensated for by means of an additional ΔD which results from the relative angle between the reticle and the substrate surface to be exposed.
[0030] To put it another way, the normal vector of the substrate surface to be exposed, which to a good approximation represents a plane area, and the normal vector of the reticle, which to a good approximation represents a plane area, are not oriented parallel or antiparallel, but rather are at the relative angle. The position of the best focus can be understood to be the position in which the depth of focus and/or resolution in the position is best, that is to say the depth of focus is greatest and/or the resolution is smallest.
[0031] The arrangement according to the invention and the method according to the invention have the advantage that they make it significantly simpler to prevent the adverse influences of the heating of the immersion fluid on the depth of focus and/or resolution. The relative angle and thus the distance between the reticle and the substrate surface to be exposed can be measured and regulated significantly more easily than a temperature which, as described above, is to be regulated accurately to a few mK.
[0032] The setting of the depth of focus and/or the resolution involves, in particular, keeping constant the depth of focus and/or resolution during the exposure of an individual electronic component to be patterned on the substrate.
[0033] Preferred developments of the invention emerge from the dependent claims. In this case, preferred developments of the immersion lithography method for the exposure of a substrate also apply to the device, and vice versa. Preferably, the distance is varied in such a way that the change in depth of focus and/or resolution caused during the exposure by a change in temperature of the immersion fluid during the exposure is compensated for.
[0034] In one development, the immersion fluid is a fluid having a high transparency at a given exposure wavelength and/or having a small dn/dT.
[0035] A high transparency of the immersion fluid, e.g. a liquid, at the exposure wavelength used during the method leads to a low absorption during the exposure, thus to a lower input of energy into the immersion fluid and thus also to less heating. A small dn/dT in turn leads to an only small change in the refractive index for a given change in temperature and thus to an only small change in the position of the best focus. The transparency is preferably more than 0.9, particularly preferably more than 0.95. The dn/dT is preferably less than 10 −3 , particularly preferably less than approximately 10 −4 .
[0036] The immersion fluid may be water or a perfluoropolyether.
[0037] Water and perfluoropolyether have a high refractive index in conjunction with good transmission properties, that is to say good beam transmissivity. Consequently, it is possible to effectively prevent the total reflection when the beam emerges from the imaging element, and to increase the numerical aperture. This in turn leads to an improved resolution or to an improved depth of focus for the same resolution. The water used is preferably high-purity deionized water, because gases, such as oxygen for example, and solids, such as impurity atoms for example, dissolved in the water influence the optical properties of the water. In particular, it is possible to use water as the immersion medium at a wavelength of 193 nm used for the lithography, and to use perfluoropolyethers, such as, for example, that known by the trade name Krytox®, for the lithography at a wavelength of 157 nm.
[0038] Preferably, the carrier is moved obliquely with respect to the reticle. That is to say that the carrier is not moved parallel to a main direction of the reticle, which to a good approximation represents a plane area, rather it is moved obliquely, that is to say at a relative angle with respect to the main direction of the reticle. The oblique movement of the carrier makes it possible to achieve in a simple manner the variation of the distance between the reticle and the substrate surface to be exposed, which substrate is arranged onto the carrier, along the direction of movement. As a result of this, a AD which is caused by the change in the refractive index of the immersion fluid as a result of the rise in temperature during the scanning of the reticle can be compensated for easily and the resolution of the exposure can be improved and/or the depth of focus of the exposure can be increased.
[0039] Particularly preferably, the reticle is tilted relative to the substrate surface to be exposed.
[0040] The tilting of the reticle relative to the substrate also makes it possible to achieve in a simple manner the variation of the distance between the reticle and the substrate surface to be exposed, which substrate is arranged onto the carrier, along the direction of movement. As a result of this, a ΔD which is caused by the change in the refractive index of the immersion fluid as a result of the rise in temperature during the scanning of the reticle can once again be compensated for easily and the resolution of the exposure can be improved and/or the depth of focus of the exposure can be increased.
[0041] The tilting of the reticle is particularly advantageous since a demagnifying imaging element is usually used in a scanning exposure device. As a result of this, the structure used to expose the substrate can be represented in enlarged fashion on the reticle. Assuming that the structure on the reticle has an extent of 100 nm×100 nm in the X-Y plane of the reticle, then it is imaged onto an area in the X-Y plane of 25 nm×25 nm in the case of an imaging element which effects 4:1 demagnification. However, the imaging element acts not only in the X-Y plane but also in the Z direction, to be precise in such a way that a change in the z position of the reticle by 16 mm brings about a shift in the focus, that is to say the X-Y plane of the sharpest image downstream of the imaging element, by only 1 mm. This corresponds to a “stepping-down” of the shift in the z position. The distance between the reticle and the substrate can thereby be regulated in a simple manner since possible inaccuracies in the regulation of the tilting of the reticle are reduced by a factor of 16.
[0042] In one development, the variation of the distance between the reticle and the substrate surface to be exposed proceeds linearly along the direction of movement of the carrier.
[0043] To consider it clearly, this means that as the movement of the substrate increases within an exposure field, that is to say a field on the substrate which is exposed by means of a reticle and which represents an individual electronic component after the processing has ended, the variation of the distance between the substrate surface to be exposed has a linear portion, that is to say that the distance becomes linearly larger or smaller. A linear decrease in the distance is advantageous since it can easily be obtained. On the other hand, both the change in the refractive index as a function of the change in the temperature and the change in the z position of the focus as a function of the change in the refractive index are linear to a first approximation. That is to say that dn/dT ≈constant and dz/dn ≈constant. It is apparent from this that in the case of an exposure device which is not a stepper but rather has a scanning mode of operation, Δz, that is to say the change in the focus position in the z direction, is proportional to the exposure energy that a point to be exposed has already experienced, and thus also proportional to the position within an illumination slot with the aid of which the reticle is scanned, which in turn has the effect that for compensating for the focal change it is advantageous to linearly vary the distance between the reticle and the substrate surface to be exposed.
[0044] The second direction may be opposite to the first direction.
[0045] The temperature of the immersion fluid is preferably regulated.
[0046] In the case of an additional temperature regulation of the immersion fluid, the temperature regulation can be used to carry out a coarse control of the depth of focus and/or the resolution of the exposure, while the fine control of the depth of focus and/or the resolution of the exposure is carried out by means of varying the distance between the reticle and the substrate surface to be exposed. That is to say that possible changes in the focus which occur as a result of inaccurate temperature regulation can be compensated for by means of the distance variation.
[0047] The imaging element may be a lens or a lens system.
[0048] In one development, the immersion fluid is introduced between the imaging element and the substrate during the exposure.
[0049] This clearly means that the immersion fluid is injected, during the exposure of a substrate, for example into the interspace between the imaging element and the substrate. Injection represents a method that can be carried out in a simple manner for providing the immersion fluid.
[0050] In one development, the distance variations are determined as offsets prior to the exposure of the substrate in a calibration step for the substrate and, during the exposure of the substrate, the offsets that have been determined and stored are used in order to carry out, that is to say set, the distance variations.
[0051] In general, the substrate is calibrated prior to the exposure within a lithography in order to correctly orient it later for the exposure. Calibration values are obtained in this case. The offsets which are produced for the compensation for the variations of the best focus position as a result of the change in temperature of the immersion fluid can then be added to said calibration values. Said offsets can be determined by calculating them, for example, or else measuring them in the calibration measurement. The calculation is explained in more detail below.
[0052] The calibration, the determination and addition of the offsets can also be carried out by the so-called “on-fly” method. For this purpose, a CCD camera that is generally present in a lithography device may be used for the calibration. In this case, “on-fly” means that the calibration is carried out directly before a directly subsequent exposure step, that is to say within a method that is not subject to any temporal interruption.
[0053] To summarize, the invention can be seen in the fact that in an immersion lithography technology, it is not attempted to prevent the effects of a change in temperature of the immersion medium primarily by regulating the temperature, but rather to compensate for this by means of varying the distance between a reticle used and a substrate surface to be exposed. To put it clearly, a relative angle between the reticle used and the substrate to be exposed is set which has a magnitude such that, by means of this relative angle, the distance between the reticle and the substrate surface to be exposed changes during the exposure of the substrate, to be precise to the extent necessary to compensate for the change in the z position of the best focus, which change is caused by the change in temperature of the immersion medium.
[0054] The relative angle must be calculated prior to the exposure in order to be able to take it into account during the exposure. In order to calculate it, it is necessary to determine the energy dose which the immersion medium takes up during the exposure, in order to determine therefrom the change in the z position of the best focus. This can be carried out during a calibration step which is already customary anyway and which is carried out for each exposure field of a substrate or per substrate once or at predetermined time intervals. Clearly, each exposure field of a substrate is scanned prior to the actual exposure by means of a calibration device in order to obtain the items of information required for the exposure. In this case, inter alia, a height profile of the substrate surface to be exposed is created in order to carry out an exact lithography. An offset is then also added to said height profile, said offset corresponding to the linearly increasing offset which is caused by the increase in temperature of the immersion medium. It should be taken into consideration that the offset does not have to be measured for every field, rather it generally suffices for the offset to be measured at predetermined time intervals. One criterion for the time intervals is, for example, that it is ensured that no alterations that affect the position of the best focus have arisen between two measurements.
[0055] The effects of the change in temperature of the immersion medium primarily reside in the fact that the refractive index of the immersion medium changes. It follows from this that the z position, that is to say the distance at which a sharp image arises downstream of an imaging element, changes with the temperature of the immersion medium. The change in the z position of the focus in turn leads, if it is not compensated for, to a deterioration in the resolution and/or a smaller depth of focus during the exposure of the substrate. The change in the z position is approximately linear over the exposure slot and can therefore be compensated for by tilting the reticle and/or substrate.
BRIEF DESCRIPTION OF THE DRAWING
[0056] Exemplary embodiments of the invention are illustrated in the FIG.s and are explained in more detail below.
[0057] FIG. FIG. 1 shows a schematic illustration of a scanning exposure device in accordance with one exemplary embodiment of the invention,
[0058] FIG. FIG. 2 shows a schematic illustration illustrating the introduction of an immersion fluid,
[0059] FIG. FIG. 3 shows a schematic illustration of the temperature of an immersion fluid during an exposure and the position of the focus in relation to the position within the exposure slot,
[0060] FIG. FIG. 4 shows a schematic side view of a scanning exposure device in accordance with a first exemplary embodiment of the invention,
[0061] FIG. FIG. 5 shows a schematic side view of a scanning exposure device in accordance with a second exemplary embodiment of the invention, and
[0062] FIG. FIG. 6 shows a schematic simplified illustration of a lithography device in accordance with the prior art.
DETAILED DESCRIPTION
[0063] shows a schematic representation of a scanning exposure device 100 for an immersion lithography. The scanning illumination device is also called a “scanner exposure tool” or scanner for short. For the purpose of improved clarity, no immersion fluid is illustrated in FIG. FIG. 1 .
[0064] A scanner 100 has a holder 101 , which accommodates a reticle 102 , an imaging element 103 , e.g. a lens or a lens system, and a carrier 104 , on which a substrate 105 is arranged. The reticle 102 is illuminated from above by a beam source (not illustrated), e.g. a laser, in FIG. FIG. 1 . The beam from the beam source passes through the reticle 102 and passes further downward in the direction of the substrate in FIG. 1 . A so-called exposure slot 106 has the effect that only a small region of the reticle 102 is exposed, that is to say only a small partial region of the reticle 102 is illuminated and the relevant beams can pass into the lens system 103 . The exposure slot 106 is indicated as a hatched region within the reticle 102 in FIG. 1 . Furthermore, in order to make it clear that only beams from a small partial region pass into the lens system 103 , this partial region is illustrated in bright fashion in FIG. 1 on the top side of the lens system 103 . The lens system 103 is formed in such a way that it generates a sharp image of structures that are present on the reticle 102 on the substrate 105 . The region of the substrate 105 which is currently being exposed is in turn illustrated as a bright strip in FIG. 1 . In general, the beam is emitted in pulsed fashion, so that a large number of short beam pulses are used to expose the substrate 105 .
[0065] In order to image all the structures of the reticle 102 on the substrate 105 , the reticle 102 moves relative to the exposure slot 106 . In FIG. 1 , this movement and the direction thereof are indicated by a first arrow 107 toward the right. Through the movement of the reticle 102 relative to the stationary exposure slot 106 , the entire reticle is scanned by the beam from the beam source and imaged on the substrate 105 . In order to attain a sharp imaging on the substrate 105 , however, the substrate 105 must also be moved. In general, the movement of the substrate 105 will be opposite to the movement of the reticle 102 since a simple lens system generates an image which is inverted. In other words, in FIG. 1 , the carrier 104 , on which the substrate 105 is arranged, moves toward the left, which is indicated by a second arrow 108 .
[0066] In the case of the movement of the reticle 102 and the carrier 104 , it must be taken into consideration that in general a lens system is used which does not image the structures arranged on the reticle 102 onto the substrate on a scale of 1:1. In FIG. 1 , the “4×” on the lens system schematically indicates that the structures are imaged onto the substrate on a scale of 4:1. In this case, the speeds of the movements of the reticle 102 and of the carrier 104 have to be adapted to the imaging scale. In general, a lens system which demagnifies the structures is used. If a lens system which demagnifies the structures e.g. by the factor four is used, then the speed at which the reticle is moved must be greater by the factor four than the speed at which the carrier 104 and hence the substrate 105 are moved.
[0067] FIG. 2 then schematically shows how an immersion fluid can be introduced between the lens system 103 and the substrate 105 .
[0068] FIG. 2 shows a side view of a detail from the arrangement for an immersion lithography method according to the invention.
[0069] FIG. 2 illustrates the lens system 103 , the carrier 105 and the substrate 105 . The holder 101 , the reticle 102 and the exposure slot 107 are not illustrated in FIG. 2 for the sake of clarity. The movement of the carrier 104 is illustrated by the double arrow 209 . The latter is intended to indicate that the carrier 104 can move in two directions depending on how the reticle 102 (not illustrated) moves. In addition, FIG. 2 symbolically illustrates a supply line 210 , by means of which an immersion fluid 211 can be introduced between the lens system 103 and the substrate 106 . In the exemplary embodiment, the immersion fluid is high-purity water, that is to say water which is low in impurities such as, for example oxygen or impurities, or a perfluoropolyether, such as, for example, the perfluoropolyether known by the trade name Krytox®.
[0070] FIG. 3 schematically shows the profile of the temperature of the immersion fluid and the z position of the focus, along the position of the exposure slot.
[0071] In FIG. 3 a , the ordinate (Y axis) represents the temperature of the immersion fluid in arbitrary units and the abscissa (X axis) represents the x position on the substrate. FIG. 3 a clearly illustrates a snapshot of the temperature over the position on the substrate. In addition, the dashed lines 312 and 313 specify the region into which the exposure slot is imaged. The two dashed lines 312 and 313 clearly represent the first and second edge boundaries of the exposure slot. In FIG. 3 a , the substrate moves toward the right, which is indicated by the arrow 316 . The movement of the substrate toward the right has the consequence that the temperature of the immersion fluid continuously increases from the region of the substrate which, through the movement of the carrier, is currently penetrating into the region into which the exposure slot is imaged ( 312 ) to the region of the substrate which is currently leaving the region into which the exposure slot is imaged ( 313 ). This continuous increase in the temperature is associated with the fact that the immersion fluid, which is introduced into the interspace between the lens system and the substrate, practically adheres to the substrate surface and thus moves concomitantly with the substrate. Consequently, the immersion fluid, which, in FIG. 3 , at the dashed line 313 , is currently leaving the region into which the exposure slot is imaged, has been subjected longest to the exposure and has thus been subjected the most greatly to a temperature increase through the partial absorption of the laser beam. After the substrate has left the region into which the exposure slot is imaged, the temperature of the immersion fluid decreases again.
[0072] In FIG. 3 b , the ordinate (Y axis) represents the z position of the best focus and the abscissa (X axis) represents the x position on the substrate. FIG. 3 b clearly illustrates a snapshot of the z position of the plane in which a sharp image is generated over the position on the substrate. In addition, the dashed lines 312 and 313 again specify the region into which the exposure slot is imaged. In FIG. 3 b , the substrate moves toward the right, which is indicated by the arrow 317 . This can be seen analogously to FIG. 3 a . The movement toward the right of the substrate has the consequence that, as shown in FIG. 3 a , the temperature, with the latter the refractive index and thus also the z position of the best focus illustrated in FIG. 3 b changes continuously in the region of the substrate which, through the movement of the carrier, is currently penetrating into the region into which the exposure slot is imaged ( 312 ) to the region of the substrate which is currently leaving the region into which the exposure slot is imaged ( 313 ). The z position of the best focus moves closer and closer to the lens system. This continuous variation of the z position is associated with the continuous rise in the temperature of the immersion fluid, since the refractive index is to a first approximation proportional to the temperature and the z position is in turn to a first approximation proportional to the refractive index. Consequently, the profile of the z position of the best focus illustrated in FIG. 3 b follows the profile of the temperature illustrated in FIG. 3 a.
[0073] FIG. 4 illustrates a schematic side view of a scanning exposure device in accordance with a first exemplary embodiment of the invention. The scanning exposure device of FIG. 4 has a reticle 402 an imaging element 403 , which is schematically illustrated as an individual lens in FIG. 4 , and a carrier 404 , on which a substrate 405 is arranged. An immersion fluid, which is not illustrated in FIG. 4 for the sake of clarity, is introduced between the substrate 405 and the lens 403 during the exposure of the substrate.
[0074] In the first exemplary embodiment, the distance between the reticle 402 and the surface to be exposed of the substrate 405 is varied in the direction of movement, or to put it another way during the movement, by means of the carrier 404 being moved obliquely with respect to the reticle 402 . The direction of movement of the reticle 402 is indicated by a first arrow 407 and is toward the left in FIG. 4 , while the direction of movement of the holder 404 and thus of the substrate 405 , which runs toward the right in FIG. 4 , is indicated by a second arrow 408 .
[0075] In order to illustrate the invention, the obliquity of the movement of the carrier 404 relative to the orientation of the reticle 402 , that is to say the relative angle formed by the reticle 402 and the carrier 404 , has been represented in a greatly exaggerated manner in FIG. 4 . On a correct scale, the relative angle that would have to be set in order to compensate for the focus position change produced by the heating of the immersion fluid would not be discernible in the FIG.
[0076] A brief explanation is given below of how it is possible to determine the size of the variation of the distance between the reticle and the substrate.
[0077] In a conventional lithography exposure device, also called an “exposure tool”, a calibration is carried out prior to the actual exposure at each field of the substrate, a so-called exposure field, which contains individual electronic components after completed processing. Said calibration is generally necessary since, for a correct exposure, that is to say an exposure with a small resolution, the individual substrate has to be measured accurately, for example in terms of its height profile. The calibration measurement then yields, inter alia, a height profile of an individual exposure field within the substrate. An offset, which as a result of the z position shift of the best focus that follows from the change in temperature of the immersion fluid can then also simply be added to said height profile. The value of the offset rises, as illustrated in FIG. 3 b , to a first approximation, linearly in the region of the exposure field which is currently just being exposed through the exposure slot. The offset, which arises as a result of the change in temperature of the immersion fluid, can be determined in a manner corresponding to the calibration measurement and be stored. Two calibrations are preferably carried out, in which case, in a first calibration, each exposure field is measured prior to the exposure and, in a second calibration, the offset is measured once for a given installation. The offset can then be corrected as required, that is to say according to the conditions at the start of the exposure of each substrate or wafer, or hourly, daily or at other given time intervals. Once the offset has been stored, e.g. in the form of a table, a so-called “look-up table”, it can then be taken into account in a subsequent exposure of the exposure field by being added to the height profile of the exposure field. The storage may take place for example in a memory of a computer, which computer can also be used in carrying out and evaluating the calibration measurement and/or in determining the offset. The storage affords the advantage that the same offsets can be used repeatedly if identical exposures, that is to say an exposure process having identical parameters, such as, for example, exposure time, photoresist, reticle, etc., are carried out. This obviates new calculations and/or new measurements of the offsets.
[0078] In order to determine the offset, it is necessary to determine the rise δT in temperature of the immersion fluid along the movement of the carrier. From this rise δT in temperature of the immersion fluid along the movement direction, it is possible to calculate the change in the refractive index δn given known dn/dT. To a first approximation, dn/dT can be assumed as a material constant of the immersion fluid for this purpose. δT can be determined by means of equation (3):
δT=(1−τ)γ/cD
[0079] Where: δT is the rise in temperature,
[0080] τ is the transmission coefficient of the immersion fluid,
[0081] γ is the energy dose required to expose the photoresist used during the exposure,
[0082] c is the specific heat of the immersion fluid, and
[0083] D is the distance between the imaging element and the substrate, that is to say the working distance.
[0084] Consequently, for the defocusing, that is to say the shift in the z position of the best focus, as a result of the change in temperature of the immersion fluid, to a first approximation, this results in equation (2) already specified above
Δ D = D · δ n n · cos 2 θ
[0085] From this it is then possible to calculate the required variation of the distance along the entire region on the substrate onto which the exposure slot is imaged, that is to say the region in FIG.s 3 a and 3 b between the lines 312 and 313 . For the linear approximation of the speed of the variation of the z position of the best focus, that is to say the necessary speed of the substrate in the direction of the z coordinate, equation (2), equation (3) and
δ n = ⅆ n ⅆ T .
δT give rise to the following equation (4)
Δ D Δ t = ⅆ n ⅆ T · ( 1 - τ ) · γ c · n · cos 2 θ · 1 Δ t
[0086] where Δt is the time for which a point on the substrate is exposed, that is to say the time required by a point in order, once it has penetrated into the region of the exposure slot, to leave this region again, to put it another way the time required by a point on the substrate in order to cover the distance from the dashed line 312 as far as the dashed line 313 in FIGS. 3 a and 3 b.
[0087] From equation (4) it is possible, as explained above, to calculate a speed in the z direction which the substrate surface to be exposed has in order to compensate for the change in the refractive index of the immersion fluid as a result of the increase in temperature of the immersion fluid during the exposure. In this case, the direction of the speed in the z direction depends on the sign of dn/dT; generally this is such that the distance between the substrate surface to be exposed and the imaging element decreases along the direction of movement in order to compensate for the changes caused by the temperature changes, as also emerges from FIG. 3 b.
[0088] The speed in the z direction can also be converted in a simple manner into a relative angle which the substrate surface to be exposed must have with respect to the reticle.
[0089] In addition to the above-described calculation of the shift in the best focus in the z direction, the shift in the best focus can also be determined experimentally. The experimental determination is simpler to carry out, under certain circumstances, than the analytical method described. By way of example, the parameters required for the calculation need not necessarily be known in this case. The z position shift of the best focus is simply measured for a given exposure device.
[0090] FIG. 5 illustrates a schematic side view of a scanning exposure device in accordance with a second exemplary embodiment of the invention. The scanning exposure device of FIG. 5 has a reticle 502 , an imaging element 503 , which is illustrated schematically as an individual lens in FIG. 5 , and a carrier 504 , on which a substrate 505 is arranged. An immersion fluid introduced between the substrate 505 and the lens 503 is not illustrated in FIG. 5 for the sake of clarity.
[0091] The illustration does, however, also show two planes that are intended to help to explain the functioning of the second exemplary embodiment. In the second exemplary embodiment, the carrier 504 with the substrate 505 is not moved obliquely, rather the reticle 502 is moved obliquely. By this means, too, it is possible to compensate for the shift in the z position of the sharpest image that is caused by the temperature increase and the change in refractive index correlated therewith. It must be taken into consideration in this case that an imaging element that effects a demagnification is usually used. This is illustrated symbolically in FIG. 5 by the “4×” depicted in the symbolic lens 403 . A demagnification on the scale of 4:1 has an effect at the distance of the best focus and thus in the z direction with a factor of 16, that is to say the demagnification factor squared (4: 1) 2 . This means that the reticle 502 has to be tilted to a significantly greater extent during the movement than the substrate 405 in the first exemplary embodiment illustrated in FIG. 4 . The speed in the z direction that results from equation (4) or the resulting relative angle must be increased by said factor of 16.
[0092] In order to illustrate these facts, FIG. 5 , as already stated, also depicts two planes. The first plane 514 shows the “tilting” of the image of the reticle 502 generated by the lens 503 . For the reason mentioned above, this first plane 514 has a weaker degree of tilting than the reticle 502 itself. The first plane 514 specifies the position, or the tilting, which the surface to be exposed of the substrate 505 would have to have in a lithography device which would have no effects of the change in refractive index as a result of an irradiation of a medium between the lens 503 and the substrate 505 . Since, however, the invention involves the use of an immersion lithography device in which an immersion fluid is introduced between lens 503 and substrate 505 , a tilting of the image, or to put it another way a variation of the z position (distance) of the best focus, arises as a result of the change in the refractive index with the temperature. This tilting is illustrated by means of a second plane 515 in FIG. 5 . The second plane specifies the variation of the best focus as a result of the change in temperature. In order to obtain the plane of the best focus after the effects of the change in refractive index as a result of the change in temperature in the immersion fluid and the tilting of the reticle, the tilting of the first plane 514 and of the second plane 515 is “added together”. This yields the resulting imaging plane on which the image of the reticle is imaged the most sharply. In FIG. 5 , the inclinations of the first plane 514 and of the second plane 515 are illustrated such that they are equal in magnitude but have opposite signs, so that the resulting imaging plane in FIG. 5 is horizontal.
[0093] Consequently, in the second exemplary embodiment illustrated in FIG. 5 , a sharp image of the reticle 502 arises on the surface to be exposed of the substrate 505 if the surface to be exposed of the substrate 505 is moved in the horizontal direction below the lens system 503 in FIG. 5 .
[0094] To summarize, the invention can be seen in the fact that in an immersion lithography technology which is carried out by means of scanning exposure device, the variations in the position of the best focus, that is to say the sharpest imaging, which as a result of the change in the refractive index of the immersion medium with the change in the temperature of the immersion medium as a result of absorption in the immersion medium, in contrast to the prior art are not prevented solely by regulating the temperature of the immersion medium, rather a compensation of these focus variations is carried out by varying a distance between the reticle and a substrate surface to be exposed along the direction of movement of the substrate. The change in the distance corresponds to an offset, which is added to the normal movement of the substrate and/or reticle, that is to say the movement such as is performed by a substrate and/or reticle in an immersion lithography device in accordance with the prior art. The value of said offset can be calculated by means of equation (4) specified above. Said offset can be understood as a linear movement in the z direction, that is to say the direction of an optical axis of the scanning exposure device. In the scanning exposure device, the optical axis corresponds to the axis along which a beam, e.g. a laser beam, which is used for the exposure propagates.
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The invention relates to an immersion lithography method which illuminates a substrate positioned on a carrier. When a substrate is illuminated, an immersion fluid is introduced between a reproducing element and the substrate and the field depth or the resolution, or both, are adjusted by varying the distance in the direction of the beam between an illuminating reticule and the surface of the substrate along a direction of movement of the carrier.
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TECHNICAL FIELD
[0001] The present invention relates to automatic detection and/or monitoring of animate presence using an ultrasonic system.
BACKGROUND
[0002] Ultrasonic transducers are sensors that convert ultrasound waves to electrical signals and electrical signals to ultrasound waves. Ultrasonic transducers that both transmit and receive are sometimes referred to as ultrasonic transceivers. Ultrasonic transducers are commonly used like radar and sonar systems to detect a target based on the response to a transmitted ultrasonic signal, for example by comparing the time interval between sending the signal and receiving an echo to determine the distance to an object or if it is in motion. Ultrasonic transducers are commonly used in cars as parking sensors to help direct the driver in reversing into a parking space.
[0003] In many cases it is of interest to keep track of living people or animals, for example to make sure that they are confined to a specific area or that they are alone in the area. Additionally it may be of interest to verify that they are alive.
[0004] In contrast in some cases it may be of interest to negate animate presence, for example to make sure that people or animals do not enter a specific area (e.g. a room) or do not come near a specific object, animal or person. Generally these objectives can be achieved by placing a guard or caretaker to watch the person, animal or object. However it would be desirable to automate this task, to reduce the need to invest in manpower.
[0005] An ultrasonic transducer could be used to detect the presence of a person, for example based on motion. However such systems do not differentiate between animate objects and inanimate objects.
SUMMARY
[0006] An aspect of an embodiment of the disclosure relates to a system and method of detecting and/or monitoring animate presence in the vicinity of the system. The system includes one or more ultrasonic transducers, receivers and an electronic circuit to analyze the measurements. The electronic circuit analyzes the signals transmitted by the transducers relative to the echo signals received by the receivers in response to identify a phase shift between the signals, the phase shifts provides indication of animate presence, for example a live person or live animal. The system provides notification to a user based on the results of the analysis. Optionally, the system differentiates between a single detected live person or animal and multiple people and/or animals. In some embodiments of the disclosure, the system can identify if the animate presence is from a grown up person, child, infant or specific types of animals.
[0007] There is thus provided according to an exemplary embodiment of the disclosure, a system for monitoring animate presence, comprising:
[0008] One or more ultrasonic transducers configured to transmit an ultrasonic signal;
[0009] One or more ultrasonic receivers configured to receive an echo signal in response to the transmitted ultrasonic signal;
[0010] An electronic circuit for comparing the transmitted signal to the received echo signal and identify a phase shift between the signals; wherein the electronic circuit identifies animate presence based on the identified phase shift.
[0011] In an exemplary embodiment of the disclosure, the electronic circuit is configured to differentiate between a single animate entity and multiple animate entities. Optionally, the electronic circuit is configured to differentiate between people and animals. In an exemplary embodiment of the disclosure, the electronic circuit is configured to send notification if more than one person is detected in a monitored room. Optionally, the electronic circuit is configured to monitor a Wi-Fi connection and provide a notification if the Wi-Fi connection is unavailable and there exists animate presence.
[0012] In an exemplary embodiment of the disclosure, the electronic circuit is configured to monitor the respiratory activity of an observed individual and activate an alarm if the respiratory activity ceases or is abnormal. Optionally, the electronic circuit is configured to monitor animate presence in a closed area and activate an alarm if no animate presence is detected or more than one organism is detected. In an exemplary embodiment of the disclosure, the system includes a communication unit for providing results with a wireless electromagnetic signal. Optionally, the system is configured to monitor animate presence in a room and provide the results to a user in a different room. In an exemplary embodiment of the disclosure, the system is shaped as a sphere to monitor in substantially any direction.
[0013] There is further provided according to an exemplary embodiment of the disclosure, a method of monitoring animate presence, comprising:
[0014] Transmitting an ultrasonic signal with one or more ultrasonic transducers; receiving an echo signal in response to the transmitted ultrasonic signal by one or more ultrasonic receivers;
[0015] Comparing the transmitted signal to the received echo signal using an electronic circuit to identify a phase shift between the signals; and
[0016] Identifying animate presence based on the identified phase shift.
[0017] In an exemplary embodiment of the disclosure, the electronic circuit is configured to differentiate between a single animate entity and multiple animate entities. Optionally, the electronic circuit is configured to differentiate between people and animals. In an exemplary embodiment of the disclosure, the electronic circuit is configured to send notification if more than one person is detected in a monitored room. In an exemplary embodiment of the disclosure, the electronic circuit is configured to monitor a Wi-Fi connection and provide a notification if the Wi-Fi connection is unavailable and there exists animate presence. Optionally, the electronic circuit is configured to monitor the respiratory activity of an observed individual and activate an alarm if the respiratory activity ceases or is abnormal. In an exemplary embodiment of the disclosure, the electronic circuit is configured to monitor animate presence in a closed area and activate an alarm if no animate presence is detected or more than one organism is detected. Optionally, results of the identifying are provided by an electromagnetic signal. In an exemplary embodiment of the disclosure, the monitoring is performed in a room and results are provided to a user in a different room. In an exemplary embodiment of the disclosure, the system is shaped as a sphere to monitor in substantially any direction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The present disclosure will be understood and better appreciated from the following detailed description taken in conjunction with the drawings. Identical structures, elements or parts, which appear in more than one figure, are generally labeled with the same or similar number in all the figures in which they appear. It should be noted that the elements or parts in the figures are not necessarily shown to scale, each element or part may be larger or smaller than actually shown.
[0019] FIG. 1 is a schematic illustration of a system for detecting animate presence, according to an exemplary embodiment of the disclosure;
[0020] FIG. 2A is a graph of a recorded echo signal in time domain, according to an exemplary embodiment of the disclosure;
[0021] FIG. 2B is a graph of a recorded echo signal in frequency domain, according to an exemplary embodiment of the disclosure;
[0022] FIG. 3A is a schematic illustration of a system for monitoring animate presence in a room, according to an exemplary embodiment of the disclosure;
[0023] FIG. 3B is a flow diagram of a method of monitoring animate presence in a room, according to an exemplary embodiment of the disclosure;
[0024] FIG. 4A is a schematic illustration of a system for monitoring animate presence in a vehicle, according to an exemplary embodiment of the disclosure;
[0025] FIG. 4B is a flow diagram of a method of monitoring animate presence in a vehicle, according to an exemplary embodiment of the disclosure;
[0026] FIG. 5A is a schematic illustration of a system for monitoring respiratory activity of an infant, according to an exemplary embodiment of the disclosure;
[0027] FIG. 5B is a flow diagram of a method of monitoring respiratory activity of an infant, according to an exemplary embodiment of the disclosure;
[0028] FIG. 6A is a schematic illustration of a system for guarding an animal, according to an exemplary embodiment of the disclosure;
[0029] FIG. 6B is a flow diagram of a method of guarding an animal, according to an exemplary embodiment of the disclosure;
[0030] FIG. 7A is a schematic illustration of a personal alarm system, according to an exemplary embodiment of the disclosure;
[0031] FIG. 7B is a flow diagram of a personal alarm system, according to an exemplary embodiment of the disclosure;
[0032] FIG. 8A is a schematic illustration of a preview security system, according to an exemplary embodiment of the disclosure; and
[0033] FIG. 8B is a flow diagram of a preview security system, according to an exemplary embodiment of the disclosure.
DETAILED DESCRIPTION
[0034] FIG. 1 is a schematic illustration of a system 100 for detecting animate presence, according to an exemplary embodiment of the disclosure. In an exemplary embodiment of the disclosure, system 100 uses one or more ultrasonic transducers 110 and one or more ultrasonic receivers 120 to monitor activity in the vicinity of the system 100 . System 100 transmits a sound wave signal 115 having a frequency in the range of 18 KHz to 1 GHz to enable a reasonable detection range (higher frequencies have a lower detection range). In an exemplary embodiment of the disclosure, the transmitted signal comprises a train of pulses having the selected frequency (for example 10 pulses per second). Receiver 120 records an echo signal 125 resulting from the transmitted sound wave signal 115 being reflected off animate and/or inanimate objects, for example a person or wall. The recorded echo signal 125 is compared to the transmitted signal 115 pulse by pulse. Optionally, an echo signal 125 from animate objects will have a phase shift due to the respiratory system of the person or animal in contrast to the echo signal 125 from inanimate objects that will maintain its phase, for example adult breathing can cause a phase shift having a frequency of about 0.3 Hz and an infant can cause a phase shift having a frequency of about 0.1 Hz. Likewise the heartbeat of an adult can cause a phase shift having a frequency of about 1.2 Hz and an infant can cause a phase shift having a frequency of about 2 Hz. Accordingly by measuring the signal propagation time, signal amplitude and phase shift one can determine the distance to an object and if it is animate or inanimate. Optionally, system 100 is pre-programmed with an empirical list of phase shift ranges for people of different ages (e.g. infants, children and grown-ups) and/or different types and ages of animals (e.g. horses, dogs, cats, bears, tigers, lions, donkeys and other animals). The empirical list is formed by measuring the phase shift resulting from sound wave signal 115 propagating through air (with a velocity of about 300 meters per second) toward various live targets at different distances (e.g. 1-10 meters). In an exemplary embodiment of the disclosure, system 100 can differentiate between people and animals and different type of animals and/or different ages/groups. Optionally, system 100 can differentiate between a single person and multiple people, for example between 2 people and 3 people, or more people.
[0035] In an exemplary embodiment of the disclosure, system 100 includes an electronic circuit 105 coupled to the transducers 110 and/or receivers 120 , the electronic circuit including one or more of the following units:
[0036] 1. A signal generator 130 to produce a continuous wave signal with a desired frequency (e.g. between 20-200 KHz). Optionally, the wave form is a sine wave or square wave or other form of wave.
[0037] 2. A pulse modulator 140 that receives the signal from the signal generator 130 and modulates it to form a train of pulses, for example about 10 pulses a second having the desired frequency. Optionally, each pulse is selected to have a duration of about 1 millisecond thus providing a detection discrimination resolution of about 15 cm.
[0038] 3. A power amplifier 150 that receives pulses from modulator 140 and amplifies them for transmission with transducers 110 .
[0039] 4. A detection synchronization unit 160 that is gated with the pulse modulator 140 to synchronize the pulses of the received echo signal 125 with the pulses of the transmitted signal 115 .
[0040] 5. A phase detector 170 that receives the echo signal 125 from the receiver 120 and provides an output signal 175 representing the phase shift identified between the echo signal 125 and the wave signal provided by the pulse generator 130 .
[0041] 6. A microprocessor 180 that receives output signal 175 and processes the signal. Optionally, the signal processing removes noise (e.g. FFT, noise reduction) and determines if the phase signal indicates the presence of one or more live people, animal's or inanimate objects.
[0042] In an exemplary embodiment of the disclosure, the electronic circuit 105 may include an onboard display 190 or may be connected to an external display e.g. a standard computer display. The display will provide indications to a user regarding the findings of system 100 . Alternatively or additionally, electronic circuit 105 is connected to a communication unit 195 , for example a Wi-Fi connector, Blue-Tooth connector, Cellular Mobile transmitter, wired link, RF transmitter, an audible alarm or audio-visual alarm to communicate with other computers, networks and/or people. Optionally, the communication unit 195 is used to notify a user, provide an alert or request action.
[0043] In an exemplary embodiment of the disclosure, system 100 receives power from a standard domestic power socket (e.g. 110V or 220V). Alternatively or additionally, system 100 may be battery powered so that it is protected against power outage and is independent of a power source at least for a specific duration. Optionally, the battery can be chargeable or replaceable.
[0044] FIG. 2A is a graph 200 of the recorded echo signal 125 in time domain and FIG. 2B is a graph 250 of the recorded echo signal 125 in frequency domain, according to an exemplary embodiment of the disclosure. Optionally, graph 200 depicts multiple overlapping pulses of the recorded echo signal 125 . In most positions the multiple pulses are essentially the same and in specific positions (e.g. affected by animate breathing or heartbeats) the multiple pulses differ. In an exemplary embodiment of the disclosure, the graphs ( 200 , 250 ) are affected by the presence of two people with distinct heart beats and breathing rates that affect the recorded echo signal 125 . Transforming the raw signal as depicted in graph 200 to the frequency domain as depicted in graph 250 helps to enhance detection of the presence of the two people. FIGS. 2A and 2B represent a 10 Hz repetitive pulse with the first person having a breathing rate causing a phase shift of 0.3 Hz and a heartbeat causing a phase shift of 1 Hz. The second person is shown to have a breathing rate causing a phase shift of 0.4 Hz and a heartbeat causing a phase shift of 1.2 Hz.
[0045] In an exemplary embodiment of the disclosure, system 100 can be used to monitor a student taking an exam in a room, wherein system 100 is used to ensure that the student works alone (e.g. during a test) without other people in the vicinity. Optionally, system 100 can be set to use a basic signal frequency of about 40 KHz to provide a detection range of about 4 meters.
[0046] FIG. 3A is a schematic illustration of a system 300 for monitoring a room for animate presence, and FIG. 3B is a flow diagram 310 of a method of monitoring a room for animate presence, according to an exemplary embodiment of the disclosure. In an exemplary embodiment of the disclosure, system 300 is designed to include electronic circuit 105 with multiple transducers 110 and multiple receivers 120 . Optionally, the transducers 110 and receivers 120 are configured to cover 360 degrees around system 300 , wherein each transducer may sample for example a meter wide (e.g. up and down) thus essentially sampling a disk shaped area of the entire room surrounding system 300 .
[0047] In an exemplary embodiment of the disclosure, system 300 is designed to monitor a room and identify if a single person is present or if there are additional people. If the number of people is greater than one an event is recorded and notification may be sent to an administrator. In the flow diagram 310 P denotes the number of attempts to detect animate presence before declaring an error, and V denotes the number of times more than one person can be detected that are allowed to be identified before sending notification to the administrator.
[0048] In an exemplary embodiment of the disclosure, P and V are initially set to zero 312 . System 300 monitors the room and searches for animate presence 314 . Optionally, if no animate presence is detected system 300 keeps waiting or may provide an alert after a time limit defined by P. If animate presence is detected then if more than one person is detected 318 then V is incremented and system 300 continues to check after a preselected time delay 316 if the extra people left the room and only one person remains, for example a person may be allowed to enter the room for a short period to provide test papers to the student. If more than one person is detected again and again, V is incremented and after a pre-selected number of time delays (m) notification is sent 320 to the administrator to take actions.
[0049] In an exemplary embodiment of the disclosure, system 300 may be used to monitor a person taking a test at home. Optionally, the person is required to isolate himself in a room and activate system 300 at the beginning of the test. If the presence of other people is detected the test can be invalidated.
[0050] FIG. 4A is a schematic illustration of a system 400 for monitoring animate presence in a vehicle 405 and FIG. 4B is a flow diagram 460 of a method of monitoring animate presence in the vehicle 405 , according to an exemplary embodiment of the disclosure. In an exemplary embodiment of the disclosure, system 400 is installed in vehicle 405 , for example by using an attachment means 450 (e.g. a vacuum rubber with a rod) to attach it to a window or roof of the vehicle 405 . Optionally, the system 400 includes one or more transducers 110 and receivers 120 to monitor an angle of about 60-90 degrees to detect animate presence in the vehicle 405 , for example an infant 415 in the front seat or back seat of the vehicle 405 . Alternatively or additionally, in a large vehicle 405 (e.g. a bus or truck) the system 400 may be installed in the center of the vehicle with detection ability of about 180 degrees or even 360 degrees. Optionally, system 400 is powered from the cigarette lighter socket 440 by a cable 430 or directly hardwired to the vehicle electronic system.
[0051] In an exemplary embodiment of the disclosure, system 400 supports cellular communications with a sim card 420 in communication unit 195 to notify a pre-programmed telephone in case a determination is made that a monitored person 415 (e.g. infant or handicapped person) is left unattended in the vehicle 405 for more than a pre-selected time. As shown in FIG. 4B the user (e.g. the vehicle driver) initializes a mobile application 462 that provides local Wi-Fi communications to system 400 . Additionally, the user turns on system 400 . System 400 checks 464 if there exists Wi-Fi communication with the application on the user's mobile device. If yes system 400 starts monitoring 466 the vehicle (e.g. a specific seat or area that system 400 is aimed at). Optionally, system 400 provides notification (e.g. a LED or audio signal) that it has started to monitor, so that if it fails to start the user is notified that an error has occurred and can troubleshoot the system 400 , for example check if the application is active on his/her mobile device or check for other errors. In an exemplary embodiment of the disclosure, system 400 initially checks for animate presence 468 for monitoring. If animate presence is detected (e.g. an infant in the monitored area of the vehicle), then system 400 checks for the presence of Wi-Fi communication 470 from the user's mobile device. As long as Wi-Fi communication is available and the animate presence is there system 400 keeps monitoring. However if Wi-Fi communication is lost for a pre-selected time (e.g. because the driver left the vehicle) but animate presence remains then system 400 will activate an alarm 472 , for example by calling the user and/or other pre-programmed entities (e.g. father, mother, other relatives or calling center) over a cellular network (e.g. using sim card 420 ) and provide notification that the monitored person 415 is left unattended in the vehicle.
[0052] FIG. 5A is a schematic illustration of a system 500 for monitoring respiratory activity of an infant 510 and FIG. 5B is a flow diagram 560 of a method of monitoring respiratory activity of an infant 510 , according to an exemplary embodiment of the disclosure. In an exemplary embodiment of the disclosure, system 500 is placed near the body or face of the infant 510 , for example on a side of a crib 520 . System 500 is equipped with one or more ultrasonic transducers 110 and one or more ultrasonic receivers 120 that are arranged, for example with a dispersion angle of between 50 to 70 degrees since in general an infant using system 500 does not move much. Optionally, a frequency of about 200 KHz instead of about 40 KHz can be used to improve detection resolution, since the measured distance is small (e.g. about 1 meter).
[0053] In an exemplary embodiment of the disclosure, system 500 is powered on 565 after putting the infant 510 in the crib 520 . Then system 500 detects breathing 570 of the infant 510 . If no breathing is detected an indication of an error 575 is provided by system 500 otherwise system 500 verifies 580 that the breathing is in the normal range for an infant, for example forming a phase shift of less than 0.6 Hz. If the breathing is normal system 500 continues to monitor the infant 510 . Otherwise if the breathing ceases or is abnormal system 500 activates an alarm 590 that uses communication unit 195 to communicate with a remote receiver 530 that is located, for example with the mother 535 or father. Optionally, the remote receiver 530 may be communicated by an RF signal or over a Wi-Fi network. In some embodiments of the disclosure, the remote receiver may be a mobile telephone that is contacted by system 500 having a sim card in communication unit 195 . In some embodiments of the disclosure, communication unit 195 is connected by a cable to remote receiver 530 .
[0054] FIG. 6A is a schematic illustration of a system 600 for guarding an animal and FIG. 6B is a flow diagram 660 of a method of guarding an animal 610 , according to an exemplary embodiment of the disclosure. Some animals are expensive and it desirable to have them monitored to prevent theft, for example purebred horses. In an exemplary embodiment of the disclosure, system 600 monitors the animal and notifies a caretaker if anybody comes near the animal 610 or if another animal is placed near the animal 610 . Optionally, system 600 includes one or more ultrasonic transducers 110 and one or more ultrasonic receivers 120 . Optionally, the transducers 110 and receivers 120 are arranged to monitor an angle of between 120 to 180 degrees to cover an entire closed area such as a stable or stall.
[0055] In an exemplary embodiment of the disclosure, system 600 is powered on 665 and attempts to detect 670 the animal 610 . If no animal is detected an error indication 690 will be produced so that the user can fix the error so that system 600 can function properly. If the animal 610 is detected the system 600 starts to monitor 675 the animal 610 . Optionally, system 600 continuously detects animate presence 680 . If animate presence is not detected an alarm 695 is activated. Optionally, the alarm uses communication unit 195 to notify the caretaker that security has been breached. Communication may be realized in the form of a sim card communicating over a cellular network or by a local Internet connection (e.g. Wi-Fi). Optionally, a vocal message may be transferred or a text message (e.g. SMS or other applications). If animate presence is detected, system 600 checks if more than one organism was detected 685 , for example if another animal or person enters the closed area. If only a single organism was detected system 600 continues to monitor the animal 610 . Otherwise system 600 activates an alarm to notify the caretaker.
[0056] FIG. 7A is a schematic illustration of a personal alarm system 700 and FIG. 7B is a flow diagram 760 of personal alarm system 700 , according to an exemplary embodiment of the disclosure. The personal alarm system can be used in a room in which a person 710 is situated alone and warn the person 710 if someone else enters the room, for example when the person 710 is asleep in a hotel room the person can be protected from thieves while sleeping. In some embodiments of the disclosure, personal alarm system 700 can be used to protect more than one person, for example 2, 3 or 4 people. In an exemplary embodiment of the disclosure, personal alarm system 700 may be placed at one side of the room to monitor the room with one or more ultrasonic transducers 110 and one or more ultrasonic receivers 120 . Optionally, the transducers 110 and receivers 120 are configured to cover 120 to 180 degrees around personal alarm system 700 to cover all of the room or at least covering the person and entrances to the room.
[0057] In an exemplary embodiment of the disclosure, the user powers on 765 the personal alarm system 700 for it to start monitoring. Personal alarm system 700 begins by detecting animate presence 770 (the person 710 ) and providing an indication (e.g. a LED) that it is functioning. The personal alarm system 700 starts monitoring the room 775 . While monitoring the personal alarm system 700 detects animate presence 780 and then determines if it detected a single person or more 785 . If only a single person was detected the personal alarm system continues to monitor the room. Otherwise if no animate presence is detected the personal alarm system provides an error indication 795 . Likewise if personal alarm system 700 detects more than one person it activates an alarm 790 to warn the person or other people (e.g. body guards that are located in another room). Optionally, personal alarm system 700 includes communication unit 195 that calls or sends a message to the other people and/or personal alarm system 700 may provide an indication in the form of an audible tone to wake up the person 710 , scare an intruder or summons help.
[0058] FIG. 8A is a schematic illustration of a preview security system 800 , and FIG. 8B is a flow diagram 860 of preview security system 800 , according to an exemplary embodiment of the disclosure. In many cases it is desirable to be able to know if there are people or animals around the corner or in a room without actually going there. In an exemplary embodiment of the disclosure, preview security system is designed as a ball that can be tossed into the room, around the corner or into a cave or other places to check if there is animate presence before entering. Optionally, preview security system includes ultrasonic transducers 110 and ultrasonic receivers 120 at various locations on the surface of the ball, so that preview security system 800 can monitor in substantially any direction. In an exemplary embodiment of the disclosure, the preview security system includes electronic circuit 105 for analyzing the measurements of the ultrasonic transducers 110 and ultrasonic receivers 120 . The results of the analysis are then transmitted wirelessly via communication unit 195 to a remote receiver 830 . Optionally, the communications may be transmitted using an RF signal or other types of wireless communications.
[0059] In an exemplary embodiment of the disclosure, preview security system 800 is powered on 865 by the user. Then it is tossed 870 into the room (e.g. through a window), into a cave, over a fence, around a wall or into any place that is of interest to check. Optionally, preview security system 800 starts monitoring 875 by measuring and analyzing the measurements to determine if there is animate presence 880 in the vicinity of the preview security system 800 . Optionally the preview security system 800 then transmits wirelessly to remote device 830 an indication if it detected the existence of animate presence 895 or the absence of animate presence 890 so that the user may respond accordingly.
[0060] It should further be appreciated that the above described methods and apparatus may be varied in many ways, including omitting or adding steps, changing the order of steps and the type of devices used. It should be appreciated that different features may be combined in different ways. In particular, not all the features shown above in a particular embodiment are necessary in every embodiment of the disclosure. Further combinations of the above features are also considered to be within the scope of some embodiments of the disclosure. It will also be appreciated by persons skilled in the art that the present disclosure is not limited to what has been particularly shown and described hereinabove.
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A system for monitoring animate presence, including one or more ultrasonic transducers configured to transmit an ultrasonic signal, one or more ultrasonic receivers configured to receive an echo signal in response to the transmitted ultrasonic signal, an electronic circuit for comparing the transmitted signal to the received echo signal and identify a phase shift between the signals; wherein the electronic circuit identifies animate presence based on the identified phase shift.
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This application is a continuation of application Ser. No. 08/574,569, filed Dec. 15, 1995 now abandoned, which is a continuation of application Ser. No. 08/425,668, filed Apr. 17, 1995 now abandoned, which is a continuation of application Ser. No. 08/054,173, filed Apr. 30, 1993, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a process for decoloring polyisocyanates containing isocyanurate and uretdione groups.
The isocyanate components employed in high-quality one- and two-component polyurethane paints having high light and weathering resistance are, in particular, polyisocyanate mixtures containing isocyanurate and uretdione groups.
These products are preferably prepared by catalytic oligomerization of aliphatic and/or cycloaliphatic diisocyanates, eg. 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethylcyclohexane (IPDI) or 1,6-diisocyanatohexane (HDI).
Examples of catalysts which can be employed are hydroxides or organic salts of weak acids with tetraalkylammonium groups, hydroxides or organic salts of weak acids with hydroxyalkylammonium groups, or alkali metal salts or tin, zinc or lead salts of alkylcarboxylic acids.
The aliphatic and/or cycloaliphatic diisocyanates are reacted in the presence of a catalyst, if desired with use of solvents and/or auxiliaries, until the desired conversion has been achieved. The reaction is then terminated by deactivating the catalyst, and the excess monomeric diisocyanate is removed by distillation. Depending on the catalyst type and reaction temperature used, polyisocyanates containing various proportions of isocyanurate and uretdione groups are obtained.
The products prepared in this way are mostly clear, but have a certain yellow coloration depending on the catalyst type, the diisocyanate quality, the reaction temperature and the reaction procedure.
However, products having a low color index are desired for the preparation of high-quality polyurethane paints. A number of processes are known from the prior art for reducing the color index of such products. Thus, DE-A-38 06 276 proposes reducing the carbon dioxide content of the HDI employed as monomer to less than 20 ppm before the oligomerization by degassing under reduced pressure and subsequently blowing nitrogen through the HDI, and employing quaternary ammonium hydroxides as the oligomerization catalyst. However, the carbon dioxide removal step is technically very complex.
EP-A-0 339 396 proposes using quaternary ammonium fluorides as the trimerization catalyst. Although this process tolerates a higher carbon dioxide content, the catalyst employed must, however, be chemically deactivated. The resultant compounds remain in the product and may result in applicational problems on further processing. A further way of preparing low-color-index polyisocyanates containing isocyanurate groups is the addition, proposed in EP-A-0 336 205, of polyester-diols to the starting diisocyanate. This allows the amount of catalyst employed to be reduced, but the resultant products are still relatively highly colored.
According to EP-A-0 377 177, aliphatic diisocyanates are oligomerized in the presence of phosphines as catalyst, and, after termination of the oligomerization, some of the unreacted diisocyanate is removed by distillation and some is converted into urethane by addition of alcohol. The reaction product is subsequently treated with peroxides. Although the peroxide treatment significantly reduces the color index of the oligomerization product, the use of peroxides is, however, associated with problems. Thus, peroxides are frequently difficult to handle industrially. Peroxides which are safer to handle are usually supplied in solution, but the dibutyl phthalate frequently used as solvent causes applicational problems in the preparation of paints.
It is an object of the present invention to provide a simple process for the effective decoloration of polyisocyanates containing isocyanurate and uretdione groups which avoids the disadvantages of the prior art.
We have found that, surprisingly, this object is achieved by treating the demonomerized polyisocyanates containing isocyanurate and uretdione groups with oxygen.
SUMMARY OF THE INVENTION
The present invention accordingly provides a process for decoloring polyisocyanates containing isocyanurate and uretdione groups which comprises treating the demonomerized polyisocyanates containing isocyanurate and uretdione groups with oxygen.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The polyisocyanates containing isocyanurate and uretdione groups are prepared by catalytic oligomerization, which is known per se, of aliphatic and/or cycloaliphatic diisocyanates.
The known aliphatic and/or cycloaliphatic diisocyanates can be employed; for processing as paint raw materials, IPDI and/or HDI, in particular, are used. The oligomerization is generally carried out at from 0 to 100° C. while passing an inert gas, preferably nitrogen, through the mixture. Catalyst which can be used are all catalysts which are known for the oligomerization of aliphatic and/or cycloaliphatic diisocyanates, for example those mentioned at the outset. In order to reduce the amount of catalyst, it is possible to add a small amount, up to about 1% by weight, based on the diisocyanate, of a diol, in particular a polyester-diol, to the diisocyanate before the oligomerization.
The diisocyanate is then warmed to the reaction temperature with stirring, and the catalyst is added slowly. For better handling, the catalyst can be dissolved in a solvent. Examples of suitable solvents are alcohols, in particular diols, ketones, ethers and esters.
When the desired conversion has been reached, the reaction is terminated by deactivating the catalyst, for example by adding a catalyst poison or by thermal decomposition. The reaction mixture is subsequently freed from the excess monomeric diisocyanate, preferably by distillation, for example by means of a thin-film evaporator.
The reaction product obtained has a pronounced yellow coloration.
In order to reduce the color index, the polyisocyanates containing isocyanurate and uretdione groups are then treated with oxygen.
This is carried most simply by passing oxygen through the polyisocyanates containing isocyanurate and uretdione groups.
Either pure oxygen or air can be employed. In addition, the gas stream may contain up to 20% by volume, based on the oxygen, of ozone. It has also proven advantageous to irradiate the reaction products with UV light at the same time as the oxygen treatment.
The reaction temperature should be from 85 to 170° C., preferably from 90 to 115° C., if air is used, from 80 to 150° C., preferably from 90 to 110° C., if oxygen is used and from 5 to 170° C., preferably from 25 to 100° C., if ozone is admixed.
It is advantageous to work in the preferred moderate temperature range, since decoloration proceeds very slowly at lower temperatures and partial re-cleaving of the oligomers can occur at higher temperatures. The oxygen treatment according to the invention is carried out at atmospheric pressure or a slight superatmospheric pressure of up to about 200 kPa. The reaction times are generally, depending on the amount of oxygen fed in, from 0.5 to 6 hours in the case of treatment with air, from 0.3 to 3.0 hours in the case of treatment with oxygen and from 5 minutes to 30 minutes if ozone is added to the oxygen stream. The optimum reaction time can easily be determined by a few preliminary experiments.
It was surprising that decoloration of the polyisocyanates containing isocyanurate and uretdione groups was possible by this very simple method. A person skilled in the art would have expected that oxygen treatment at the temperatures used would result in a deepening in the color, especially as it is known, for example from JP-A-157 657, that the presence of oxygen during the oligomerization of aliphatic diisocyanates gives strongly colored products.
The novel process makes it possible to decolor polyisocyanates containing isocyanurate and uretdione groups without the need to modify the oligomerization process. It is also possible to further decolor oligomerization products having low color indices.
EXAMPLES
Example 1
700 g of an HDI modified with isocyanurate groups and having an NCO content of 22.3%, a residual HDI content of 0.08% by weight and a color index of 63 Hazen, measured in accordance with DIN/ISO 6271, were introduced into a reactor fitted with stirrer and gas-inlet tube, and were warmed to 160° C. Air was passed through the HDI for 50 minutes at this temperature at a rate of 5.0 l/h. The reaction mixture was then cooled to room temperature.
After the treatment, the oligomerized HDI had an NCO content of 22.2%, a residual HDI content of 0.68% by weight and a color index of 5 Hazen, measured in accordance with DIN/ISO 6271.
Example 2
700 g of an HDI modified with isocyanurate groups and having an NCO content of 22.3%, a residual HDI content of 3.0% by weight and a color index of 100 Hazen, measured in accordance with DIN/ISO 6271, were introduced into a reactor as described in Example 1 and warmed to from 158 to 162° C. Air was then passed through the HDI for 40 minutes at a rate of 5.0 l/h. After cooling, the color index was 35 Hazen, measured in accordance with DIN/ISO 6271.
Example 3
700 g of an HDI modified with isocyanurate groups and having an NCO content of 22.3%, a residual HDI content of 2.8% by weight and a color index of 35 Hazen, measured in accordance with DIN/ISO 6271, were introduced into a reactor as described in Example 1 and warmed to 131° C. Air was then passed through the HDI for 40 minutes at a rate of 30 l/h. After cooling, the color index was 15 Hazen, measured in accordance with DIN/ISO 6271.
Example 4
50 g of an HDI modified with isocyanurate groups were introduced into a reactor as described in Example 1 and warmed to 120° C. Air was passed through the HDI for 25 minutes at this temperature at a rate of 3.0 l/h. The color index dropped from 14 to 2 Hazen, measured in accordance with DIN/ISO 6271.
Example 5
The procedure was similar to that of Example 4, but the reaction temperature was kept at 100° C. The color index of the HDI dropped from 16 to 11 Hazen, measured in accordance with DIN/ISO 6271.
Example 6
The procedure was similar to that of Example 4, but the reaction temperature was 90° C. and the reaction time was 95 minutes. The color index of the HDI dropped from 31 to 17 Hazen, measured in accordance with DIN/ISO 6271.
Example 7
20 m 3 /h of air were passed into a continuous stirred reactor charged with 400 kg/h of an HDI modified with isocyanurate groups and having a residual HDI content of 4% and a color index of 80 Hazen, measured in accordance with DIN/ISO 6271, in such a manner that the liquid was flushed-through vigorously. The mean residence time of the HDI was 2.8 hours, and the reaction temperature was 120° C. The color index of the product leaving the reactor was 30 Hazen, measured in accordance with DIN/ISO 6271.
Example 8
The procedure was similar to that of Example 7, but the mean residence time was 2.5 hours and the reaction temperature was 110° C. The color index of the HDI dropped from 60 to 25 Hazen, measured in accordance with DIN/ISO 6271.
Example 9
The procedure was similar to that of Example 7, but the residual HDI content of the HDI modified with isocyanurate groups was 2.0% by weight. The color index dropped from 80 to 40 Hazen, measured in accordance with DIN/ISO 6271.
Example 10
20 m 3 /h of air were passed into a continuous stirred reactor charged with 360 kg/h of an HDI modified with isocyanurate groups and having an NCO content of 22.2%, a residual HDI content of 0.08% by weight and a color index of 60 Hazen, measured in accordance with DIN/ISO 6271, in such a manner that the liquid was flushed-through vigorously. The mean residence time of the HDI was 5.8 hours, and the reaction temperature was 95° C. The color index of the product leaving the reactor was 15 Hazen, measured in accordance with DIN/ISO 6271.
Example 11
The procedure was similar to that of Example 10, but with a product feed of 370 kg/h, a mean residence time of 5.6 hours and a reaction temperature of 90° C. The color index of the HDI dropped from 60 to 25 Hazen, measured in accordance with DIN/ISO 6271.
Example 12
330 g of an HDI modified with isocyanurate groups and having an NCO content of 22.4%, a residual HDI content of 0.08% by weight and a color index of 35 Hazen, measured in accordance with DIN/ISO 6271, were introduced into a 500 ml reactor fitted with gas-dispersion stirrer having a maximum speed of 2,000 rpm, and were warmed to 90° C. An ozone/oxygen mixture containing 250 g of ozone per m 3 of oxygen was passed in via the stirrer for 7 minutes at this temperature at a rate of 50 l/h. The color index of HDI after the treatment was less than 5 Hazen, measured in accordance with DIN/ISO 6271; the other product parameters remained unchanged.
Example 13
The procedure was similar to that of Example 12, but the HDI modified with isocyanurate groups had an NCO content of 22.3%, a residual HDI content of 3.0% by weight and a color index of 40 Hazen, measured in accordance with DIN/ISO 6271, and the reaction time was 10 minutes. The color index of the HDI after the treatment was 5 Hazen, measured in accordance with DIN/ISO 6271; the other product parameters remained unchanged.
Example 14
3.1 kg of HDI modified with isocyanurate groups and to which 0.03% by weight of benzoyl chloride had been added were warmed to 70° C. in a 3.4 l reactor fitted with the gas-dispersion stirrer described in Example 12. An ozone/oxygen mixture containing 240 g of ozone per m 3 of oxygen was passed in via the stirrer for 15 minutes at this temperature at a rate of 50 l/h. The color index of the HDI dropped from 40 to 6 Hazen, measured in accordance with DIN/ISO 6271.
Example 15
The procedure was similar to that of Example 12, but the reaction temperature was 90° C., the ozone concentration was 44 g per m 3 of oxygen and the reaction time was 10 minutes. The color index of the HDI dropped from 50 to 6 Hazen, measured in accordance with DIN/ISO 6271.
Example 16
800 g of an HDI modified with isocyanurate groups and having an NCO content of 22.4%, a residual monomer content of 0.10% by weight and a color index of 128 Hazen, measured in accordance with DIN/ISO 6271, were introduced into a reactor fitted with gas-inlet tube and stirrer, and warmed to 90° C. 13 l/h of oxygen having a purity of 99.9% were bubbled through the gas-inlet tube into the liquid at this temperature. The color index of the HDI was 86 Hazen after a reaction time of 30 minutes, 62 Hazen after 60 minutes and 37 Hazen after 210 minutes. The other product parameters remained unchanged.
Example 17
The procedure was similar to that of Example 16, but the HDI modified with isocyanurate groups had a color index of 94 Hazen, measured in accordance with DIN/ISO 6271, and the reaction temperature was 105° C. The color index of the HDI was 41 Hazen after 30 minutes, 29 Hazen after 60 minutes, 21 Hazen after 90 minutes and 8 Hazen after 120 minutes, measured in accordance with DIN/ISO 6271.
Example 18
30 g of an HDI modified with isocyanurate groups and having an NCO content of 23.3%, a residual monomer content of 3.2% by weight and a color index of 51 Hazen were warmed to 161° C. in the presence of air. Table 1 shows the dependence of the color index on the reaction time.
______________________________________Time (min) 0 10 15 20 30 50 70Color index (Hazen) 51 20 11 7 14 34 51______________________________________
The HDI had the following product parameters after completion of the experiment: NCO content 22.4%, residual monomer content 3.1% by weight.
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A process for decoloring polyisocyanates containing isocyanurate and uretdione groups comprises treating the demonomerized polyisocyanates containing isocyanurate and uretdione groups with oxygen.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is continuation of copending International Application No. PCT/FR06/002698 filed Dec. 11, 2006, which designated the United States, and which claims priority to French Patent Application No. FR 05/12953, filed Dec. 20, 2005, the disclosures of each of which is expressly incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a rigid coupling for pipes carrying pressurized fluid, allowing these pipes to be connected while pressurized fluid remains in one of them.
This coupling comprises, in a way known per se, a male element and a female element of which the ends that are to be connected are closed by valves. The male element, connected to a tool actuated by the fluid, contains pressurized fluid, while the female element connected to the fluid source is not under pressure.
Patent EP 0 847 511, in the name of the applicant, describes a coupling such as this in which the female element has a fixed external sleeve with an end for connection to a pipe supplying hydraulic fluid, and a slideable internal body containing the valve of the female element, a return spring being interposed between the external sleeve and the mobile internal body.
Each valve comprises a valve shutter that presses against the valve shutter of the other valve upon connection, a return spring pressing this shutter against a seat and a limit stop limiting the opening travel of the shutter.
The limit stop of the male element containing pressurized fluid is fixed, while the limit stop of the female element is slideably mounted in the female element so that it can occupy a forward fixed position in which the shutter is pressed against the limit stop when the male and female elements are connected, and so as to be able to retreat into the female element so as to allow the shutter associated therewith to retreat further than the aforementioned opening travel, the distance retreated corresponding substantially to the opening travel of the shutter of the male element.
The coupling also comprises means of locking and of returning the sliding limit stop into/in the forward position, these means allowing the retreating movement of the sliding limit stop upon connection of the male and female elements, and locking the sliding limit stop in the forward position once this connection has been made.
In a coupling such as this it is necessary to allow the mobile internal body to move in and out with respect to the fixed external sleeve. For this reason, it is common practice for the internal body that can move inside the fixed external sleeve to be “hydraulically balanced”, that is to say to use relationships between pressures and surface areas such that the sum of the forces generated by the pressure effects cancel each other out.
The return spring acting on the mobile internal body is capable of compensating for the small potential difference in forces that may be due to manufacturing tolerances manifested in the form of different diameters and different levels of friction.
Here, the technique used is the one known as “differential balancing”.
The central fluid stream is continuous. Three sealing members are used, two of identical diameter D 1 and a third of a higher diameter D 2 such that D 2 /D 1 =√2. This relationship allows the sealing cross section of small diameter D 1 to be the same as the cross section of the annulus formed between the small diameter D 1 and the large diameter D 2 .
The supply of pressurized fluid to the annulus between the large and small diameters is achieved via a through-hole passing through the mobile internal body.
The forces exerted on the two small-diameter sealing members and on the annulus between the large and small diameter are of the same magnitude but of opposite directions, thus balancing the position of the mobile internal body in the fixed external sleeve at a location predefined by the limit stops of the return spring that returns the internal body.
This technique is economically attractive as to the production of the mechanical parts and displays good hydrodynamic characteristics, but the mechanical relationship between the mobile internal body which notably bears the female shutter and the fixed external sleeve is complicated to achieve.
To achieve this mechanical relationship, the means for locking and for returning the sliding limit stop in/into the forward position usually comprise mobile sleeve tubes internal and external to the mobile internal body of the female element, and connected to one another via balls or pegs passing through the mobile internal body.
These elements both balance (in the hydraulic sense) the positions of the shutters of the male and female elements in a position such that the circuit is open to the hydraulic fluid, and allow the shutter to effect an overtravel inside the female element in order mechanically to lock the male and female elements in spite of the approximately 3 to 4 mm protrusion of the shutter of the male element, which protrusion is due to the pressurized fluid contained therein.
Because the male and female elements are mechanically connected and locked, the opening of the hydraulic circuit, and therefore the balancing of the shutters of the male and female elements, is done by subjecting the female element to the hydraulic line pressure until such point as the pressure therein is enough to counter the pressure in the male element and open the valve thereof.
This arrangement calls for a great many components and thus entails a great deal of accuracy in producing and assembling these components, to the detriment of the overall cost of the product.
SUMMARY OF THE INVENTION
The present invention aims to avoid these disadvantages by providing a rigid coupling for pipes carrying pressurized fluid, comprising a lower number of components, particularly for selectively locking and returning the sliding limit stop in/into the forward position.
To this end, the subject of the present invention is a rigid coupling for pipes carrying pressurized fluid, as described in the preamble, and in which the shutter of the female element is extended at the rear by a retractable limit stop member of substantially tubular overall shape made of an elastically deformable material having at least one outward radial projection forming a limit stop against a corresponding inward radial projection of the internal body, and an open end facing the mouth of the cylindrical cavity in the connection end, the simultaneous retreat of the internal body inside the external sleeve and of the shutter inside the internal body having the effect of narrowing this open end by forcibly inserting it into said cylindrical cavity at the connection end, so as to retract said limit stop.
Thus, the inventive idea is to combine the shutter of the female element with a single member bearing the limit stop for the shutter and capable of deforming elastically upon connection of the male and female elements so as to retract the limit stop and allow the shutter its overtravel. This elastic member prevents the possibility of the shutter of the female element being driven into the female element under the effect of an axial load due to the hydrodynamic forces of the “male-to-female” flow and accidentally shutting off the circuit. This coupling is inexpensive to produce because it comprises just one elastic limit stop member.
Advantageously, the mouth of the cylindrical cavity at the connection end is chamfered in such a way as to form an annular ramp, and the open end of the retractable limit stop member is of frustoconical shape so that it can slide against this annular ramp, become narrowed, and enter the cavity.
In an illustrative embodiment, the retractable limit stop member has at least two longitudinal slots creating longitudinal legs which are kept in the normal position by the elasticity of the limit stop member.
The retractable limit stop member for example comprises an anterior part for attachment to the shutter and a rod-shaped main body provided with at least two guide fins projecting radially outward, which do not disrupt the flow of fluid and position and guide the sliding of the limit stop member inside the internal body.
These and other advantages will be readily apparent to those skilled in the art based upon the disclosure contained herein.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings wherein:
FIG. 1 is a view in longitudinal section of the female element of coupling according to the invention;
FIG. 2 is a perspective view of one component of the female element of said coupling;
FIGS. 3-6 are views in longitudinal section, in three successive positions in the connecting with the male and female elements of the coupling; and
FIG. 7 is a view similar to FIG. 3 when the male element does not contain any pressurized fluid.
The drawings will be described further in connection with the following Detailed description of the Invention.
DETAILED DESCRIPTION OF THE INVENTION
The coupling according to the invention depicted in the figures comprises a male element 2 and a female element 3 of which the ends that are to be connected are closed by valves.
In FIG. 1 , the female element 3 comprises three assembled parts 25 , 26 and 27 which form a fixed external sleeve 28 and a so-called “adapter” end 29 for connecting to the pipe, and two assembled parts 20 and 21 forming an internal body 22 containing the valve of the female element 3 .
The internal body 22 is able to slide with respect to the external sleeve 28 , a spring 30 being interposed between the same. The spring 30 normally keeps the internal body 22 and the external sleeve 28 in the relative position shown in FIG. 1 .
The valve of the female element 3 comprises a seat formed by an annular projection 31 , a valve shutter 45 extended forward by a cylindrical pin 46 .
The shutter 45 is extended at the rear via a retractable limit stop member 32 of substantially tubular overall shape made of a highly technical thermoplastic, with a diameter corresponding, give or take the required clearance, to the internal diameter of the part 21 of the internal body 22 , so as to slide in the body 22 .
As indicated more specifically in FIG. 2 , the retractable limit stop member 32 comprises an anterior part for attachment to the shutter 45 and a rod-shaped main body provided with four guide fins 47 projecting radially outward. These fins 47 also position and guide the member 32 in the internal body 22 and do not disrupt the flow of fluid and can also leave a sufficiently large fluid passage cross section so that the assembly enjoys good hydrodynamic performance, that is to say presents a projected surface of approximately 100 mm 2 .
The rear part of the retractable limit stop member 32 is open facing the mouth of the cylindrical cavity in the connection end 29 , and has two longitudinal slots creating opposing and diametrically opposed longitudinal legs 33 which are kept in their normal position by the elasticity of the member 32 .
The two legs 33 are elastically deformable inward in the radial direction so as to form a kind of tongs arrangement, and emerge from the internal body 22 near the end 29 for connection to the pipe.
The component 20 behind the component 21 has, in succession, from front to rear, a first internal diameter substantially corresponding to the internal diameter of the component 21 , then a second internal diameter smaller than the first, and finally a third internal diameter that is smaller still, substantially corresponding to the internal diameter of the end 29 for connection to the fluid supply pipe (not depicted).
The rear wall of the fins 47 of the member 32 presses against a spring 41 which presses against a shoulder which delimits said first and second internal diameters of the component 20 of the internal body 22 .
The legs 33 are surrounded by the turns of the spring 41 . For this, the two legs 33 are essentially inscribed inside a cylindrical volume of a diameter corresponding, give or take the clearance, to the third internal diameter of the component 20 that forms part of the internal body 22 .
However, the legs 33 each have an outward radial projection 34 the outside diameter of which corresponds, give or take the clearance, to the second internal diameter of the component 20 of the body 22 . The projection 34 forms a limit stop against an annular shoulder 40 which delimits said second and third internal diameters of the component 20 of the internal body 22 .
Furthermore, the ends of the legs 33 which emerge from the component 20 of the internal body 22 near the end 29 for connection to the pipe each also form an outward radial shoulder 35 inscribed inside a volume of frustoconical shape, of a shape that complements that of an annular ramp formed at the mouth of the adapter 29 and inclined toward the pipe.
The legs 33 can enter the adapter 29 by deforming radially inward under the pressure of said annular ramp at the mouth of the adapter 29 against the corresponding ramps formed by the shoulders 35 at the ends of the legs 33 .
Furthermore the component 21 of the internal body 22 comprises, at its cavity intended to accept the male element 2 , balls 51 engaged in radial bores formed through the wall of the component 21 of the body 22 . These balls 51 can move radially in these bores between an internal position depicted in FIGS. 1 , 4 and 5 , and an external position depicted in FIGS. 3 , 6 and 7 .
The external sleeve 28 for its part comprises, level with the balls 51 , an internal annular projection 55 with inclined lateral sides, delimiting two grooves 56 and 57 .
FIG. 3 illustrates the first step in connecting the coupling that forms the subject of the invention, when the male element 2 is engaged in the cavity of the female element 3 . In a way known per se, the valve of the male element comprises a seat 5 , a shutter 6 extended on the inside by a guide stem 7 , a return spring 8 pressing this shutter 6 against the seat 5 and a fixed limit stop 9 accepting the sliding stem 7 and against which the spring 8 presses. The limit stop 9 limits the opening travel of the shutter 6 .
On the outside, the shutter 6 comprises a cylindrical pin 15 which presses against the cylindrical pin 46 of the shutter 45 of the female element upon connection of the male and female elements.
Furthermore, the male element 2 comprises an external annular projection 16 with inclined lateral sides delimiting two grooves 17 and 18 .
The male element 2 , connected to the tool operated by the fluid, contains pressurized fluid while the female element 3 connected to the fluid source is not under pressure.
During engagement of the male element 2 , the projection 16 encounters the balls 51 which are held in their furthest-in position by the projection 55 situated facing them. At the same time, the pin 15 of the shutter 6 comes into contact with the corresponding pin 46 belonging to the shutter 45 .
Continued engagement of the male element 2 causes the internal body 22 to move, to the right in the figure, with respect to the external sleeve 28 .
This movement leads to compression of the springs 30 and 41 , and engagement of the legs 33 inside the adapter 29 via inward radial deformation (narrowing) under the effect of the annular ramp at the mouth of the adapter 29 pressing against the corresponding ramps formed by the shoulders 35 at the ends of the legs 33 .
This movement continues until the balls 51 lie facing the groove 57 and are pushed into this groove by the inclined lateral side of the projection 16 .
Here, retreat against the action of the spring 41 , and therefore radial deformation, of the legs 33 are significant enough that the projections 34 of the legs 33 engage “under” the annular shoulder 40 of the component 20 of the internal body 22 so that the limit stop that limits the travel of the shutter 45 is thus retracted.
With the male element 2 now completely engaged in the cavity of the female element 3 , the groove 17 faces the balls 51 , and these balls 51 are driven into this groove 17 , thus locking the male 2 and female 3 elements together.
When the axial force of engagement of the male element 2 in the female element 3 is released as depicted in FIG. 4 , the spring 30 is released and returns the internal body 22 and the external sleeve 28 to their original relative position, the ends of the legs 33 still being “narrowed” inside the adapter 29 .
When pressure is established in the female element 3 , the fluid moves the member 32 and the shutter 45 to the left in the figures as far as their position depicted in FIG. 5 .
By virtue of the spring 41 , the two valves are therefore opened, with the two shutters 6 and 45 immobilized, the shutter 6 being in abutment against the fixed limit stop 9 and the shutter 45 and its support member 32 pressing against the spring 41 .
The legs 33 are released from their position inside the adapter 29 and return to the un-narrowed “open” position through their natural elasticity. They therefore come into abutment via their projections 34 against the annular shoulder 40 (of the travel limit stop) of the component 20 of the body 22 so that the limit stop that limits the travel of the shutter 45 is re-established.
Disconnection (see FIG. 6 ) of the male 2 and female 3 elements is performed by pulling on the male element, this moving the internal body 22 to the left until the balls 51 enter the groove 56 . The valve of the female element 3 is then closed and sealed.
The flow of fluid through the member 32 is undisturbed and the guide fins 47 optimize this flow.
Furthermore, the shutter 45 forms an integral part of the member 32 and is perfectly guided in the body 22 , which gives the valve the ability to withstand high pressures.
The spring 9 is softer than the spring 41 which means that if there is no pressure in the male element 2 , the valve of the male element 2 opens (see FIG. 7 ) merely under the return force of the spring 41 which force, in accordance with standard ISO7241-A for ½″ pipe, is greater than 45 N.
The member 32 in this instance is made of a highly technical thermoplastic that could equally be made of brass, stainless steel or any other material capable of meeting the following specifications:
a longitudinal elastic modulus that is high in order to withstand the compression loadings resulting from the axial component of the hydrodynamic forces; a transverse elastic modulus that is high in order to develop sufficient force for returning the legs 33 of the member 32 to the open (un-narrowed) position thus butting against the shoulder 40 ; a coefficient of elongation A % that is high in order to tolerate significant deflection of the legs 33 without remnant deformation; the ability to uphold minimum characteristics at temperatures in excess of 110° C.
As goes without saying, the invention is not restricted to the single embodiment described hereinabove by way of indicative example; on the contrary, it encompasses all embodiment and application variants thereof that follow the same principle. Thus, in particular, it would not be a departure from the scope of
the invention if the shutter 45 or the member 32 were to be made of several assembled elements made of the same material or different materials.
It would also be possible to design a similar mechanism with a member again in the form of ridged tongs, but secured to the adapter 29 .
During the connection phase, upon the retreat movement, this member is made to close by the piston (component 20 ) thus retracting during the double travel retreat of the shutter 45 of the female element. In equilibrium, by virtue of its elasticity, the “tongs” re-open to the open position and provide the shutter 45 with a positive limit stop effect once the shutter has returned to the circuit-open position.
This alternative, which does not fall within the context of the present invention, is of some benefit in the selection of materials which can then be more conventional than in the present invention because the technical and dimensional characteristics can be divided across two components rather than exhibited by just one.
By contrast, the characteristics of this version are limited in terms of the maximum authorized return flow rate. This limit is directly linked with the spring force characteristics of the spring 30 that returns the mobile internal body 22 .
Specifically, all the shutters of the male 2 and female 3 elements are subjected to hydrodynamic forces, in a flow from the male element 2 toward the female element 3 , which will push on the “tongs” of the adapter 29 namely an element of the fixed external sleeve 28 . Further, the force reacting these hydrodynamic loadings is provided by the mechanism that locks the male element 2 which is secured to the mobile internal body 22 of the female element 3 and therefore has a tendency to leave the fixed external sleeve 28 . Only the spring 30 compensates for this phenomenon between the two fixed and mobile frames of reference and when the force due to the hydrodynamic forces becomes greater than the spring force of the spring 30 , the male element 2 becomes uncoupled unintentionally and causes the hydraulic circuit to be suddenly closed. The male element 2 has then to be recoupled in order to make the hydraulic system operational again.
The limits observed on a test rig demonstrate that accidental disconnection occurs at around about 1501/min for a spring 30 rated at 220 N and ½″ hydraulic coupling with relatively continuous passage cross sections of about 100 mm 2 .
As it is anticipated that certain changes may be made in the present invention without departing from the precepts herein involved, it is intended that all matter contained in the foregoing description shall be interpreted as illustrative and not in a limiting sense. All references including any priority documents cited herein are expressly incorporated by reference.
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The rigid coupling device includes a closure valve extended by a retractable sliding stop member of general tubular shape made from elastically deformable material, having at least one outward radial projection forming a stop against a corresponding inward radial projection of a movable interior body that contains the valve. The stop member has an open end opposite the opening of the cylindrical cavity of one end connecting to the conduit. Simultaneous withdrawal of the interior body and of the valve into the interior body has the effect of causing this open end to contract, forcibly inserting it into the cylindrical cavity of the connecting end in such a manner as to overcome the stop.
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TECHNICAL FIELD
The present invention is directed toward building components used for building construction and, more particularly, toward a construction for premanufactured, composite panels or other composite building components that exhibit improved strength, weight, and size characteristics.
BACKGROUND OF THE INVENTION
Recent changes in todays housing industry has led to an increased desire by builders for using pre-manufactured, or fabricated, construction components. As example, builders are now able to use pre-manufactured building panels, for walls, roofs, floors, doors and other building components which lend themselves to a composite structure. Such components are desirable since they decrease greatly the time and expense involved in constructing new building structures. However, the use of pre-manufactured building components requires these components to meet the structural specifications necessary for the resulting structure. The structural specifications are typically based on three structural criteria that are of primary interest, i.e., load bearing strength, shear strength, and total weight. Additional criteria that may effect the desired specifications are fire resistance, thermal efficiency, acoustical rating, rot and insect resistance, and water resistance. In addition, it is desirable for pre-manufactured components to be readily transportable, e.g., lightweight, easily packaged, and easily handled.
Pre-manufactured composite components for building construction have in the past had a variety of constructions. A common component is a laminated or composite, panel. One such panel includes a core material of foam, or other insulating material, that may in some embodiments have vertical members for adding structural support. The core material is positioned between wood members and the combination fixed together, e.g., nailed, screwed, and/or glued together. These panels suffer from the disadvantages of being combustible as well as inadequate sound barriers. Further, these panels are subject to rot, decay, and insect attack. Accordingly, panels constructed in this manner are not deemed satisfactory in many modern building applications.
In a variation of the above-described building panel, a laminated skin is fixed to the outside of the wood members. In addition to the inadequacies discussed above, these panels suffer from the added disadvantage of being more expensive.
In another known construction for building panels, a foam core is positioned between metal members. Decorative material is typically bonded to the outside of the metal members to provide these building panels. These panels are expensive and suffer from the disadvantage of being very sound transmissive. As a result of their sound transmission properties, an inside wall is generally required to provide an acoustical barrier, thereby further increasing the cost of using these panels. Such panels are not generally suitable for load-bearing applications.
Concrete panels have been used as a base for laminating composite layers. Building panels, however, constructed with prior art concrete compositions result in a rough, often wet, surface having a lamination bonding quality that is difficult and inconsistent. As a result, laminated skin surfaces, such as veneer, phenolic, vinyl, etc., cannot be sufficiently bound to the rough surface of concrete panels without considerable secondary preparation. It is desirable, however, to be able to firmly and cost effectively affix to the building panels, laminated skin surfaces such as those discussed above. Accordingly, in addition to the lack of flexibility, high weight, and lack of insulating properties, these prior art concrete panels are further disadvantageous because of the inability to consistently affix laminated skin surfaces to the rough and/or damp surface of the concrete.
Accordingly, it is desirable to provide building panels or other composite building components that are relatively lightweight and strong. It is further desirable to provide such a building component that is also a good heat and sound insulator. It is further desirable to provide such a building component that is also resistant to water, fire and rotting. It is also desirable to provide a building component having all of the foregoing properties, and which is easily handled and reasonably :priced. To accomplish these criteria across a wide range of applications, it is desirable for a manufacturer to be able to change weight versus size versus strength relationships readily. The above-cited popular constructions do not generally provide a natural method of changing size versus weight versus strength relationships over a wide dynamic range.
SUMMARY OF THE INVENTION
The present invention is directed toward a method for constructing building panels and other composite building .components including the step of applying an organic component to a side cover surface material and permitting the organic polymer to dry. A filler material is provided wherein the filler material includes a sufficient amount of a chemically active component to bond with the organic component on the surface of the side cover surface material. The side cover surface material is then positioned in contact with the filler material while the filler material is being poured/placed so that the organic polymer of the side cover surface material will bond with the chemically compatible components of the filler material in order that the side cover surface material will become a bound integral part of the building component.
A unique point of difference in this invention and common practice within the building component industry is: strength and weight adjustable cement compositions (not limited to Portland Cement based products) are poured into pre-constructed 2 to 6 sided box or half box forms in such a manner as to complete building component construction in one step, in that the form box or half form box is an integral part of the final product.
In one presently preferred embodiment of the invention, the filler material of building panels constructed in accordance with the method of the subject invention is a cement composition containing fluid pockets wherein each of the fluid pockets is of substantially similar size and wherein the fluid pockets are substantially evenly distributed throughout the cement base. The building panel may also include panel surface material having an organic component applied to a first side thereof wherein the first side of the panel surface material is substantially integrally formed with the cement composition by the bonding of organic components on the panel inside surface and organic compatible constituents in the cement composition.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial isometric view of a panel constructed in accordance with the subject invention;
FIG. 2 is a partial exploded view of the panel illustrated in FIG. 1; and
FIG. 3 is a partial isometric view of the panel illustrated in FIGS. 1 and 2.
The above figures, with dimensional changes, can represent configurations of other building components such as beams, braces, and doors. The word "panel" is used herein in the most general, all-inclusive sense.
DETAILED DESCRIPTION OF THE INVENTION
A building panel 100 constructed in accordance with the subject invention is illustrated in FIGS. 1, 2, and 3. The building panel 100 includes first and second skin surfaces 102 and 104 positioned on opposite sides of the panel 100. The skin surfaces 102 and 104 are separated by a top and bottom 112 and 114, respectively, and first and second joining sides 116 and 118. The first and second skin surfaces 102 and 104, the top and bottom 112 and 114, and the first and second joining sides 116 and 118, are fastened together to form a core chamber, as will be described in more detail below.
The first and second joining sides 116 and 118 each have a tongue and groove 120 formed therein. The tongue and groove 120 extends from the top 112 to the bottom 114. The first joining side 116 is positioned with its tongue extending toward the second joining side 118 and the second joining side is positioned with its tongue extending away from the first joining side 116 so that the tongue and groove of adjacent building panels will mate with one another. The tongue and grooves 120 are therefore used for connecting a plurality of building panels 100 to construct a structure as is known in the art.
It will be appreciated, however, by those skilled in the art that although the present invention is shown and described by reference to a tongue and groove 120, to be used for connecting adjacent building panels 100, other apparatus could be used for this purpose. One connecting structure that may be suitable for use with the subject invention is the connecting structure shown and described in U.S. Pat. Nos. 5,012,625 and 5,090,170, entitled "BUILDING ENCLOSURE SYSTEM AND METHOD" and "BUILDING ENCLOSURE SYSTEM", respectively, both issued to Robert L. Propst. Other arrangements for providing the connecting structure provided by the tongue and grooves 120 could be used, as will readily become apparent to those skilled in the art.
The building panel 100 also includes a handling system having first and second support rods 106 and 108 that extend from the top 112 to the bottom 114. The support members may be constructed of metal, plastic, or other material suitable for supporting the insulating core during preparation of the building panel. The first and second support rods each have an engagement system including a plurality of female/female connectors 126 fixed to first and second threaded ends 122 and 124 of the first and second support rods 106 and 108. As will be described below, the handling system, including the first and second support rods 106 and 108, is an integral part of the building panel 100. The handling system provides support to the building panel 100 when it is being constructed and, in combination with the engagement system, facilitates handling of the building panel 100 after it is constructed.
After the building panel 100 is constructed, one end of the female/female connectors 126 is exposed, as illustrated in FIG. 1. Any connector of proper size having male threads can be mated with the female/female connectors of the building panel 100 to enable handling of the building panel. As an example, during construction an eyelet 128 (FIG. 3) may be mated with the female/female connectors 126 to enable lifting and positioning of the building panel 100 with construction machinery. After positioning, a bolt 130 may be mated with the female/female connectors 126 to fix a roof structure or other structure to the building panel 100.
Although the engagement system of the building panel 100 is shown and described herein by reference to the female/female connectors 126, other apparatus can be combined with the support rods 106 and 108 to enable handling of the building panel 100. Further, although two support rods 106 and 108 are illustrated herein as extending from the top 112 to the bottom 114, those skilled in the art will appreciate that more or less support rods could be used in differing configurations and positions, as part of or independent of the handling system, without departing from the scope and spirit of the subject invention. Those skilled in the art will recognize that the number and position of the support rods can also be varied to vary the resulting strength and weight characteristics of the panel.
An insulating core 110 is positioned interior of the core chamber for providing insulation to the building panel 100. During construction, the insulating core 110 is mounted to the first and second support rods 106 and 108 and thereby positioned interior of the core chamber. In a presently preferred embodiment of the invention, the insulating core 110 is positioned substantially centered between the first and second skin surfaces 102 and 104, the top and bottom 112 and 114, and the first and second joining sides 116 and 118. However, in other applications it may be desirable to alter the positioning or construction of the support rods 106 and 108 to vary the positioning of the insulating core 110.
The insulating core 110 may be secured to the first and second support rods 106 and 108 by a variety of methods that will readily become apparent to those skilled in the art. As an example, the insulating core 110 may be fabricated on the first and second support members 106 and 108 and the combination positioned in the core chamber as described above. As another alternative, the first and second support members may be placed in the core chamber and the insulating core 110 later secured thereto by suitable means. As an alterative to securing the insulating core 110 to the first and second support rods 106 and 108, the first and second support rods can provide temporary support to the insulating core 110, without being secured thereto, as will be described below.
The insulating core 110 may be selected for providing any type of insulation to the building panel 100. As examples, the insulating core 110 may be selected to provide thermal, noise, or other insulation to the building panel 100. Preferably, a lightweight material is selected for the insulating core 110 so that the strength to weight ratio of the building panel 100 can be maximized. The insulating core 110 also includes a plurality of through connectors 132 that extend from the first side 102 to the second side 104 to provide shear connectors to the panel 100, as will be described in more detail below.
The top 112 includes a fill hole 134 through which a filler material. 136 (FIG. 1) is deposited. The filler material is poured into the core chamber through the fill hole 134. The filler material fills the through connectors 132 so that when the cement composition cures, shear connectors are provided in the through connectors 132.
The filler material 136 is selected from a material that can be introduced into the core chamber in relatively fluid form to take the form of the core chamber and to fill the through connectors 132. The filler material 136 is further selected to be a material that can be hardened, by curing or otherwise, to provide structural rigidity to the building panel 100. In a presently preferred embodiment of the invention, the filler material 136 is selected as a relatively lightweight material to improve the overall strength to weight ratio of the building panel 100.
As an example, in one presently preferred embodiment of the invention, the filler material 136 is an improved cement composition such as that disclosed and claimed in U.S. patent application Ser. No. 07/859,585 entitled "IMPROVED CEMENT COMPOSITION AND MATERIAL", filed Mar. 27, 1992, by Grant Record, the disclosure of which is incorporated herein, in its entirety, by the foregoing reference thereto. The cement composition is created from cellular cement and a sufficient amount of diatomaceous earth to substantially improve the insulating and fire-resistance properties of the composition while not detracting materially from its strength, and other proprietary materials used to strengthen the material. The cellular cement is created to include a plurality of fluid pockets 135 having substantially the same size and shape, wherein the fluid in the pockets is of a density less than that of the cement used in the composition. By adding the fluid pockets 135 to the composition, the overall density and weight of the composition is decreased and the insulating properties of the composition are enhanced.
It will be apparent, however, to those skilled in the art that other materials could be used for the filler material 136, without departing from the true scope and spirit of the subject invention. The primary consideration in selecting the appropriate filler material is the desired strength to weight ratio to be maintained, in combination with minimum strength and maximum weight specifications. Accordingly, the filler material will be selected to provide predetermined load bearing strength and weight characteristics. In applications where the load bearing strength can be less than that desired for load bearing panels, materials much lighter than those used for load bearing panels may be used for the filler material 136.
After the filler material 136 is introduced into the core chamber to take the form of the core chamber, and to fill the through connectors 132 the filler material is cured or dried, by the most appropriate method. The resulting panel will include a plurality of shear connectors that are formed by the fill material in the througholes 132. The effect of the shear connectors is to substantially increase the shear strength of the building panel 100. Accordingly, in addition to varying the load bearing strength and weight characteristics of the building panel by varying the composition of the filler material, as discussed above, the shear strength of the building panel can be increased and/or decreased by varying the number and positioning of shear connectors, i.e., varying the number and positioning of througholes in the insulating core 110. Therefore, the construction for the building panel 100 provides the user with the ability to select load bearing strength, shear strength, and weight, by varying the composition of the filler material and the construction, positioning, number, shape, etc., of the shear connectors. Still further, both the load bearing strength and the shear strength of the building panel 100 may be altered by varying the size and positioning of the insulating core 110 and resultant change in filler material 136 thickness. Still other variations will readily become apparent to those skilled in the art, e.g. using two insulating cores to construct an intermediate post; providing a channel diagonally across the insulating core to provide a cross bracing member, etc.
The resulting building panel may be constructed with compressive strengths in excess of about 40,000 pounds per square inch (per ASTM E-72 which calls for worst case eccentric loading) and weight of 2 to 10 pounds per square foot (based on 4'×8'×6" panel). Further, the building panel is fire and water proof and impervious to rot and insect damage. Still further, the building panel is a good thermal and acoustical insulator. A typical building panel, constructed with a thickness of 6 inches will exhibit an insulating value in excess of R30.
Structural panels made with the cement compositions described above are lightweight, so that it is easier to handle the structural panels, thereby decreasing the cost of the resulting structure. Construction of a composite building panel as described here is an example of an embodiment of the invention. The building panel is prepared by placing an amount of the above described cement composition in a mold or box form. An insulating material is then placed in the form and an additional amount of the above described cement composition is placed on top of the insulating material so that the insulating material is intermediate the cement composition. After curing, the resulting building panel is highly thermally insulating (30+"R"), strong, and lightweight. The building panel may be impregnated with a polymer to provide a smooth and bondable outer surface integral with the subsurface for binding laminate finishes.
In an alternative embodiment of the present invention, the inside of the first and second skin surfaces 102 and 104 are coated with an organic polymer that is dried prior to adding the filler material to the core chamber. The organic polymer is applied while the first and second skin surfaces 102 and 104 are positioned inside the core chamber, however, those skilled in the art will appreciate that the organic polymer may be added to the first and second skin surfaces 102 and 104 prior to positioning them in the core chamber. The organic polymer is typically selected to provide bonding strength between the first and second skin surfaces 102 and 104 and the filler material 136 when the filler material contains chemically active components that react with the organic coated surfaces of the first and second skin surfaces.
After the first and second skin surfaces are in position with the organic polymer dried to the surface thereof, the filler material is added to the core chamber and the building panel 100 is placed in a convenient location for the combination to cure. After curing, the first and second skin surfaces become an integral part of the building panel 100, eliminating the need for otherwise fixing a surface material to the panel as with prior art constructions.
In another alternative construction for the building panel, a box form is provided with an outside dimension corresponding to the width, height, and thickness of the desired building panel. The box form includes first and second generally planar sides that are spaced from one another by a distance corresponding to the desired thickness of the building panel. Support members, such as first and second support rods 106 and 108 (FIGS. 1 and 2), are positioned interior of the box form for supporting an insulating core during preparation. The support members are generally oriented horizontally and/or vertically and positioned centrally of the box form.
An insulating core is then positioned proximate the support members thereby to be supported in the box form generally centered between the first and second planar sides. A panel surface material, such as for example, a laminate or other known skin surface, is positioned inside the box form proximate the first and second planar sides. The panel surface material may comprise one or more sides of the resulting building panel. In a presently preferred embodiment of the invention, all six surfaces of the building panel are placed in the box form, e.g., first and second skin surfaces 102 and 104, top and bottom 112 and 114, and first and second joining sides 116 and 118, described by reference to FIGS. 1 and 2, may be placed in the box form. In another presently preferred embodiment of the invention, only two surfaces of the building panel, e.g., first and second skin surfaces 102 and 104, illustrated in FIGS. 1 and 2, are placed in the box form. It will be apparent to those skilled in the art that any number and selection of surfaces of the building panel may be placed in the box form in accordance with the subject invention.
In another alternate embodiment of the above-described building panel, a four to six sided box form made of magnesium oxide, or similar material, is filled with a filler material with or without cores inserted. This configuration can be used as a fire resistant door, a building panel, a beam component, etc. The chief feature of this embodiment is that both main side surfaces of the six sided box can be customized to replicate any desired surface during the box molding process. This material can look like a brick, natural rock, wood, or smooth surface and it is impervious to very high heat (in excess of 2,000° F.).
In a further alternate embodiment of the above described building panel, organic components are added to the cement composition in addition to, or in lieu of, being added to the panel surface material. In addition, the panels may be prepared per the above paragraphs except without the insulating core. Such solid panels will not decompose upon exposure to very high temperatures (1,800 degrees F., or greater) or upon cool down from such high temperature exposures.
From the foregoing, it will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims.
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A composite building component is formed of a cement composition having a sufficient amount of diatomaceous earth and/or other thermally insulating material(s), in specific ratio to entrained air contained in fluid pockets, to provide substantial thermal insulation and resistance to decomposition which would otherwise occur at very high temperatures. The cement composition is poured/placed in a 2 to 6 sided pre-formed box or half box with integral insulating core. The pre-formed box becomes bound to the poured/placed cement composition and upon curing, becomes an integral part of the final product. The cement composition may also include an amount of fibrous material and/or organic binder(s) (integrally and/or impregnated) sufficient to increase the tensile strength, handleability, and machineability of the building components. A cement composition is initially created to include a plurality of fluid pockets as the basis for achieving the features cited. The number and size of the fluid pockets is adjusted to provide different strength verses weight ratio products. The building components include a surface material that has an organic polymer applied to a first side thereof. The cement composition is provided with a sufficient amount of a chemically active component to bind with the organic polymer applied to the surface material so that the surface material is substantially integrally formed with the building component. The ratio of building component weight versus strength versus size can be readily adjusted by varying the internal core geometry and size, versus total end product size, versus density/strength of cement composition filler material.
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BACKGROUND OF THE INVENTION
1) Field of the Invention
The invention relates to a wafer-type tumbler cylinder, the cylinder shaft of which facilitates the placement of the wafers and springs and, furthermore, one spring is positioned in a relatively wider rectangular notch, thereby serving as a shared spring for every two wafers. The amount of spring is reduced by half and it's able to prevent from prying or unlocking. Moreover, it's more convenient for lock makers to make and assemble various cylinders in different shapes or different length.
2) Description of the Prior Art
Conventional wafer-type tumblers, as shown in FIG. 14 , are typically comprised of a sleeve 1 a , a cylinder 2 a , and a plurality of wafers 3 a and their springs 4 a . The sleeve 1 a consists of a sleeve body 10 having a bore 11 extending through it lengthwise, a minimum of one lengthwise slot 12 disposed along the inside of the bore 11 , and a bearing edge 13 at the leading end of the bore 11 . As shown in FIG. 15 , the cylinder 2 a has a keyway 21 through the center and, furthermore, a flange 22 and a drive section 23 at the front and rear ends, with a shaft 20 movably installed in the bore 11 of the sleeve 1 a ; the shaft 20 has disposed one or more diametrically oriented, rectangular through-holes 24 and, furthermore, at the two sides of each rectangular through-hole 24 is a C-shaped recess 25 and a horizontally oriented U-shaped recess 26 (as shown in FIGS. 16 and 17 ), for the installation of one or more wafer 3 a and spring 4 a sets. The cylinder 2 a , after the installation of the wafers 3 a and their springs 4 a , is first fitted into the bore 11 of the sleeve 1 a and, furthermore, such that the one end of each wafer 3 a is subjected to the elastic force of its spring 4 a , and then postured against and inserted into the slot 12 inside the bore 11 , thereby obstructing the clockwise and counter-clockwise rotation of the cylinder 2 a situated in the bore 11 ; at the same time, the flange 22 at the front end of the cylinder 2 a is seated on the bearing edge 13 at the leading end of the bore 11 in order to inset securely the bore 11 ; additionally, the drive section 23 at the rear end of the cylinder 2 a is mounted with a lock tool or electric driver so as to check whether the tumbler is locked or electrified.
Because each wafer 3 a of the conventional wafer-type tumbler, in addition to a window 31 in the middle thereof, has an opposing spring tab 32 and a locating tab 34 ; when the wafer 3 a is inserted into each rectangular through-hole 24 on the shaft 20 of the cylinder 2 a , it is first necessary to install a spring 4 a into the C-shaped recess 25 at one side of the rectangular through-hole 24 , following which the wafer 3 a is then inserted into the rectangular through-hole 24 ; but during the installation, since the wafer body 30 of the wafer 3 a has the spring tab 32 , its insertion occurs without any resistance along the C-shaped recess 25 ; however, the locating tab 34 , disposed in the other side of the wafer body 30 , must similarly undergo insertion through the C-shaped recess 25 along the rectangular through-hole 24 , and, as a result, friction occurs along the interior wall of the rectangular through-hole 24 at the lateral extent of the C-shaped recess 25 , and only after this does the wafer body 30 reach into the horizontally oriented U-shaped recess 26 , where it becomes nested onto the bottom of the horizontally oriented U-shaped recess 26 (as shown in FIGS. 16 and 17 ), and also only then is the cylinder 2 a installed in the bore 11 of the sleeve 1 a , which completes the assembly of one wafer-type tumbler mechanism. As such, during the insertion of each wafer 3 a into the rectangular through-hole 24 on the shaft 20 , the operation is difficult and adversely affects the production process. After each wafer 3 a has been inserted into the rectangular through-hole 24 , the locating tab 34 on the wafer body 30 is nested onto the bottom of the horizontally oriented U-shaped recesses 26 ; however, the height of the locating tab 34 is quite limited and, furthermore, the locating tab 34 is subjected to the outwardly exerted elastic force of the spring 4 a , the wafer 3 a is often ejected out of the rectangular through-hole 24 . Such situation results in a troublesome and inconvenient assembly operation as the cylinder 2 a is inserted into the bore 11 of the sleeve 1 a , which likewise adversely affects the production process.
Moreover, based on the locking and unlocking structure of the conventional wafer-type tumbler, it depends entirely on the installation of the shaft 20 on the cylinder 2 a with a plurality of wafers 3 a ; hence, as indicated in FIG. 15 , the rectangular keyway 21 must be disposed through the center of the shaft 20 to facilitate insertion of the serrated blade 51 on the key 5 a (as shown in FIG. 19 ), which causes each wafer 3 a extending into the end of the slot 12 in the bore 11 to fully react within the outer diameter of the shaft 20 , thereby achieving the objective of locking or unlocking. Since the cylinder 2 a of the conventional wafer-type tumbler is typically made of aluminum-zinc alloy material in an integrated molding process, and the keyway 21 disposed through the center of the shaft 20 also penetrates the internal section of the shaft 20 ; as a result, it is not possible to mold a corrugated keyway having a narrow width. It's only possible to mold a keyway with a width of 1.5 mm or more, and as indicated in FIG. 14 , the shape of the keyhole 211 only can be formed as reverse Z-shaped or other similar contour, which has a triangular projecting element 212 at the two lateral inner sides of the keyhole 211 respectively (one triangular projecting element is concealed by the flange 22 , so it's not viewable); the keyway 21 along the internal section of the shaft 20 not only is formed as relatively wide rectangular shape, but also has disposed at most one lengthwise triangular projecting element 212 at one side of the keyway 21 , as indicated in FIGS. 15 and 18 . As a result, the prior art is easily broken by thieves and pried or unlocked by burglars.
Due to the shape of the keyway 21 and its keyhole 211 on the shaft 20 of the cylinder 2 a in the conventional wafer-type tumbler, the design of which is formed as relatively wide rectangular and reverse Z-shaped contour, and furthermore, the two triangular projecting elements 212 are disposed in opposing position and at close distance along the two lateral inner sides of the keyhole 211 ; therefore, the serrated blade 51 of the key 5 a must be fabricated of a thicker metal plate. Even though the whole key 5 a may be formed by punching the metal plate, the serrated blade 51 (as indicated in FIGS. 19 and 20 ) must undergo milling or planing process to form as reverse Z-shaped section by means of a miller or planer, and it also has to undergo cutting or milling process to make a lengthwise V-shaped groove 511 at each of the lateral sides. Therefore, in terms of production, the process is extremely inconvenient and, furthermore, both time and labor consuming.
In view of the serrated blade 51 of the conventional wafer-type tumbler cylinder, there are such inconveniences and shortcomings during the process of production and assembly; such production cost is greater and not cost-effective and also the theftproof capability of the prior art still remained deficient, so the inventor of the invention herein conducted research which culminated in the improved wafer-type tumbler cylinder of the present invention.
SUMMARY OF THE INVENTION
The objective of the invention herein is to provide a wafer-type tumbler cylinder having a spring positioned in a relatively wider rectangular notch to serve as a shared spring for every two wafers. The amount of spring is reduced by half and the theftproof capability is much improved.
Another objective of the invention herein is to provide a wafer-type tumbler cylinder that is easily made and assembled into different shapes or different length of cylinder. It is cost-effective for lock makers to save the production cost of molds.
To achieve the first objective of the invention herein, the shaft of the cylinder consists of a first and a second semicircular columnar body that are insertionally conjoined into an integration, and furthermore, respectively disposed at the front and rear ends of the first semicircular columnar body are a flange and a drive section; although, on the inner lateral surfaces of the first and second semicircular columnar bodies, one or more rightward and leftward U-shaped slots are disposed; only disposed in every two rightward or leftward U-shaped slots is a relatively wider rectangular notch. As a wafer is installed in each of the two rightward (or leftward) U-shaped slots, a spring is positioned in the relatively wider rectangular notch to serve as a shared spring for every two wafers. The material cost of a spring is saved; besides, it's able to prevent from prying effectively because a burglar can not pry two wafers supported by a shared spring.
Another embodiment of shaft of the cylinder consists of a first and a second semicircular columnar bodies with identical shape and dimension, which are combined into an integration; furthermore, a semicircular tenon (or semi-rectangular or other shaped tenon) respectively disposed at the front and rear ends of each said semicircular columnar body enables, following the installation with a plurality of wafers and their springs, the respective fitting of a sleeve ring and a drive section onto the front and rear ends to thereby assemble one shaft. As such, it's convenient to produce and assemble different numbers of wafers into different length of shafts, and as different shapes of inner hole of the sleeve ring and the corresponding shape of cavity of the drive section are fitted thereon, it is quite convenient to manufacture longer or shorter shafts so as to assemble the wafer-type tumblers with different length or different shapes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded drawing of the wafer-type tumbler of the invention.
FIG. 2 is an exploded drawing of the wafer-type tumbler cylinder of the invention.
FIG. 3 is a cross-sectional view of the invention herein when the wafer-type tumbler is not installed with wafers and when the serrated blade of the key is inserted.
FIG. 4 is cross-sectional view of the invention herein when the wafer-type tumbler is interlocked.
FIG. 5 is a cross-sectional view as the wafer-type tumbler is installed with one wafer and its spring.
FIGS. 5-1 is a cross-sectional drawing, as viewed from a perspective in FIG. 5 , to show the adjacent wafer and its spring of the invention herein.
FIG. 6 is an orthographic drawing of the wafer-type tumbler key of the invention.
FIG. 7 is a cross-sectional drawing of the serrated blade of the wafer-type tumbler key.
FIG. 8 is an isometric drawing of the preferred embodiment of the cylinder in the present invention.
FIG. 9 is an exploded drawing of the preferred embodiment of the cylinder in the present invention.
FIG. 10 is a cross-sectional drawing of the invention herein, as viewed from the perspective of line 10 ˜ 10 ′ in FIG. 8 .
FIG. 11 is an exploded drawing of another preferred embodiment of the cylinder with wafers and a spring.
FIG. 12 is a vertically sectional view of the cylinder as viewed from the perspective in FIG. 11 .
FIG. 13 is a cross-sectional drawing of the invention herein, as viewed from the perspective of line 13 ˜ 13 ′ in FIG. 12 .
FIG. 14 is an exploded drawing of the conventional wafer-type tumbler.
FIG. 15 is a cross-sectional drawing of the conventional wafer-type tumbler when the wafers are not installed.
FIG. 16 is a cross-sectional drawing of the conventional wafer-type tumbler wherein a wafer and it spring are disposed.
FIG. 17 is a cross-sectional drawing, as viewed from a perspective in FIG. 16 , to show the adjacent wafer and its spring.
FIG. 18 is a cross-sectional view of the conventional wafer-type tumbler when the serrated blade of the key is inserted.
FIG. 19 is an orthographic drawing of the conventional wafer-type tumbler key.
FIG. 20 is a cross-sectional view of the serrated blade of the key in the conventional wafer-type tumbler.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 , the wafer-type tumbler of the invention herein, in common with the above-mentioned conventional wafer-type tumbler, is comprised of a sleeve 1 , a cylinder 2 , a plurality of wafers 3 and their springs 4 ; the structure of the sleeve 1 and the method for installing with the cylinder 2 are the same as those of said conventional wafer-type tumbler. There is no need to go into details. However, a shaft 20 of the cylinder 2 , as shown in FIG. 2 , consists of a first and a second semicircular columnar body 20 a and 20 b that are integrated with each other; furthermore, respectively disposed at the front and rear ends of the first semicircular columnar body 20 a are a flange 22 and a drive section 23 ; at the inner lateral surface between said flange 22 and drive section 23 is a transversely U-shaped indentation 201 , the length of which matches with the second semicircular columnar body 20 b so as to complete the assembly of the shaft 20 on the cylinder 2 (as indicated in FIG. 1 .) On the inner lateral surfaces of the first and the second semicircular columnar body 20 a and 20 b , one or more rightward U-shaped slots 24 a and leftward U-shaped slots 24 b are disposed for the installation of said wafers 3 ; however, only in each of the rightward U-shaped slots 24 a on said first semicircular columnar body 20 a is disposed a rectangular notch 27 matching the dimension of the spring 4 , thereby facilitating the placement of each wafer 3 and its spring 4 into each said U-shaped slot 24 a and said rectangular notch 27 on said first semicircular columnar body 20 a , following which the second semicircular columnar body 20 b is then fitted thereon for an integral unity; after that, the shaft 20 of said cylinder 2 is inserted into a shaft hole 11 in said sleeve 1 to assemble the wafer-type tumbler of the present invention, as illustrated in FIG. 5 as well as FIGS. 5-1 .
When said first and second semicircular columnar body 20 a and 20 b are molded into shape, two half-keyways 21 a and 21 b are formed as corrugated contour in the center of the inner lateral surfaces thereof, furthermore, one or more posts 28 (as shown in FIG. 2 ) and holes 29 (which are concealed by the second semicircular columnar body 20 b , so please refer to FIG. 4 ) are disposed at the front and rear ends of each said inner lateral surface. As such, the second semicircular columnar body 20 b , via the insertion of said posts 28 through said holes 29 , is correspondingly fixed with the first semicircular columnar body 20 a into a unity so as to complete the assemblage of the cylinder 2 , as indicated in FIGS. 1 , 3 and 4 ; at the same time, along the common center of the first and second semicircular columnar body 20 a and 20 b , a keyway 21 (as shown in FIG. 4 ) is formed as corrugated contour, with a narrower width of 0.5 mm, thereby preventing theft by means of a metal sheet or other equivalent tool inserted for burglarizing.
Since the keyway 21 disposed at the center of the cylinder 2 is approximately 0.5 mm in width and is fabricated as corrugated passage, a serrated blade 51 of a key 5 (as depicted in FIGS. 6 and 7 ) is produced by directly punching an approximately 0.5 mm or thinner metal plate, and a plastic grip 52 is coated onto the opposite end thereof, thereby facilitating the user holding the key for locking and unlocking the wafer-type tumbler; it is not necessary to mill and plane any lengthwise grooves nor other milling and planing processes. To facilitate the insertion of said very thin serrated blade 51 into the keyway 21 in the shaft 20 of the cylinder 2 , it is then necessary, in the center of the flange 22 at the front end of said shaft 20 , to dispose a rectangular, flared keyhole 211 that is in line with said keyway 21 . As for the drive section 23 at the rear end of said shaft 20 , in addition to the depiction shown in FIG. 1 and FIG. 2 wherein the drive section 23 is shaped as square or rectangular rod body 230 , said drive section 23 may be shaped as threaded, circular, oblate, tubular or other shaped rod body (not shown in the drawings) to make the design of said drive section 23 match with a lock tool or electric driver, thereby enabling said drive section 23 to fasten with said lock tool or electric driver by means of screws or rivets.
Furthermore, since the wafers 3 of the wafer-type tumbler of the invention herein do not require mounting in rectangular through-holes 24 (as depicted in FIG. 14 ), said wafers 3 can be fixed on said shaft 20 securely, as shown in FIG. 1 , by a window 31 formed in the center of each wafer body 30 along with a spring tab 32 at one side thereof, and there is no need to dispose any locating tab thereon.
Referring to FIGS. 8 and 9 , these two figures are isometric and exploded drawings of the preferred embodiment of a cylinder 2 ′ of the present invention. A shaft 20 on the cylinder 2 ′ consists of a first and a second semicircular columnar body 20 ′ a and 20 ′ b (both of identical shape and dimension) that are conjoined into an integral unity; furthermore, respectively disposed at the front and rear ends of each semicircular columnar body 20 ′ a and 20 ′ b is a semicircular tenon 202 and 203 which is respectively fitted onto a sleeve ring 22 a and a drive section 23 to constitute a cylinder 2 ′, as indicated in FIG. 8 . The said semicircular tenons 202 at the front ends of said semicircular columnar body 20 ′ a and 20 ′ b are correspondingly coupled to form a complete tenon, and the said semicircular tenons 203 at the rear ends thereof are correspondingly coupled to form a complete tenon. To enable the precise placement of the sleeve ring 22 a and the drive section 23 onto the front and rear ends of the integrated semicircular columnar bodies 20 ′ a and 20 ′ b , as well as to prevent dislodging and comparative rotation, the sleeve ring 22 a has an inner hole 221 in a ring body 220 a , which is a D-shaped hole with a minimum of one secant planar edge 222 along one lateral wall, and furthermore, an opening 223 through one side of the ring body 220 a , wherein the center of said opening 223 is aligned and parallel with said secant planar edge 222 ; a facet 204 is disposed correspondingly along the outer extent of the semicircular tenon 202 of either the first or the second semicircular columnar body 20 ′ a or 20 ′ b . As such, the complete tenon that is coupled by means of said semicircular tenons 202 at the front ends of said semicircular columnar body 20 ′ a and 20 ′ b is installed with the sleeve ring 22 a , and then a drill is used, through the opening 223 , to pierce into the front semicircular tenon 202 having said facet 204 thereof, thereby enabling the insertion of a pin 6 for securing and fixing, as depicted in FIG. 10 .
Additionally, the drive section 23 , along the inner end of its square or rectangular rod body 230 , has an extended sleeve 231 so as to enable the conjoinment with the complete tenon coupled by means of the semicircular tenons 203 at the rear ends of said semicircular columnar body 20 ′ a and 20 ′ b.
The extended sleeve 231 has disposed a D-shaped cavity 234 having a minimum of one secant planar edge 232 along the inner wall at one side thereof such that an aperture 233 is formed at one side of the extended sleeve 231 , of which the center is aligned and parallel with said secant planar edge 232 ; similarly a facet 204 is correspondingly disposed along the outer extent of the semicircular tenon 203 at the rear end of either the first or the second semicircular columnar body 20 ′ a or 20 ′ b . As such, the semicircular tenons 203 are assembled into a complete tenon, which is installed with said extended sleeve 231 , and in common with the depiction shown in FIG. 10 as well as previous arrangement, a pin 6 a illustrated in FIG. 9 is fixed with said extended sleeve.
As for the molding process of said first and second semicircular columnar bodies 20 ′ a and 20 ′ b with identical shape and dimension, the structural and installation arrangement of the corresponding half-keyways 21 a , 21 b and the rectangular notches 27 , the integration of more than one pair of posts 28 and holes 29 , as well as the arrangement of wafers 3 and their springs 4 , are the same with the first and second semicircular columnar body 20 a , 20 b of the cylinder 2 in the first embodiment of the invention herein; therefore, it shall not be further elaborated. Furthermore, the semicircular tenons 202 and 203 disposed on the two ends of the first and second semicircular columnar bodies 20 ′ a and 20 ′ b , in addition to the shape of semicircle, they may also be shaped as semi-square, semi-rectangular, semi-hexagonal or semi-polygonal tenons, or even as semi-oval or semi-oblate tenons; moreover, the shape of the inner hole 221 in the ring body 220 a of the sleeve ring 22 a accords with that of the D-shaped cavity 234 in the extended sleeve 231 on the drive section 23 ; at the same time, the shape of the rod body 230 on said drive section 23 may also be disposed as threaded, circular, oblate, tubular or other shaped rod body (not shown in the drawings.)
FIG. 11 is an exploded drawing of another preferred embodiment of the shaft 20 of the cylinder 2 ′ in the invention herein with wafers 3 and a spring 4 . Said shaft 20 also consists of a first and second semicircular columnar body 20 ′ a and 20 ′ b with identical shape and dimension, which are conjoined into an integral unity, and the preferred embodiment of the semicircular columnar bodies 20 ′ a and 20 ′ b , between every two rightward U-shaped slots 24 a or every two leftward U-shaped slots 24 b disposed in the inner lateral surfaces thereof, is modified by disposing a relatively wider rectangular notch 27 ′; meanwhile, each wafer 3 is modified by disposing a horizontal L-shaped tab 33 at one side of its wafer body 30 . As such, between every pair of (or every two) correspondingly rightward U-shaped slots 24 a or leftward U-shaped slots 24 b of each semicircular columnar body 20 ′ a and 20 ′ b is installed a wafer 3 respectively, and only one spring 4 is positioned in each relatively wider rectangular notch 27 ′, wherein said spring 4 is served as a shared spring for every two wafers 3 a and 3 b , as shown in FIGS. 12 and 13 . This embodiment of the shaft 20 of the cylinder 2 ′ can similarly be utilized in the preceding embodiment of the shaft 20 of the cylinder 2 .
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A wafer-type tumbler cylinder comprises a sleeve, a cylinder, some wafers and some springs. A shaft of the cylinder includes a first and a second semicircular columnar body. The first semicircular columnar body includes a front flange, a rear drive section and a U-shaped indentation at the inner lateral surface that provides for insertion into the second semicircular columnar body. On the first and second semicircular columnar bodies, one or more slots are disposed to fasten with the wafers. A relatively wider rectangular notch is disposed between the inner sides of every two slots, which are respectively installed with a wafer; only one spring is positioned in the wider rectangular notch, thereby serving as a shared spring for every two wafers. The material cost of a spring is saved; besides, it's able to prevent from prying effectively because a burglar cannot pry two wafers supported by a shared spring.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to high gas barrier packaging films exhibiting good shrinkage and containing an antifog composition for packaging foods and the like. The films are useful for producing modified atmosphere packages that preserve and enhance the shelf life of food and non-food oxygen sensitive items.
2. Description of the Related Art
Containers have long been used to store perishable foods, such as meats, fruits and vegetables, prior to sale in the marketplace to consumers. Maximizing the time in which the food remains preserved in the containers minimizes the amount of spoilage.
The environment around which the food is preserved is an important factor in the preservation process. It is important that the food is maintained at an adequate temperature, while also controlling the molecular and chemical content of the gases surrounding the food. By providing an appropriate gas content to the environment surrounding the food, the food can be better preserved when maintained at the proper temperature or even when it is exposed to variations in temperature. This gives the food producer some assurance that the food will be in an acceptable condition when it reaches the consumer.
Preferred modified atmosphere packaging systems for foods, including raw meats, exposes these foods to extremely low levels of oxygen because it is well known that the freshness of meat can be preserved longer under anaerobic conditions than under aerobic conditions. Maintaining low levels of oxygen minimizes the growth and multiplication of aerobic bacteria.
Many multilayered films for modified atmosphere packaging systems are known. In this regard, U.S. Pat. No. 5,919,547 shows a laminate which delaminates into a substantially gas-impermeable portion and a gas-permeable portion. U.S. Pat. No. 6,060,136 teaches a multilayer film having first and second outer layers and an inner layer. The first and second outer layers comprise a homogeneous ethylene/alpha-olefin copolymer and the inner layer comprises a thermoplastic elastomer. This film is not taught to be heat shrinkable. U.S. Pat. No. 5,766,772 describes multi-layer heat-shrinkable film endowed with anti-fog properties having a different structure from this invention.
It would be advantageous to provide a multilayered packaging film which is heat shrinkable, sealable to a food container and an effective gas barrier. It is also desirable that a film having these properties also have permanent anti-fog properties and are less expensive to manufacture than films of the prior art.
SUMMARY OF THE INVENTION
The invention provides a multilayered film which comprises a nylon film attached to a surface of a first polyethylene film via an intermediate adhesive layer, a surface of an ethylene vinyl alcohol film attached to another surface of the first polyethylene film, a surface of a second polyethylene film attached to another surface of the ethylene vinyl alcohol film, and an antifog composition on another surface of the second polyethylene film or incorporated into the second polyethylene film.
The invention also provides a process for producing a multilayered film which comprises coextruding an ethylene vinyl alcohol film to a surface of a first polyethylene film and coextruding a second polyethylene film to another surface of the ethylene vinyl alcohol film; either applying an antifog composition onto another surface of the second polyethylene film or incorporating an antifog composition into the second polyethylene film; and then either coextruding or laminating a nylon film onto another surface of the first polyethylene film via an intermediate adhesive layer.
The invention further provides a food package which comprises a container having an open portion and a multilayered film sealing the open portion; which multilayered film comprises a nylon film attached to a surface of a first polyethylene film via an intermediate adhesive layer, a surface of an ethylene vinyl alcohol film attached to another surface of the first polyethylene film, a surface of a second polyethylene film attached to another surface of the ethylene vinyl alcohol film, and an antifog composition on another surface of the second polyethylene film or incorporated into the second polyethylene film; the multilayered film being positioned such that the antifog composition is on the open portion.
The invention still further provides a multilayered film which comprises a nylon film attached to a surface of an oxygen barrier film, a polyethylene film attached to another surface of the oxygen barrier film via an adhesive layer, and an antifog composition on another surface of the polyethylene film or incorporated into the polyethylene film.
The present invention provides a multilayered packaging film which is heat shrinkable, sealable to a food container and an effective gas barrier. The film of this invention also has permanent anti-fog properties and is less expensive to manufacture than films of the prior art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the production of a multilayered film according to the invention, first an ethylene vinyl alcohol film is applied onto a surface of a first polyethylene film and a second polyethylene film is applied onto another surface of the ethylene vinyl alcohol film.
Ethylene vinyl alcohol compounds are well known in the art and readily commercially available. Copolymers of ethylene and vinyl alcohol suitable for use in the present invention can be prepared, for example, by the methods disclosed in U.S. Pat. Nos. 3,510,464; 3,560,461; 3,847,845; 3,595,740 and 3,585,177. The ethylene vinyl alcohol copolymer can be a hydrolyzed ethylene vinyl acetate copolymer. The degree of hydrolysis can range from about 85% to about 99.5%. The ethylene vinyl alcohol copolymer preferably contains from about 15 to about 65 mol percent ethylene and more preferably about 25 to about 50 mol percent ethylene. Copolymers of lower than 15 mol percent ethylene tend to be difficult to extrude while those above 65 mol percent ethylene have reduced oxygen barrier performance. The term “ethylene/vinyl alcohol copolymer” or “EVOH” is intended to comprise also the hydrolyzed or saponified ethylene/vinyl acetate copolymers and refers to a vinyl alcohol copolymer having an ethylene comonomer, which may be obtained, for example, by the hydrolysis of an ethylene/vinyl acetate copolymer or by chemical reaction of ethylene monomers with vinyl alcohol.
The first and second polyethylene films are preferably attached to the ethylene vinyl alcohol film by coextrusion, lamination, coating, sputtering or evaporation. Of these coextrusion is the most preferred. Non-limiting examples of suitable materials for the polyethylene films are low density polyethylene (LDPE), linear low density polyethylene (LLDPE), linear medium density polyethylene (LMDPE), linear very-low density polyethylene (VLDPE), linear ultra-low density polyethylene (ULDPE), high density polyethylene (HDPE). Of these, the most preferred is low density polyethylene.
An antifog composition is applied onto another surface of the second polyethylene film, preferably by coextrusion or by coating. In an alternate embodiment of the invention, an antifog composition is incorporated into the second polyethylene film rather than attaching a separate antifog layer. Non-limiting examples of antifog compositions are glycerol monoesters of a saturated or unsaturated fatty acid having from about 8 to about 20 carbon atoms, glycerol diesters of a saturated or unsaturated fatty acid having from about 8 to about 20 carbon atoms and ionic surfactants having phosphate, sulfate or quaternary amine functional end groups. Also suitable as antifog compositions are surfactants including anionic, cationic, nonionic and amphoteric surfactants. Suitable ionic surfactants have phosphate, sulfate or quaternary amine functional end groups. Other antifog compositions include sorbitan esters of aliphatic carboxylic acids, glycerol esters of aliphatic carboxylic acids, esters of other polyhydric alcohols with aliphatic carboxylic acids, polyoxyethylene compounds, such as the polyoxyethylene sorbitan esters of aliphatic carboxylic acids and polyoxyethylene ethers of higher aliphatic alcohols. Preferred antifog compositions are glycerol monooleate, glycerol monostearate and blends thereof. When the antifog composition is incorporated into the second polyethylene film, it is blended into the polyethylene film composition in an amount of from about 0.1 weight percent to about 5 weight percent. When the antifog composition is coated on the second polyethylene film it is preferably applied at a coating weight of from about 0.2 to about 0.6 g/m 2 . Suitable antifog compositions are described, for example, in U.S. Pat. No. 5,766,772.
A layer of a nylon film is attached to the second polyethylene film via an intermediate adhesive layer or tie layer. The adhesive layer may be applied either directly onto the nylon film or onto the first polyethylene layer by any appropriate means in the art, such as by coating. Any suitable adhesive may be employed. Such adhesives include polyurethanes, epoxies, polyesters, acrylics, anhydride modified polyolefin and blends thereof. Modified polyolefin compositions have at least one functional moiety selected from the group consisting of unsaturated polycarboxylic acids and anhydrides thereof. Such unsaturated carboxylic acid and anhydrides include maleic acid and anhydride, fumaric acid and anhydride, crotonic acid and anhydride, citraconic acid and anhydride, itaconic acid an anhydride and the like. The adhesive layer may also optionally comprise a colorant, an ultraviolet light absorber or both.
The nylon film is preferably attached to the first polyethylene film by lamination. Suitable nylons within the scope of the invention non-exclusively include homopolymers or copolymers selected from aliphatic polyamides and aliphatic/aromatic polyamides having a molecular weight of from about 10,000 to about 100,000. General procedures useful for the preparation of polyamides are well known to the art. Such include the reaction products of diacids with diamines. Useful diacids for making polyamides include dicarboxylic acids which are represented by the general formula
HOOC—Z—COOH
wherein Z is representative of a divalent aliphatic radical containing at least 2 carbon atoms, such as adipic acid, sebacic acid, octadecanedioic acid, pimelic acid, suberic acid, azelaic acid, dodecanedioic acid, and glutaric acid. The dicarboxylic acids may be aliphatic acids, or aromatic acids such as isophthalic acid and terephthalic acid. Suitable diamines for making polyamides include those having the formula
H 2 N(CH 2 ) n NH 2
wherein n has an integer value of 1-16, and includes such compounds as trimethylenediamine, tetramethylenediamine, pentamethylenediamine, hexamethylenediamine, octamethylenediamine, decamethylenediamine, dodecamethylenediamine, hexadecamethylenediamine, aromatic diamines such as p-phenylenediamine, 4,4′-diaminodiphenyl ether, 4,4′-diaminodiphenyl sulphone, 4,4′-diaminodiphenylmethane, alkylated diamines such as 2,2-dimethylpentamethylenediamine, 2,2,4-trimethylhexamethylenediamine, and 2,4,4-trimethylpentamethylenediamine, as well as cycloaliphatic diamines, such as diaminodicyclohexylmethane, and other compounds. Other useful diamines include heptamethylenediamine, nonamethylenediamine, and the like.
Useful polyamide homopolymers include poly(4-aminobutyric acid) (nylon 4), poly(6-aminohexanoic acid) (nylon 6, also known as poly(caprolactam)), poly(7-aminoheptanoic acid) (nylon 7), poly(8-aminooctanoic acid)(nylon 8), poly(9-aminononanoic acid) (nylon 9), poly(10-aminodecanoic acid) (nylon 10), poly(11-aminoundecanoic acid) (nylon 11), poly(12-aminododecanoic acid) (nylon 12), nylon 4,6, poly(hexamethylene adipamide) (nylon 6,6), poly(hexamethylene sebacamide) (nylon 6,10), poly(heptamethylene pimelamide) (nylon 7,7), poly(octamethylene suberamide) (nylon 8,8), poly(hexamethylene azelamide) (nylon 6,9), poly(nonamethylene azelamide) (nylon 9,9), poly(decamethylene azelamide) (nylon 10,9), poly(tetramethylenediamine-co-oxalic acid) (nylon 4,2), the polyamide of n-dodecanlanedioic acid and hexamethylenediamine (nylon 6,12), the polyamide of dodecamethylenediamine and n-dodecanedioic acid (nylon 12,12) and the like. Useful aliphatic polyamide copolymers include caprolactam/hexamethylene adipamide copolymer (nylon 6,6/6), hexamethylene adipamide/caprolactam copolymer (nylon 6/6,6), trimethylene adipamide/hexamethylene azelaiamide copolymer (nylon trimethyl 6,2/6,2), hexamethylene adipamide-hexamethylene-azelaiamide caprolactam copolymer (nylon 6,6/6,9/6) and the like. Also included are other nylons which are not particularly delineated here.
Of these polyamides, preferred polyamides include nylon 6, nylon 6,6, nylon 6/6,6 as well as mixtures of the same. Of these, nylon 6/6,6 is most preferred.
Aliphatic polyamides used in the practice of this invention may be obtained from commercial sources or prepared in accordance with known preparatory techniques. For example, poly(caprolactam) can be obtained from Honeywell International Inc., Morristown, N.J. under the trademark CAPRON®.
Exemplary of aliphatic/aromatic polyamides include poly(tetramethylenediamine-co-isophthalic acid) (nylon 4,I), polyhexamethylene isophthalamide (nylon 6,I), hexamethylene adipamide/hexamethylene-isophthalamide (nylon 6,6/6I), hexamethylene adipamide/hexamethyleneterephthalamide (nylon 6,6/6T), poly (2,2,2-trimethyl hexamethylene terephthalamide), poly(m-xylylene adipamide) (MXD6), poly(p-xylylene adipamide), poly(hexamethylene terephthalamide), poly(dodecamethylene terephthalamide), polyamide 6T/6I, polyamide 6/MXDT/I, polyamide MXDI, and the like. Blends of two or more aliphatic/aromatic polyamides can also be used. Aliphatic/aromatic polyamides can be prepared by known preparative techniques or can be obtained from commercial sources. Other suitable polyamides are described in U.S. Pat. Nos. 4,826,955 and 5,541,267, which are incorporated herein by reference.
Each of the first and second polyethylene films, nylon film, ethylene vinyl alcohol film, and adhesive layers may optionally also include one or more conventional additives whose uses are well known to those skilled in the art. The use of such additives may be desirable in enhancing the processing of the compositions as well as improving the products or articles formed therefrom. Examples of such include: oxidative and thermal stabilizers, lubricants, release agents, flame-retarding agents, oxidation inhibitors, oxidation scavengers, dyes, pigments and other coloring agents, ultraviolet light absorbers and stabilizers, organic or inorganic fillers including particulate and fibrous fillers, reinforcing agents, nucleators, plasticizers, as well as other conventional additives known to the art. Such may be used in amounts, for example, of up to about 10% by weight of the overall composition. Representative ultraviolet light stabilizers include various substituted resorcinols, salicylates, benzotriazole, benzophenones, and the like. Suitable lubricants and release agents include stearic acid, stearyl alcohol, and stearamides. Exemplary flame-retardants include organic halogenated compounds, including decabromodiphenyl ether and the like as well as inorganic compounds. Suitable coloring agents including dyes and pigments include cadmium sulfide, cadmium selenide, titanium dioxide, phthalocyanines, ultramarine blue, nigrosine, carbon black and the like. Representative oxidative and thermal stabilizers include the Period Table of Element's Group I metal halides, such as sodium halides, potassium halides, lithium halides; as well as cuprous halides; and further, chlorides, bromides, iodides. Also, hindered phenols, hydroquinones, aromatic amines as well as substituted members of those above mentioned groups and combinations thereof. Exemplary plasticizers include lactams such as caprolactam and lauryl lactam, sulfonamides such as o,p-toluenesulfonamide and N-ethyl, N-butyl benylnesulfonamide, and combinations of any of the above, as well as other plasticizers known to the art.
As mentioned above, the first and second polyethylene films are preferably attached to the ethylene vinyl alcohol film by coextrusion. For example, the polymeric material for the individual layers, are fed into infeed hoppers of a like number of extruders, each extruder handling the material for one or more of the layers. The melted and plasticated streams from the individual extruders are fed into a single manifold co-extrusion die. While in the die, the layers are juxtaposed and combined, then emerge from the die as a single multiple layer film of polymeric material. After exiting the die, the film is cast onto a first controlled temperature casting roll, passes around the first roll, and then onto a second controlled temperature roll, which is normally cooler than the first roll. The controlled temperature rolls largely control the rate of cooling of the film after it exits the die. Additional rolls may be employed. In another method, the film forming apparatus may be one which is referred to in the art as a blown film apparatus and includes a multi-manifold circular die head for bubble blown film through which the plasticized film composition is forced and formed into a film bubble which may ultimately be collapsed and formed into a film. Processes of coextrusion to form film and sheet laminates are generally known. Typical coextrusion techniques are described in U.S. Pat. Nos. 5,139,878 and 4,677,017.
Alternatively the individual layers may first be formed as separate layers and then laminated together under heat and pressure with or without intermediate adhesive layers. Lamination techniques are well known in the art. Typically, laminating is done by positioning the individual layers on one another under conditions of sufficient heat and pressure to cause the layers to combine into a unitary film. Typically the polyethylene films, the ethylene vinyl alcohol film, the adhesive and nylon layers are positioned on one another, and the combination is passed through the nip of a pair of heated laminating rollers by techniques well known in the art. Lamination heating may be done at temperatures ranging from about 120° C. to about 175° C., preferably from about 150° C. to about 175° C., at pressures ranging from about 5 psig (0.034 MPa) to about 100 psig (0.69 MPa), for from about 5 seconds to about 5 minutes, preferably from about 30 seconds to about 1 minute.
Preferably the nylon film is oriented prior to being attached to the first polyethylene film. For the purposes of the present invention the term draw ratio is an indication of the increase in the dimension in the direction of draw. Preferably, in the present invention the film nylon film is drawn to a draw ratio of from 1.5:1 to 5:1 uniaxially in at least one direction, i.e. its longitudinal direction, its transverse direction or biaxially in each of its longitudinal and transverse directions. Preferably, the film is simultaneously biaxially oriented, for example orienting a plasticized film in both the machine and transverse directions at the same. This results in dramatic improvements in clarity strength and toughness properties. Preferably, the nylon film is biaxially oriented and is not heat set so that it is shrinkable both in its transverse and longitudinal directions.
Although each layer of the multilayer film structure may have a different thickness, the thickness of the nylon layer is from about 1 μm to about 25 μm, preferably from about 3 μm to about 8 μm, and more preferably from about 4 μm to about 6 μm. The thickness of the ethylene vinyl alcohol layer is from about 1 μm to about 25 μm, preferably from about 2 μm to about 8 μm and more preferably from about 3 μm to about 5 μm. The thickness of each of the first and second polyethylene films is from about 1 μm to about 50 μm, preferably from about 10 μm to about 30 μm, and more preferably from about 12 μm to about 25 μm. Further, if a separate antifog layer is included, the thickness of that antifog layer is from about 1 μm to about 25 μm, preferably from about 2 μm to about 8 μm and more preferably from about 3 μm to about 5 μm. While such thicknesses are preferred, it is to be understood that other film thicknesses may be produced to satisfy a particular need and yet fall within the scope of the present invention.
The oxygen transmission rate (OTR) of the multilayered film of the invention may be determined via the procedure of ASTM D-3985. In the preferred embodiment, the multilayered film according to this invention has an OTR of about 0.1 cc/100 in 2 /day or less, preferably from about 0.085 cc/100 in 2 /day or less and more preferably from about 0.07 cc/100 in 2 /day or less at 65% relative humidity at 20° C.
The multilayered film of the invention is preferably heat shrinkable, generally by an amount of from about 2% to about 30%, more preferably from about 10% to about 20% in its length, or its width or each of its length and width. To provide a tightly adhering lid for a tray, for example, the film only need to exhibit shrinkage on the order of about 2 to about 3%. However, in order to have the film also form (unrestrained) about the side of the tray, higher shrinkage in the film is desirable. The multilayered film may further have printed indicia between the first polyethylene film and its attached nylon film. Since such printing is on an internal surface of the structure, it will not rub off when the surface is contacted. Optionally, the multilayered film may be uniaxially or biaxially oriented in a manner and in an amount indicated above for the nylon film and is not heat set so that it is shrinkable both in its transverse and longitudinal directions. In this case the nylon film may or may not have been oriented already.
The film preferably has a puncture resistance of at least about 1600 grams as measured by ASTM F 1306. Preferably the film has a haze of about 5% or less as measured by ASTM D1003.
The multilayered film is useful for forming a food package including a container, such as a tray, having an open portion and the multilayered film sealing the open portion. Such a structure is generally referred to a lidding film. The multilayered film is positioned such that the antifog composition is adjacent to the open portion, that is, facing the inside of the container. Such containers are suitable for packaging a variety of raw meats such as beef, pork, poultry, and veal, among others. A packaged food may comprises the food package and a food product such as a meat in the food package.
The container may have enclosed side walls, a floor and an top opening defining a central cavity wherein the open top optionally has a substantially flat peripheral rim. The multilayered film surrounds the container and is heat shrunk and heat sealed to it via the second polyethylene film such that the antifog composition is on the open portion (facing inward). The container may comprise a material such as cardboard, paperboard, boardstock, a plastic and combinations thereof. Preferred plastics include any one of several thermosetting or thermoplastic resins any of which are capable of sealing to the lidding material. Examples of materials include acrylonitrile, an acrylic polymer, polyethylene terephthalate (PET) or copolymers thereof, polyvinyl chloride, polycarbonate, polystyrene and polypropylene. In use the lidding film is positioned around the open portion and is caused to shrink, e.g. by the application of heat, a sufficient amount to seal the open portion of the container.
The invention further contemplates additional layers being attached to the multilayered film either before or after attaching the nylon layer, for example, first polyethylene/adhesive/EVOH/adhesive/second polyethylene; or first polyethylene/adhesive/oxygen barrier/adhesive/second polyethylene. Further, the nylon layer may be attached to the first polyethylene film by coextrusion, lamination, or coating by extrusion coating of the nylon with or without an intermediate adhesive. It is also within the scope of the invention that any shrinkable film may be substituted for the nylon layer. Suitable shrinkable films other than nylons include polyesters, oriented polyolefins, and combinations thereof. Additionally, other suitable oxygen barrier films or coatings other than ethylene vinyl alcohol include polyvinyl alcohol, polyvinylidene chloride and combinations thereof.
It is also within the contemplation of the invention that the multilayered film comprises a nylon film attached to a surface of an oxygen barrier film, a polyethylene film attached to another surface of the oxygen barrier film via an adhesive layer, and an antifog composition on another surface of the polyethylene film or incorporated into the polyethylene film. As mentioned above, the oxygen barrier film may comprise a coating of ethylene vinyl alcohol, polyvinylidene chloride or combinations thereof.
The following non-limiting examples serve to illustrate the invention.
EXAMPLE 1
A film having the structure Substrate A/Adhesive/Substrate B is produced wherein Substrate A is a 60 gauge (0.60 mil) shrinkable nylon 6/6,6 copolymer film having 20 to 25% shrinkage in both directions. The adhesive is a polyurethane based adhesive for indirect food contact coated at a weight of 1.0 to 1.5 lb/ream. Substrate B is a 5 layer coextrusion of Antifog PE/tie/EVOH/tie/PE, with EVOH at 25% of the total 1 mil film. The antifog additive is a glycerol monooleate (GMO). The antifog PE side of the coextrusion is the sealing side when the structure is heat sealed to a barrier tray. The total thickness of the film structure was 1.6-1.7 mils, and oxygen transmission rate was 0.008 cc O 2 /100 in 2 /day at 10° C., 80% RH.
EXAMPLE 2
A film having the structure Substrate A/Adhesive/Substrate B is produced wherein Substrate A and Adhesive are as Example 1. Substrate B is a coextrusion of 5 layers: Antifog PE/tie/EVOH/tie/Antifog PE with EVOH at 25% of the total 1 mil film. The antifog additive is a glycerol monooleate (GMO). The total thickness of the film structure was 1.6-1.7 mils, and oxygen transmission rate was 0.008 cc O 2 /100 in 2 /day at 10° C. , 80% RH.
EXAMPLE 3
A film having the structure Substrate A/Adhesive/Substrate B/Antifog Coating C is produced wherein Substrate A and Adhesive are as Example 1. Substrate B has 5 layers: PE/tie/EVOH/tie/PE without any compound loading of the antifog. The antifog coating is a glycerol monostearate (GMS) coated at a weight of 0.20-0.25 lb/ream. The total thickness of the film structure was 1.6-1.7 mils, and oxygen transmission rate was 0.008 cc O 2 /100 in 2 /day at 10° C., 80% RH. The light transmission was 93.2%, the haze level was 3.27 and the clarity was 95 .
EXAMPLE 4
A film having the structure Substrate A/EVOH coating/Adhesive/Substrate B is produced wherein Substrate A is as Example 1. An EVOH coating is applied on the Substrate A with a coating weight of 1 to 2 lb/ream to provide an oxygen barrier. The adhesive is polyurethane or epoxy to bond the EVOH coating to the second substrate. Substrate B is a 1 mil coextrusion of PE/tie/EVOH/tie/Antifog PE with the EVOH layer below 18% of the total thickness. The total thickness of the film structure was 1.6-1.7 mils.
EXAMPLE 5
Films from Example 2 were used as lidding film to seal polyethylene trays with a meat patty inside. The heat seal conditions were 250° F. (121° C.) seal temperature and 350° F. (177° C.) knife temperature. The seal was good and there was no significant water condensation on the antifog coating.
EXAMPLE 6
Example 5 was repeated using films from Example 4 with polystyrene trays having a polyethylene sealant web, as well as polypropylene trays. The heat seal conditions were 330° F. (166° C.) seal temperature and 350° F. (177° C.) knife temperature. The seal was good and there was no significant water condensation on the antifog coating.
EXAMPLE 7
Example 5 was repeated using films made from Example 3 with polystyrene trays having a polyethylene sealing web. The heat seal conditions were 275-300° F. (135-149° C.) seal and 300° F. (149° C.) knife. There was no significant water condensation on the antifog coating after 72 hours.
While the present invention has been particularly shown and described with reference to preferred embodiments, it will be readily appreciated by those of ordinary skill in the art that various changes and modifications may be made without departing from the spirit and scope of the invention. It is intended that the claims be interpreted to cover the disclosed embodiment, those alternatives which have been discussed above and all equivalents thereto.
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The invention relates to high gas barrier packaging films exhibiting good shrinkage and containing an antifog composition for modified atmosphere packaging of foods and the like. The films are useful for producing modified atmosphere packages that preserve and enhance the shelf life of food and non-food oxygen sensitive items. The films exhibit excellent shrinkage, permanent antifog, easy processing and low cost of manufacture.
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CROSS REFERENCE TO RELATED APPLICATIONS
This is a File Wrapper continuation of U.S. Ser. No. 08/185,338 filed on Jan. 24, 1994 and assigned to Motorola, Inc., now abandoned.
This application is related to U.S. application Ser. No. 08/100,812, filed Aug. 2, 1993, entitled "MULTIPLE VOLTAGE BATTERY CELL", by Francis P. Malaspina and Anaba Anani, and assigned to Motorola, Inc.
TECHNICAL FIELD
This invention relates in general to charging regimes for secondary battery cells, and particularly to charging regimes for cells capable of multiple voltage operation.
BACKGROUND
Conventional electrochemical cells are designed and manufactured to use ampere-hour electrode capacities within a specified extent of reaction. This restriction is necessary in order to hold the cell at a specified nominal voltage. Conversely, cell voltage may be regulated within a given range so as to maintain the needed extent of reaction. For example, nickel-cadmium (Ni-Cd), nickel-metal hydride (Ni-MH), nickel-hydrogen (Ni-H 2 ), and lead acid chemistries have average nominal cell voltages of 1.2V, 1.23V, 1.23V, and 2.1V, respectively.
Apparatus and methods for charging these types of batteries typically rely upon a single change in the slope of the battery voltage charging curve in order to determine when charging should be terminated. For example, U.S. Pat. No. 4,639,655 to Westhaver, et. al., for "METHOD AND APPARATUS FOR BATTERY CHARGING" discusses a charging regime which looks for a "knee region" in the battery charging curve to determine the stop point in the charging regime. The "knee region" is that part of the charging curve where the slope of the curve (i.e., the rate of change of cell voltage versus time) either begins to decrease, or in fact becomes negative.
Similarly, U.S. Pat. No. 4,388,582 to Saar, et. al. for "APPARATUS AND METHOD FOR CHARGING BATTERIES" discusses monitoring a battery characteristic, such as battery voltage, to identify "inflection points" in the charging curve. These inflections points are related to changes in the slope of the charging curve, and indicate at what stage, and when the charge should be terminated. The charge is typically terminated when the slope of the curve either decreases, or becomes negative.
These battery charging regimes will not however, work with the multiple voltage battery cell disclosed and claimed in the referenced '812 application. Since the '812 cell is multiple voltage, (i.e., operates at two or more distinct operational voltage regimes) the cell is characterized by a charging curve wherein the slope of the charging voltage versus time, (for example) decreases at least twice. Using the methods described in the above-referenced patents, the multiple voltage cell described in the '812 application would be only partially charged at best.
Accordingly, there exists a need to provide a cell charging apparatus, and charging regime capable of fully charging multiple voltage electrochemical cells capable of operating at multiple voltage levels.
SUMMARY OF THE INVENTION
Briefly, according to the invention, there is provided a method of charging an electrochemical cell capable of multiple voltage operation. The method includes the steps of providing a rechargeable cell adapted to operate in more than one voltage regime, i.e. at multiple voltage levels. After placing the multiple voltage electrochemical cell into a charging apparatus, a charging current is supplied to the cell. While current is being applied, at least one physical characteristic of the cell is measured and plotted as a function of time. The plotted characteristic versus time yields a characteristic profile curve.
The physical characteristic measured and plotted may be, for example, cell voltage, cell pressure, cell temperature, cell current or combinations thereof. As time progresses while charging, each of the aforementioned characteristics typically reach a first plateau, increase for a period, ultimately reaching a final plateau and decreasing. By taking advantage of this phenomena, it is possible to determine the cell's charge termination point by selecting a termination point to be consistent with at least the second occurrence of the slope of the generated profile curve being zero. The number of occurrences of the profile curve being substantially zero would correspond to the number of voltage regimes which the electrochemical cell is capable of being operated at.
Also disclosed is a charging apparatus for recharging an electrochemical cell capable of multiple voltage operation. The charging apparatus includes a power supply means capable of charging the cell to different voltage levels, a controller coupled electrically to the power supply means and the electrochemical cell. The controller is adapted to measure at least one physical characteristic of said cell via a plurality of sensing lines.
Operatively disposed in the controller, as by being burned in or embedded in the controller, is a charging algorithm adapted to measure a physical characteristic of the electrochemical cell, and provide a profile curve which is a function of said characteristic versus time. By employing this curve, the charging apparatus is able to determine a charge termination point by terminating said charging upon the second or subsequent occurrence of the slope of the profile curve being zero.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph of potential versus extent of reaction of a prior art electrochemical cell.
FIG. 2 is a graph of electrode potential versus extent of reaction in a multiple voltage electrochemical cell.
FIG. 3 is a schematic diagram of a battery cell configuration for a multiple voltage electrochemical cell.
FIG. 4 is a graph illustrating cell voltage versus time during charging of a multiple voltage electrochemical cell.
FIG. 5 is a data structure flow chart illustrating the elements of a battery charging apparatus in accordance with the invention.
FIG. 6 is a flow chart illustrating a method for charging a multiple voltage cell in accordance with the invention.
FIG. 7 is a flow chart illustrating the fast charge termination module for a multiple voltage cell in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward.
A conventional battery cell comprises a positive electrode, a negative electrode and an electrolyte. The electrodes must be separated from each other to prevent direct electronic contact. The difference in their individual electrode potentials determine the nominal voltage of the cell. In these cells, voltages are regulated within a certain range so as to maintain the needed capacity. This is illustrated in FIG. 1 for the general case of a nominal cell voltage, E f . The dashed line E + represents the average or nominal potential of the positive electrode while the line E - is the average potential of the negative electrode. Dashed line R is the reference potential. The cell voltage profile is the difference of the electrode potential profiles at each point of the extent of reaction, yielding a nominal cell voltage represented by the line E f . During a normal discharge cycle, the individual electrodes are discharged according to the positive and negative electrode potential profiles 10 and 20 shown. The output of the cell, monitored externally via the positive and negative terminals, follows the cell voltage profile 30 as indicated. The average of this voltage profile is the nominal cell voltage reported for the cell.
The battery cell described and claimed in the related patent application is constructed in a "multiple function" configuration in which the cell voltage is tailored according to the different applications, and is capable of operating at several nominal voltage regimes. FIG. 2 is an illustration of electrode potential profiles for active materials that could be used as electrode couples for cell voltage tailoring. Zones Q1 and Q2 are extents of reactions (or capacities) corresponding to the different regions of operation. Dashed line E c is the nominal potential of one electrode of the electrode couple, represented here as the positive electrode or cathode. Dashed lines E a1 and E a2 are nominal potentials of the tailoring or control electrode with two separable extents of reaction. When used as electrode couples in a cell, operating cell voltages E c -E a1 or E c -E a2 can be attained independently via appropriate cell assembly and re-charging.
In this illustration, it is assumed that the cathode is cell capacity limiting, and the voltage of the cell is determined by the state of charge of the anode. In practice, this role can be reversed, while the principle of operation remains the same. When the potential of the cathode is fixed at an average nominal value E c , and the state of charge of the anode is controlled to the potential E a1 , the cell voltage will be fixed at E c -E a1 . Similarly, when the state of charge is controlled to E a2 , the cell voltage will be E c -E a2 . Hence by monitoring the state of charge of the control electrode, the cell voltage can be tailored for different applications with different voltage requirements. Operation in two different voltage regimes is illustrated by line 40 of FIG. 2 wherein the first voltage regime corresponds to extent of reaction Q1, and the second corresponds to extensive reaction Q2.
There are several arrangements that can be employed to achieve the necessary pre-charged configuration of the cell. The first involves assembling the cell with active electrode materials that have been pre-charged to a desired voltage level or extent of reaction. This allows the cell to be assembled so that it is either cathode or anode capacity limiting. This is akin to a traditional electrochemical cell arrangement, with the subtle but significant difference that one electrode is tailored to operate at a selected voltage level, the level being chosen from two or more possible voltage regimes. Operation in a different voltage regime, for use in a different application with a different voltage range, would require the cell to be pre-charged to a different state prior to assembly.
In another preferred embodiment, the cell is pre-charged to the voltage of the desired application. When the cell is constructed such that the cell capacity is limited by the capacity of the tailored electrode, then the fixed-voltage electrode is manufactured to contain enough active material to accommodate the total amount of electroactive species in the entire regions of activity. Charging and discharging for this configuration is achieved via a simple voltage indicator that specifies the operational voltage range, thus making switching between voltage regimes relatively simple.
Referring now to FIG. 3, the control electrode 102 may be either the positive or negative couple of the cell 100. The fixed-potential electrode 104 serves as the other electrode of the couple, without any difference in the cell's operation and performance. An electrolyte 106 provides the ionic/electrical coupling of the two electrodes 102 and 104. A controller 110 monitors the battery cell voltage and other necessary parameters as well as providing charging control capabilities as required. A power supply 112 delivers the power needed to charge the battery cell 100. The relationship between the cell 100, controller 110, and the power supply 112, as well as a charging regime are discussed in greater detail with respect to FIGS. 5-7.
Referring now to FIG. 4, there is illustrated therein an electrochemical cell charge profile of, for example cell voltage, during charging, wherein changes in cell voltage are plotted as a function of time. As may be appreciated from a perusal of FIG. 4, the slope of the charging curve may approach zero (0), or become zero (0), or even become negative at least twice; once at the point defined by time t 1 and voltage V 1 and once at the point defined by time t 2 and voltage V 2 . The number of such slope changes is largely dependent upon the number of voltage regimes in which the cell is adapted to operate. As noted hereinabove, conventional battery chargers relying upon change in slope of the charging profile will terminate the charging regime at the point V l -t 1 , producing a partially charged battery. While illustrated using the example of voltage, it is to be understood that the charging profile may be calculated by slope, absolute value, area, differentiation, polarization voltage and others. Moreover, the profiles may be monitored by voltage, temperature, current, internal cell pressure, impedance, or other battery characteristics.
Referring now to FIG. 5, there is illustrated therein a data structure flow chart showing the relationship of the cell 100, controller 110, and power supply 112 in a battery charging apparatus in accordance with the instant invention. The charging routine, described in greater detail in FIG. 6, may be embedded in or burned into the controller 110. The charging apparatus will be able to monitor the necessary parameters in order to charge one or more electrochemical cells disposed therein. The power supply 112 delivers charge to cell 100 via power-in-line 116, which is in turn controlled by the controller 110, via line 120. The power source 112 also provides power to the controller 110 via auxiliary power line 118. This power will maintain controller 110 operation in order for it to monitor the electrochemical cell 100 during the charging thereof and regulate power flow from the power supply 112, via control line 120. The controller 110 may be a conventional microprocessor including a conventional memory.
The controller 110 monitors the cell 100 via a plurality of monitor lines electrically coupled to a cell 100 disposed in the charging apparatus. These lines include a B+sense line 122, T-sense line 124, I-sense line 126 and pre-sense line 128. The B+sense line 122 is connected to the controller, and monitors cell voltage. The T- sense line 124 monitors cell temperature, and the I sense line 126 monitors the charge current sent from the power source 112 to the cell 100. The pre-sense line 128 indicates the state of charge required by a particular cell. For example, the pre-sense line 128 will indicate whether or not to charge a cell to voltage V 1 or V 2 (of FIG. 4).
Referring now to FIG. 6, there is illustrated therein a flow chart describing the steps of a charging regime in accordance with the instant invention. The controller 110 of FIG. 5 is first initialized as indicated in step 202. This initialization step insures that all logic and electronic states in the controller are in order to begin monitoring the electrochemical cell. Initialization typically occurs when the power supply is first electrically coupled to the controller 110 (i.e., when the controller is turned on) and may reoccur every time the power source is reconnected.
After initialization, a battery detection module 204 is activated to determine whether or not an electrochemical cell is present in the charging apparatus. Assuming the presence of an electrochemical cell, the charging algorithm determines the temperature of the cell, as indicated in step 206. The controller, via T-sense line 124, (of FIG. 5) will check to assure that the temperature of the cell is within a pre-selected temperature window. If the cell is, a fast charging regime will be started, as described below. If the temperature is outside the preselected temperature window, the charging apparatus will indicate to the user that such is the case, and not initiate the charging routine. The temperature window may be, for example, between 10 and 40 degrees Celsius for NiCd and Ni-MH cells.
If the temperature of the cell is within the pre-selected temperature window as specified in step 206, then the controller 110 will initiate the battery identification module 208. This module will determine cell specific information, such as the voltage necessary to charge the cell to one or more of the multiple voltages of the cell (i.e., V1 or V2 of FIG. 4). This cell information is transmitted to the controller 110 via pre-sense line 128.
Having sampled the temperature and battery identification information, the controller 110 will access a fuel gauge module 210 which will determine the total capacity of the cell, and the capacity-to-full of the cell. Fuel gauge module 210 may thus provide for very accurate charging to the specified capacity of the cell.
After determining the capacity of the cell, a fast charge module 212 sends a control signal to the power supply 112 initiating charging of the cell. The fast charge termination module 214 (discussed in greater detail with respect to FIG. 7) periodically checks the cell for the appropriate termination level. Once the termination level is reached, the trickle/maintenance charge module 216 will begin a relatively slow charge of the cell by altering the control signal provided along control line 120. This will maintain the electrochemical cell in the fully charged state while in the charging apparatus. If the cell is left in the charging apparatus for longer than a pre-selected maximum time, the battery complete module 218 will shut down the charging apparatus altogether in order to prevent overcharging the cell. This module will also periodically monitor the cell to determine whether or not additional charging is required.
Referring now to FIG. 7, there is illustrated therein the steps of the fast charge termination module 214 of FIG. 6. Fast charge termination module 214 consists of several individual sub-modules. The first such module is the "Read B+ sense" module 220, which monitors the cell voltage. Information collected in module 220 is analyzed by the "ΔB+ slope decision module" 222. If the slope of the voltage approaches 0, the routine proceeds to step 224. If the slope is not approximately 0, then charge continues to be applied to the cell.
Assuming the slope to be approximately or equal to 0, the routine proceeds to step 224, and determines whether or not the battery identification voltage is greater than the active cell voltage. If the cell voltage is greater than the battery identification voltage (for example, V1 or V2 of FIG. 5), then the charge is terminated as illustrated in step 226. If not, charging continues until the condition is met. Thus, the charging apparatus may be adjusted to terminate the charging regime upon the detection of either one, or more occurrences of a zero (0) slope of the charging curve.
While the preferred embodiments of the invention have been illustrated and described, it will be clear that the invention is not so limited. Numerous modifications, changes, variations, substitutions and equivalents will occur to those skilled in the art without departing from the spirit and scope of the present invention as defined by the appended claims.
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A method (200) of charging a multiple voltage battery is disclosed. The multiple voltage battery is characterized by a preselected operating voltage and a charge profile curve having at least two occurrences of the slope thereof being substantially zero. The number of occurrences of the slope of the charge profile curve being substantially zero corresponds to the number of voltage levels the cell is adapted to operate in. The method recognizes the signature charging profile of the multiple voltage level battery and is thus capable of terminating battery charge at the level corresponding to the preselected operating voltage.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a division of U.S. application Ser. No. 11/858,436, filed Sep. 20, 2007, now allowed, which is a division of U.S. application Ser. No. 11/404,273, filed Apr. 14, 2006, now U.S. Pat. No. 7,288,656, issued Oct. 30, 2007, which is a continuation of International application No. PCT/FR2004/002,643, filed Oct. 15, 2004, all of which are incorporated herein by reference in their entirety; which claims the benefit of priority of French Patent Application No. 03/12,165, filed Oct. 17, 2003.
BACKGROUND OF THE INVENTION
Field of the Invention
The subject of the present invention is N-heterocyclyl-methylbenzamide derivatives, their preparation and their therapeutic application.
SUMMARY OF THE INVENTION
The compounds of the invention correspond to general formula (I)
in which
R represents a hydrogen atom or a vinyl group;
n represents 0 or 1 or 2 when R represents a hydrogen atom and n represents 1 when R represents a vinyl group;
X represents a group of formula CH or a nitrogen atom when R represents a hydrogen atom and X represents a group of formula CH when R represents a vinyl group;
R 1 represents either a phenyl or naphthyl group optionally substituted with one or more substituents chosen from halogen atoms, linear or branched (C 1 -C 6 )alkyl, hydroxyl and (C 1 -C 6 )alkoxy groups, the trifluoromethyl group, or a cyclohexyl group, or a heteroaryl group chosen from the thienyl, pyridinyl, oxazolyl, furanyl, thiazolyl, quinolinyl, and isoquinolinyl groups;
R 2 represents either a hydrogen atom, or one or more substituents chosen from halogen atoms and the trifluoromethyl, (C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, thienyl, phenyloxy, hydroxyl, mercapto, thio(C 1 -C 6 )alkyl and cyano groups or a group of general formula —NR 4 R 5 , SO 2 NR 4 R 5 , —SO 2 —(C 1 -C 6 )alkyl, —SO 2 -phenyl, —CONR 4 R 5 , —COOR 7 , —CO—(C 1 -C 6 )alkyl, —CO-phenyl, —NHCOR 8 , —NHSO 2 —(C 1 -C 6 )-alkyl, —NHSO 2 -phenyl and —NHSO 2 NR 4 R 5 or a group of formula —OCF 2 O attached at the 2- and 3-positions of the phenyl group;
the groups (C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, —SO 2 —(C 1 -C 6 )alkyl, —CO—(C 1 -C 6 )alkyl and —NHSO 2 —(C 1 -C 6 )alkyl being optionally substituted with one or more groups R 3 ;
the groups phenyl, —SO 2 -phenyl, —CO-phenyl and —NHSO 2 -phenyl being optionally substituted with a group R 6 ;
R 3 represents a halogen atom, or a phenyl, (C 1 -C 6 )alkoxy or —NR 4 R 5 group;
R 4 and R 5 represent, independently of each other, a hydrogen atom or a (C 1 -C 6 )alkyl group or R 4 and R 5 form with the nitrogen atom bearing them a pyrrolidine ring, a piperidine ring or a morpholine ring;
R 6 represents a hydrogen atom, a halogen atom, a trifluoromethyl group, a cyano group, a hydroxyl group, a mercapto group, a (C 1 -C 6 )alkyl or (C 1 -C 6 )alkoxy group;
R 7 represents a hydrogen atom or a (C 1 -C 6 )alkyl group optionally substituted with one or more groups R 3 , or a phenyl group optionally substituted with a group R 6 ;
R 8 represents a (C 1 -C 6 )alkyl group optionally substituted with one or more groups R 3 , or a (C 1 -C 6 )alkoxy group, or a phenyl group optionally substituted with a group R 6 .
DETAILED DESCRIPTION OF THE INVENTION
Among the compounds of general formula (I), a number of subgroups of preferred compounds can be distinguished:
group 1: compounds of threo configuration and of general formula (I) in which n represents 0 or 1;
group 2: compounds of group 1 in whose formula X represents a group of formula CH;
group 3: compounds of group 2 in whose formula R represents a hydrogen atom;
group 4: compounds of group 3 in whose formula n represents 1;
group 5: compounds according to group 4 in whose formula R 1 represents an optionally substituted phenyl group.
The compounds of formula (I) may contain several asymmetric centers. They can therefore exist in the form of enantiomers or diastereoisomers. These enantiomers, diastereoisomers and mixtures thereof, including the racemic mixtures, form part of the invention.
More particularly, the compounds of formula (I), for which R═H, can exist in the form of threo ((1S,2S) and (1R,2R)) or erythro ((1S,2R) and (1R,2S)) diastereoisomers or of pure enantiomers or as a mixture of such isomers.
The compounds of formula (I) can exist in the form of bases or of addition salts with acids. Such addition salts form part of the invention.
These salts are advantageously prepared with pharmaceutically acceptable acids, but the salts of other acids useful, for example, for the purification or isolation of the compounds of formula (I) also form part of the invention. The compounds of formula (I) can also exist in the form of hydrates or solvates, namely in the form of associations or combinations with one or more molecules of water or with a solvent. Such hydrates and solvates also form part of the invention.
The compounds of the invention exhibit a particular activity as specific inhibitors of the glycine transporters glyt1 and/or glyt2.
The compounds of general formula (I) may be prepared by a method illustrated by scheme 1 which follows.
According to scheme 1, a diamine of general formula (II), in which n, X, R and R 1 are as defined above, is coupled with an activated acid or an acid chloride of general formula (III) in which Y represents a leaving group, such as a halogen atom, and R 2 is as defined above, using methods known to persons skilled in the art.
The diamines of general formula (II), in which R═H and n, X and R 1 are as defined above, may be prepared by a method illustrated by scheme 2 which follows.
The ketone of general formula (IV), in which n, X and R 1 are as defined above, is reacted with benzyloxyhydroxylamine hydrochloride, at the reflux temperature of pyridine, in order to obtain the oxime of general formula (V). The two forms Z and E of the oxime may be separated according to methods known to persons skilled in the art such as chromatography on a silica gel column.
The oxime (V), preferably in the Z hydrochloride form, is then reduced at the reflux temperature of tetrahydrofuran with lithium aluminum hydride to give the predominantly threo-diamine of general formula (II).
By reducing the E form of the oxime of general formula (V), a diamine (II) mixture is obtained in the form of the two diastereoisomers (threo/erythro).
The erythro- and threo-diastereoisomers may be separated according to methods known to persons skilled in the art such as chromatography on a silica gel column.
Another variant preparation of the diamines of general formula (II), in which R and R 1 are as defined above, n is equal to 1 and X is a CH, is illustrated by the scheme 3 which follows.
The alcohols of general formula (VI) are converted to amines by a Mitsunobu reaction according to the method described in Bull. Soc. Chim. Belg . (106), 1997, 77-84 and in Tetrahedron: Asymmetry , (6), 1995, 1699-1702, both of which are incorporated herein by reference in their entirety.
Moreover, the chiral compounds of general formula (I), corresponding to the enantiomers (1R,2R) or (1S,2S) of the threo-diastereoisomer and to the enantiomers (1S,2R) or (1R,2S) of the erythro-diastereoisomer, may also be obtained either by separating the racemic compounds by high performance liquid chromatography (HPLC) on a chiral column, or from the chiral amine obtained either by resolving the racemic amine of general formula (II), by the use of a chiral acid, such as tartaric acid, camphorsulfonic acid, dibenzoyltartaric acid, N-acetylleucine, by fractional and preferential recrystallization of a diastereoisomeric salt from a solvent of the alcohol type, or by enantioselective synthesis from an erythro- or threo-chiral alcohol using a method similar to that described in scheme 3. The chiral alcohols may be obtained by a method similar to that described in Tetrahedron , (55), 1999, 2795-2810, which is incorporated herein by reference in its entirety. In the case where R represents a vinyl group and R 1 represents a quinolinyl group, the diamine of general formula (II) may be prepared according to scheme 3 using the corresponding commercially available chiral alcohols.
The racemic ketone of general formula (IV) may be prepared either by deprotonation of an activated complex of the bridged cyclic amines and reaction with an electrophile, such as an ester or a Weinreb amide, according to a method similar to that described in Chem. Commun., 1999, 1927-1928, which is incorporated herein by reference in its entirety, or by reaction of an organometallic compound on the ethyl ester of 2-quinuclidinic acid, according to a method similar to that described in J. Med. Chem., 1980, 180-184, which is incorporated herein by reference in its entirety, or by oxidation of the corresponding alcohol obtained by various methods similar to those described in J. Org. Chem., 50, 1985, 29-31 and Chem. Comm., 1999, 1927-1929, which is incorporated herein by reference in its entirety, with oxidizing agents known to persons skilled in the art such as manganese dioxide or the oxalyl chloride-dimethyl sulfoxide system.
The alcohols of general formula (VI) may also be obtained by reducing the corresponding ketones of general formula (IV) under conditions known to persons skilled in the art.
The acids and acid chlorides of general formula (III) are commercially available or are prepared by analogy with methods known to persons skilled in the art.
For example, 4-amino-3-chloro-5-trifluoromethylbenzoic acid may be prepared by chlorination of 4-amino-5-trifluoromethylbenzoic acid with sulfuryl chloride in a chlorinated solvent such as chloroform, according to a method similar to that described in Arzneim. Forsch ., 34, 11a, (1984), 1668-1679, which is incorporated herein by reference in its entirety.
2,6-Dichloro-3-trifluoromethylbenzoic acid may be prepared by methods similar to those described in U.S. Pat. No. 3,823,134, which is incorporated herein by reference in its entirety.
The benzoic acids derived from sulfonamides may be prepared according to methods similar to those described in patents DE-2436263, BE-620741, DE-1158957, U.S. Pat. No. 3,112,337, GB-915259, U.S. Pat. No. 3,203,987, DE-642758, EP-68700, FR-2396757, DE-2734270, and in J. Pharm. Pharmacol . (1962), 14, 679-685. The meta-chlorosulfonylated acids may be obtained according to a method similar to those described in J. Chem. Soc . (C), (1968), 13, and in U.S. Pat. No. 2,273,444, DE-19929076, EP-0556674. All of the aforementioned references are incorporated herein by reference in their entirety.
Chlorosulfonylation at the ortho or para position may be carried out starting with a diazonium salt according to a method similar to that described in U.S. Pat. No. 3,663,615, which is incorporated herein by reference in its entirety, with 4-amino-3-chlorobenzoic acid.
The sulfonamides are obtained by the reaction of the chlorosulfonylated derivatives in the presence of an excess of amine in a solvent such as tetrahydrofuran, at room temperature or under reflux.
The secondary sulfonamides may be methylated according to a method similar to that described in patent BE-620741, which is incorporated herein by reference in its entirety. The primary sulfonamides may be reacted with an isocyanate, in a solvent such as tetrahydrofuran, in the presence of a base such as potassium carbonate. Some sulfoxide derivatives of benzoic acids are described in patents DE-2056912, DE-2901170 and U.S. Pat. No. 3,953,476 or may be obtained by methods similar to those described in patent BE-872585 and in J. Org. Chem . (1991), 56(1), 4976-4977. All of the aforementioned references are incorporated herein by reference in their entirety.
The benzoic acid derivatives of general formula (III), in which R 2 represents a branched alkyl group, may be prepared according to methods similar to that described in U.S. Pat. No. 4,879,426 and in Syn. Lett . (1996), 473-474 and J. Med. Chem . (2001), 44, 1085-1098. All of the aforementioned references are incorporated herein by reference in their entirety.
The benzoic acid derivatives of the biphenyl type may be prepared according to methods known to persons skilled in the art. Finally, the carbonylated benzoic acids may be synthesized according to methods similar to those described in U.S. Pat. No. 3,725,417 and GB-913100 and in Chem. Pharm. Bull ., (1988), 36(9), 3462-3467 and J. Labelled Compd. Radiopharm ., (1997), 39(6), 501-508. All of the aforementioned references are incorporated herein by reference in their entirety.
The esters or amides may be introduced by direct carbonylation with a strong base at the para position of the acid, under the conditions described in Tetrahedron Lett ., (2000), 41, 3157-3160, which is incorporated herein by reference in its entirety.
Finally, the cyano derivatives of benzoic acids are obtained by heating a halogenated benzoic acid or ester in the presence of potassium cyanide, a catalyst of the tetrakistriphenylphosphinepalladium type, in a solvent of the tetrahydrofuran type, according to a method similar to that described in J. Org. Chem. (1967) 62, 25, 8634-8639, which is incorporated herein by reference in its entirety.
Other acids and acid chlorides of general formula (III) may be obtained according to methods similar to those described in patents EP-0556672, U.S. Pat. No. 3,801,636 and in J. Chem. Soc ., (1927), 25 , Chem. Pharm. Bull ., (1992), 1789-1792 , Aust. J. Chem ., (1984), 1938-1950 and J.O.C., 1980), 527. All of the aforementioned references are incorporated herein by reference in their entirety.
The examples which follow illustrate the preparation of a few compounds of the invention. It should be noted however that these examples are provided for illustration purposes and in no way limit the scope of the present invention. The elemental microanalyses, and the IR and NMR spectra, and the HPLC on a chiral column confirm the structures and the enantiomeric purities of the compounds obtained.
The numbers indicated in brackets in the headings of the examples correspond to those of the 1 st column of the table given later.
In the names of the compounds, the dash “-” forms part of the word, and the dash “_” only serves for splitting at the end of a line; it is deleted in the absence of splitting, and should not be replaced either by a normal dash or by a gap.
Example 1
Compound No. 3
Threo-2-Chloro-N-[(1-azabicyclo[2.2.2]oct-2-yl)phenylmethyl]-3-trifluoromethylbenzamide hydrochloride 1:1
1.1. (Z)-1-Azabicyclo[2.2.2]oct-2-yl(phenyl)methanone O-benzyloxime hydrochloride
2.2 g (9.35 mmol) of 1-azabicyclo[2.2.2]oct-2-yl(phenyl)methanone ( Chem. Commun., 1999, 1927-1928) and 3 g (18.69 mmol) of benzyloxyhydroxylamine hydrochloride in 50 ml of pyridine are introduced into a 100 ml round-bottomed flask equipped with magnetic stirring, and the mixture is heated under reflux for 20 h.
After evaporation of the solvents under reduced pressure, the residue is diluted with water and chloroform, the aqueous phase is separated, and it is extracted with chloroform. After washing the combined organic phases, drying over sodium sulfate and evaporation of the solvent under reduced pressure, the residue is purified by chromatography on a silica gel column, eluting with a mixture of chloroform and methanol.
There are obtained 0.5 g of a fraction corresponding to (E)-1-azabicyclo[2.2.2.]oct-2-yl(phenyl)methanone O-benzyloxime and 2.25 g of another fraction corresponding to (Z)-1-azabicyclo[2.2.2.]oct-2-yl(phenyl)methanone O-benzyloxime hydrochloride
m.p. 195-197° C.
1.2. threo-[1-Azabicyclo[2.2.2.]oct-2-yl(phenyl)-methyl]amine
1.3 g (34.32 mmol) of lithium aluminum hydride in suspension in 10 ml of tetrahydrofuran are placed in a 250 ml three-necked flask equipped with magnetic stirring under a nitrogen atmosphere, 2.2 g (6.16 mmol) of (Z)-1-azabicyclo[2.2.2.]oct-2-yl(phenyl)methanone O-benzyloxime hydrochloride are added in portions and the mixture is heated under reflux for 2 h.
After cooling, the solution is hydrolyzed at 0° C. with successively 1.3 ml of water and then 1.3 ml of aqueous sodium hydroxide at 15% and 3.9 ml of water. The heterogeneous mixture is filtered on Celite®, the filtrate is concentrated under reduced pressure and then the residue is diluted with 1N hydrochloric acid and chloroform. The organic phase is separated and the aqueous phase is basified with aqueous ammonia. It is extracted twice with chloroform. After washing the combined organic phases, drying over sodium sulfate and evaporating the solvent under reduced pressure, 1.25 g of threo-[1-azabicyclo[2.2.2.]oct-2-yl(phenyl)methyl]-amine are obtained in the form of an oil which crystallizes and which is used as it is in the next step.
Melting point: 120-140° C.
1.3. threo-2-Chloro-N-[(1-azabicyclo[2.2.2]oct-2-yl)-phenylmethyl]-3-trifluoromethylbenzamide hydrochloride 1:1
0.51 g (2.12 mmol) of 2-chloro-3-trifluoromethylbenzoic acid chloride in solution in 5 ml of chloroform is placed in a 100 ml round-bottomed flask equipped with magnetic stirring, in the presence of 0.29 g (2.12 mmol) of potassium carbonate at 0° C., and a solution of 0.42 g (1.93 mmol) of threo-[1-azabicyclo-[2.2.2.]oct-2-yl(phenyl)methyl]amine in solution in 5 ml of chloroform is poured in and the mixture is stirred at room temperature for 6 h.
After hydrolyzing with water and diluting with chloroform, the aqueous phase is separated and it is extracted with chloroform. After washing the combined organic phases, drying over sodium sulfate and evaporating the solvent under reduced pressure, the residue is purified by chromatography on a silica gel column, eluting with a mixture of chloroform and methanol. 0.18 g of an oily product is obtained.
The latter is dissolved in a few ml of propan-2-ol, 6 ml of a 0.1N hydrochloric acid solution in propan-2-ol are added and the mixture is concentrated under reduced pressure in order to reduce the volume of the solvent. After trituration, 0.15 g of hydrochloride is finally isolated in the form of a solid.
Melting point: 257-262° C.
Example 2
Compound No. 4
Threo-2,6-Dichloro-N-[(1-azabicyclo[2.2.2]oct-2-yl)phenylmethyl]-3-trifluoromethylbenzamide hydrochloride 1:1
0.36 g (1.38 mmol) of 2,6-dichloro-3-trifluoromethylbenzoic acid, 0.187 g (1.38 mmol) of hydroxybenzotriazole, 0.264 g (1.38 mmol) of 1-[3-(dimethylamino)-propyl]-3-ethylcarbodiimide hydrochloride in solution in 7 ml of chloroform are introduced into a 100 ml round-bottomed flask equipped with magnetic stirring, and the mixture is stirred at room temperature for 30 min.
0.3 g (1.38 mmol) of threo-[1-azabicyclo[2.2.2.]oct-2-yl(phenyl)methyl]amine in solution in 5 ml of chloroform is added and the mixture is stirred at room temperature overnight.
After hydrolyzing with water and diluting with chloroform, the aqueous phase is separated and it is extracted with chloroform. After washing the combined organic phases, drying over sodium sulfate and evaporating the solvent under reduced pressure, the residue is purified by chromatography on a silica gel column, eluting with a mixture of chloroform and methanol. 0.37 g of an oily product is obtained.
The latter is dissolved in a few ml of propan-2-ol, 20 ml of a 0.1N hydrochloric acid solution in propan-2-ol are added and the mixture is concentrated under reduced pressure in order to reduce the volume of the solvent. After trituration, 0.35 g of hydrochloride is finally isolated in the form of a solid.
Melting point: 270-273° C.
Example 3
Compound No. 14
2-Chloro-N-(8α,9S)cinchonan-9-yl)-3-trifluoromethylbenzamide hydrochloride 2:1
3.1. 8α-9S-Cinchonan-9-amine
0.74 g (2.5 mmol) of 8α,9R-cinchonan-9-ol (cinchonidine) and 0.79 g (3 mmol) of triphenylphosphine in suspension in 15 ml of tetrahydrofuran are introduced into a 100 ml three-necked flask equipped with magnetic stirring, under a nitrogen atmosphere, and 3.5 ml of a 0.9 M solution of hydrazoic acid in benzene (3 mmol) are added. A solution of 0.55 ml (2.75 mmol) of diisopropylcarbodiimide in 1.5 ml of tetrahydrofuran is added to this solution dropwise and the mixture is heated at 40° C. for 16 h.
0.65 g (2.5 mmol) of triphenylphosphine is added and the mixture is stirred for 30 min, 0.5 ml of water is added and the stirring is resumed for 6 h.
The mixture is hydrolyzed with 1N hydrochloric acid and diluted with chloroform. The aqueous phase is basified with aqueous ammonia and it is extracted several times with chloroform. After washing the combined organic phases, drying over sodium sulfate and evaporating the solvent under reduced pressure, 0.97 g of an orange-colored oil is obtained containing 8α,9S-cinchonan-9-amine which is used crude in the next step.
3.2. 2-Chloro-N-(8α,9S-cinchonan-9-yl)-3-trifluoromethylbenzamide hydrochloride 2:1
According to the method described in Example 1.3, starting with 0.97 g (3.3 mmol) of 8α,9S-cinchonan-9-amine, 0.84 g (3.4 mmol) of 2-chloro-3-trifluoromethylbenzoic acid chloride and 0.5 g (3.63 mmol) of potassium carbonate, 0.360 g of oil is obtained which is dissolved in 30 ml of 1N hydrochloric acid. The aqueous phase is extracted with chloroform and then the solvent is evaporated under reduced pressure. 0.26 g of hydrochloride is thus obtained in the form of a white solid.
Melting point: 185-205° C.; [α] D 25 =−5.4 (c=0.986, MeOH).
Example 4
Compound No. 17
2,6-Dichloro-N-[(1S)-[(2S)(1-azabicyclo[2.2.2]oct-2-yl)phenylmethyl]-3-(trifluoromethyl)benzamide hydrochloride 1:1
4.1 (1S)-[(2S)-1-Azabicyclo[2.2.2.]oct-2-yl(phenyl)-methyl]amine D-tartrate
9.4 g (43.45 mmol) of threo-[1-azabicyclo[2.2.2.]oct-2-yl(phenyl)methyl]amine are dissolved in 150 ml of ethanol. A solution of 6.52 g (43.45 mmol) of D-tartaric acid in solution in 200 ml of ethanol is poured in. After evaporating the solvent under reduced pressure, the residue is placed in 500 ml of a solution of ethanol and of water (9/1) and then heated until dissolution is obtained. After 3 successive recrystallizations, 5.39 g of (1S)-[(2S)-1-azabicyclo-[2.2.2.]oct-2-yl(phenyl)methyl]amine D-tartrate are obtained.
Melting point: 125-135° C.
[α] D 25 =−46.1 (c=0.616; MeOH).
4.2. 2,6-Dichloro-N-[(1S)-[(2S)(1-azabicyclo[2.2.2]oct-2-yl)phenylmethyl]-3-(trifluoromethyl)benzamide hydrochloride 1:1
3.33 g (12.02 mmol) of 2,6-dichloro-3-(trifluoromethyl)benzoic acid chloride in solution in 30 ml of chloroform are placed in a 100 ml round-bottomed flask equipped with magnetic stirring in the presence of 1.82 g (13.22 mmol) of potassium carbonate at 0° C., and a solution of 2.6 g (12.02 mmol) of (1S)-[(2S)-1-azabicyclo[2.2.2.]oct-2-yl(phenyl)methyl]amine (obtained by basification of the salt described in 4.1, followed by extraction) in solution in 40 ml of chloroform is poured in and the mixture is stirred at room temperature for 6 h.
After hydrolyzing with water and diluting with chloroform, the aqueous phase is separated and it is extracted with chloroform. After washing the combined organic phases, drying over sodium sulfate and evaporating the solvent under reduced pressure, the residue is purified by chromatography on a silica gel column, eluting with a mixture of chloroform and methanol.
5.4 g of an oily product are obtained.
The latter is dissolved in a few ml of chloroform, 600 ml of a solution of ether saturated with hydrochloric acid are added, and the mixture is concentrated under reduced pressure. The residue is recrystallized from ethyl acetate. 4.7 g of 2,6-dichloro-N-[(1S)-[(2S)(1-azabicyclo[2.2.2]oct-2-yl)phenylmethyl]-3-(trifluoromethyl)benzamide hydrochloride are thus obtained.
Melting point: 264-268° C.
[α] D 25 =+61.10 (c=0.32; MeOH)
Example 5
Compound No. 26
Threo-N-[1-Azabicyclo[2.2.2]oct-2-yl(4-fluorophenyl)-methyl]-2,6-dichloro-3-(trifluoromethyl)benzamide hydrochloride 1:1
5.1 1-Azabicyclo[2.2.2]oct-2-yl(4-fluorophenyl)-methanol
1.11 g (10 mmol) of quinuclidine in 40 ml of dry tetrahydrofuran at 0° C. are placed in a 100 ml three-necked flask under argon. 1.33 ml (10.5 mmol) of ether-boron trifluoride complex are added dropwise and the mixture is stirred for 30 min at 0° C. (solution A). In parallel, 2.47 g (22 mmol) of dry potassium tert-butoxide in 60 ml of dry tetrahydrofuran are placed in a 250 ml three-necked flask under argon. The mixture is cooled to −70° C. and 22 ml of a 1M solution of sec-butyllithium in the cyclohexane/hexane mixture (22 mmol) are poured in dropwise while the temperature is kept below −60° C. (solution B). At the end of the addition, the solution A is delivered by a cannula-like tube into the solution B while the temperature is kept at around −70° C. The mixture is kept stirring for 2 h.
2.36 mol (22 mmol) of distilled 4-fluorobenzaldehyde in solution in 20 ml of tetrahydrofuran at −70° C. are placed in a 50 ml three-necked flask under argon. The solution B is delivered by a cannula-like tube while the temperature is kept at around −70° C. The resulting solution is left for 30 min at −70° C. and allowed to rise to −20° C. The mixture is then hydrolyzed with a 10% hydrochloric acid solution. The mixture is extracted with ether and then the aqueous phase is taken up and basified with aqueous ammonia. The mixture is extracted with chloroform and then the solvent is evaporated under reduced pressure. The residue is purified by flash chromatography on a silica gel column, eluting with a mixture of chloroform and methanol. 0.53 g of 1-azabicyclo[2.2.2]oct-2-yl(4-fluorophenyl)methanol is thus obtained in the form of a yellowish solid.
Melting point: 69-70° C.
5.2 1-Azabicyclo[2.2.2]oct-2-yl(4-fluorophenyl)methanone
1.3 ml of dimethyl sulfoxide in 40 ml of tetrahydrofuran at −70° C. are placed in a 250 ml three-necked flask under nitrogen, and 0.9 ml of oxalyl chloride (11 mmol) is added dropwise and the mixture is kept stirring for 30 min at this temperature. A solution of 1 g (4.6 mmol) of 1-azabicyclo[2.2.2]oct-2-yl(4-fluorophenyl)methanol in 40 ml of tetrahydrofuran is added dropwise. After 30 min, 4 ml (27.6 mmol) of triethylamine are added at −70° C. The reaction mixture is then stirred for 30 min at −70° C., for 30 min at 0° C. and then for 1 h at room temperature.
The mixture is poured into an aqueous ammonia solution and then extracted several times with chloroform. The organic phases are dried over sodium sulfate and evaporated under reduced pressure. The residue is purified by chromatography on a silica gel column, eluting with a mixture of chloroform and methanol. 1 g of 1-azabicyclo[2.2.2]oct-2-yl(4-fluorophenyl)methanone is thus obtained.
Melting point: 68-69° C.
5.3 (Z)-1-Azabicyclo[2.2.2]octyl(4-fluorophenyl)methanone O-benzyloxime hydrochloride
According to the procedure described in Example 1.1, starting with 1.17 g (5 mmol) of ketone, 1.4 g of (Z)-1-azabicyclo[2.2.2]octyl(4-fluorophenyl)methanone O-benzyloxime hydrochloride are obtained after trituration, in ether, of the residue obtained after the treatment of the reaction.
Melting point: 202-203° C.
5.4 threo-1-Azabicyclo[2.2.2]octyl(4-fluorophenyl)-methanamine
According to the procedure described in 1.2, starting with 1.47 g (4.54 mmol) of (Z)-1-azabicyclo[2.2.2]octyl(4-fluorophenyl)methanone O-benzyloxime hydrochloride, 1 g of threo-1-azabicyclo[2.2.2]octyl(4-fluorophenyl)methanamine (diastereoisomeric excess, de=90%).
5.5 N—[(S)-(2S)-1-Azabicyclo[2.2.2]oct-2-yl(4-fluorophenyl)methyl]-2,6-dichloro-3-(trifluoromethyl)benzamide hydrochloride 1:1
According to the procedure described in 1.3, starting with 0.39 g (1.66 mmol) of threo-1-azabicyclo-[2.2.2]octyl(4-fluorophenyl)methanamine, 0.5 g (1.83 mmol) of 2,6-dichloro-3-trifluoromethylbenzoic acid chloride, 0.25 g (1.83 mmol) of potassium carbonate, 0.79 g of threo-N-[1-azabicyclo[2.2.2]oct-2-yl(4-fluorophenyl)methyl]-2,6-dichloro-3-(trifluoromethyl)benzamide is obtained, after purification by chromatography, in the form of an oil which is salified with a solution of gaseous hydrochloric acid in ethyl ether.
Melting point: 290-291° C.
The other compounds are obtained according to the methods described in Examples 1, 2 and 5 from other functionalized aldehydes.
The following Table 1 illustrates the chemical structures of a few compounds of the invention.
In the “R” column, —CH═CH 2 denotes a vinyl group, in the “R 1 ” column, C 6 H 5 denotes a phenyl group and 4-C 9 H 6 N denotes a quinolin-4-yl group. In the “Salt” column, - denotes a compound in the base state, “HCl” denotes a hydrochloride and “tfa” denotes a trifluoroacetate.
The compounds 14, 19 to 23, 24 of the table exist in the hydrochloride or dihydrochloride form (see table) solvated with one or more water molecules.
The compounds 15 and 16 of the table form a pair of enantiomers which are separated by preparative HPLC using a 20 μm CHIRACEL® AD column and, as solvent, a 95/5 isohexane/propan-2-ol mixture, likewise for the compounds 17 and 18.
Table 2 gives the physical properties, the melting points and optical rotations of the compounds of the table. “(d)” indicates a melting point with decomposition.
TABLE 1
(I)
No.
R 1
R
X
n
R 2
Salt
Stereochemistry
1
C 6 H 5
H
CH
1
3-SO 2 N(CH 3 ) 2 , 4-Cl
—
threo (1R,2R; 1S,2S)
2
C 6 H 5
H
CH
1
2-Cl, 5-CF 3
HCl
threo (1R,2R; 1S,2S)
3
C 6 H 5
H
CH
1
2-Cl, 3-CF 3
HCl
threo (1R,2R; 1S,2S)
4
C 6 H 5
H
CH
1
2,6-(Cl) 2 , 3-CF 3
HCl
threo (1R,2R; 1S,2S)
5
C 6 H 5
H
CH
1
2-Cl, 3-CH 3 , 6-F
HCl
threo (1R,2R; 1S,2S)
6
C 6 H 5
H
CH
1
2-Cl, 3-CH 3
HCl
threo (1R,2R; 1S,2S)
7
C 6 H 5
H
CH
1
2,4,6-(Cl) 3
HCl
threo (1R,2R; 1S,2S)
8
C 6 H 5
H
CH
1
2-CH 3 , 3-CF 3
HCl
threo (1R,2R; 1S,2S)
9
C 6 H 5
H
CH
1
2,6-(Cl) 2
HCl
threo (1R,2R; 1S,2S)
10
C 6 H 5
H
CH
1
2,5-(CF 3 ) 2
HCl
threo (1R,2R; 1S,2S)
11
C 6 H 5
H
CH
1
2-F, 3-Cl, 6-CF 3
HCl
threo (1R,2R; 1S,2S)
12
C 6 H 5
H
CH
1
2-CH 3 , 3-Cl
HCl
threo (1R,2R; 1S,2S)
13
C 6 H 5
H
CH
1
2,3-(Cl) 2
HCl
threo (1R,2R; 1S,2S)
14
4-C 9 H 6 N
CH═CH 2
CH
1
2-Cl, 3-CF 3
2HCl
(1S,2S)
15
C 6 H 5
H
CH
1
2-Cl, 3-CF 3
tfa
(1R,2S)
16
C 6 H 5
H
CH
1
2-Cl, 3-CF 3
tfa
(1S,2S)
17
C 6 H 5
H
CH
1
2,6-(Cl) 2 , 3-CF 3
HCl
(1S,2S)
18
C 6 H 5
H
CH
1
2,6-(Cl) 2 , 3-CF 3
HCl
(1R,2R)
19
C 6 H 5
H
N
1
2-Cl, 3-CF 3
2HCl
threo (1R,2R; 1S,2S)
20
C 6 H 5
H
N
1
2,6-(Cl) 2 , 3-CF 3
2HCl
threo (1R,2R; 1S,2S)
21
C 6 H 5
H
N
1
2,6-(Cl) 2
2HCl
threo (1R,2R; 1S,2S)
22
C 6 H 5
H
N
1
2-CH 3 , 3-CF 3
2HCl
threo (1R,2R; 1S,2S)
23
C 6 H 5
H
N
1
2-CH 3 , 3-Cl
2HCl
threo (1R,2R; 1S,2S)
24
C 6 H 5
H
CH
1
3,5 (Cl) 2 , 4-NH 2
HCl
threo (1R,2R; 1S,2S)
25
4-F—C 6 H 4
H
CH
1
2-Cl, 3-CF 3
HCl
threo (1R,2R; 1S,2S)
26
4-F—C 6 H 4
H
CH
1
2,6-(Cl) 2 , 3-CF 3
HCl
threo (1R,2R; 1S,2S)
27
1-naphthyl
H
CH
1
2,6-(Cl) 2 , 3-CF 3
HCl
threo (1R,2R; 1S,2S)
28
1-naphthyl
H
CH
1
2-Cl, 3-CF 3
HCl
threo (1R,2R; 1S,2S)
29
1-naphthyl
H
CH
1
2-CH 3 , 3-Cl
HCl
threo (1R,2R; 1S,2S)
30
2-CH 3 —C 6 H 4
H
CH
1
2-Cl, 3-CF 3
HCl
threo (1R,2R; 1S,2S)
31
2-CH 3 —C 6 H 4
H
CH
1
2,6-(Cl) 2 , 3-CF 3
HCl
threo (1R,2R; 1S,2S)
32
C 6 H 5
H
CH
1
6-CH 3 , 3-Cl, 2-NH 2
HCl
threo (1R,2R; 1S,2S)
33
C 6 H 5
H
CH
1
3,6-(Cl) 2 , 2-NH 2
HCl
threo (1R,2R; 1S,2S)
34
C 6 H 5
H
CH
1
2,6-(Cl) 2 , 3-CH 3
HCl
threo (1R,2R; 1S,2S)
35
C 6 H 5
H
CH
1
2-CH 3 , 3-Cl
HCl
(1S,2S)
36
C 6 H 5
H
CH
1
2-Cl, 3-CF 3
HCl
erythro (1S,2R; 1R,2S)
37
4-F—C 6 H 4
H
CH
1
2-CH 3 , 3-Cl
HCl
threo/erythro; 9/1
38
3-F—C 6 H 4
H
CH
1
2,6-(Cl) 2 , 3-CF 3
HCl
threo (1R,2R; 1S,2S)
39
3-F—C 6 H 4
H
CH
1
2,6-(Cl) 2 , 3-CF 3
HCl
erythro (1S,2R; 1R,2S)
40
4-F, 3-CH 3 —C 6 H 3
H
CH
1
2-CH 3 , 3-OCH 3
HCl
threo/erythro 1/1
41
4-F, 3-CH 3 —C 6 H 3
H
CH
1
3,5-(OCH 3 ) 2
HCl
threo/erythro 1/1
42
4-F, 3-CH 3 —C 6 H 3
H
CH
1
2,6-(Cl) 2 , 3-CF 3
HCl
threo (1R,2R; 1S,2S)
43
3-F—C 6 H 4
H
CH
1
2-CH 3 , 3-OCH 3
HCl
threo (1R,2R; 1S,2S)
44
C 6 H 5
H
CH
1
2-OCH 3 , 5-Cl
HCl
(1S,2S)
45
C 6 H 5
H
CH
1
2-Br, 5-OCH 3
HCl
(1S,2S)
46
C 6 H 5
H
CH
1
2,3-(OCF 2 O)
HCl
(1S,2S)
47
C 6 H 5
H
CH
1
2,6-(OCH 3 ) 2
HCl
(1S,2S)
48
C 6 H 5
H
CH
1
3,5-(OCH 3 ) 2
HCl
(1S,2S)
49
C 6 H 5
H
CH
1
2,3-(OCH 3 ) 2
HCl
(1S,2S)
50
C 6 H 5
H
CH
1
2-NH 2 , 3-CH 3
2HCl
(1S,2S)
51
C 6 H 5
H
CH
1
2-OCH 3 , 3,6-(Cl) 2
HCl
(1S,2S)
52
C 6 H 5
H
CH
1
3-(O—C 6 H 5 )
HCl
(1S,2S)
53
C 6 H 5
H
CH
1
2,5-(OCH 3 ) 2
HCl
(1S,2S)
54
C 6 H 5
H
CH
1
2-CH 3 , 3-OCH 3
HCl
(1S,2S)
55
C 6 H 5
H
CH
1
2-OCH 3 , 3,5(Cl) 2
HCl
(1S,2S)
56
C 6 H 5
H
CH
1
2-Cl, 6-CH 3
HCl
(1S,2S)
57
C 6 H 5
H
CH
1
2-NH 2 , 6-CH 3
2HCl
(1S,2S)
58
C 6 H 5
H
CH
1
2-NH 2 , 5-Br
2HCl
(1S,2S)
59
C 6 H 5
H
CH
1
2-NH 2 , 5-CH 3
2HCl
(1S,2S)
60
C 6 H 5
H
CH
1
2-OCH 3 , 3-CH 3
HCl
(1S,2S)
61
C 6 H 5
H
CH
1
2-NH 2 , 5-OCH 3
2HCl
(1S,2S)
62
C 6 H 5
H
CH
1
2-NH 2 , 3-OCH 3
2HCl
(1S,2S)
63
C 6 H 5
H
CH
1
2-Cl, 5-CH 3
HCl
(1S,2S)
64
C 6 H 5
H
CH
1
2-OCH 3 , 5-CH 3
HCl
(1S,2S)
65
C 6 H 5
H
CH
1
2-CH 3 , 3-OH
HCl
(1S,2S)
66
C 6 H 5
H
CH
1
2-CH 3 , 5-Cl
HCl
(1S,2S)
67
4-OCH 3 —C 6 H 4
H
CH
1
2,6-(Cl) 2 , 3-CF 3
HCl
threo (1R,2R; 1S,2S)
68
4-OH—C 6 H 4
H
CH
1
2,6-(Cl) 2 , 3-CF 3
—
threo (1R,2R; 1S,2S)
69
3-F—C 6 H 4
H
CH
1
2-CH 3 , 3-Cl
HCl
threo (1R,2R; 1S,2S)
TABLE 2
No.
m.p. (° C.)
[α] D 25 (°)
1
233-235
—
2
267-269
—
3
257-262
—
4
270-273
—
5
315-316
—
6
319-320
—
7
>300
—
8
281-283
—
9
359-361
—
10
281-283
—
11
347-349
—
12
311-313
—
13
316-318
—
14
185-205
−5.4 (c = 0.986 MeOH)
15
196-197
−51.3 (c = 1.03 MeOH)
16
214-215
+48.2 (c = 0.618 MeOH)
17
264-268° C.
+61.1 (c = 0.32 MeOH)
18
265-268
−58.9 (c = 0.3 MeOH)
19
207-208
—
20
214-215
—
21
210-211
—
22
215-217
—
23
210-212
—
24
336-339
—
25
271-273
—
26
290-291
—
27
317-318
—
28
314-315
—
29
315-316
—
30
215-230
—
31
210-220
—
32
328-330
—
33
275-280
—
34
338-344
—
35
295-300
+55.2 (c = 0.3 MeOH)
36
287-291
—
37
>300
—
38
232-234
—
39
289-291
—
40
124-126
—
41
154-156
—
42
254-256
—
43
280-282
—
44
162-164
+87.4 (c = 0.32; MeOH)
45
275-277
+43.8 (c = 0.32; MeOH)
46
191-193
+42.4 (c = 0.32; MeOH)
47
234-236
+53.2 (c = 0.30; MeOH)
48
297-299
+21.3 (c = 0.31; MeOH)
49
284-286
+68.6 (c = 0.32; MeOH)
50
244-246
+41.1 (c = 0.30; MeOH)
51
194-196
+73.9 (c = 0.29; MeOH)
52
105-108
+26.7 (c = 0.30; MeOH)
53
169-171
+82.3 (c = 0.30; MeOH)
54
298-300
+46.6 (c = 0.31; MeOH)
55
213-215
+75.9 (c = 0.30; MeOH)
56
331-333
+67.9 (c = 0.31; MeOH)
57
295-297
+79.4 (c = 0.30; MeOH)
58
244-246
+16.1 (c = 0.30; MeOH)
59
282-284
+26.4 (c = 0.31; MeOH)
60
235-237
+116.6 (c = 0.29; MeOH)
61
278-280
+14.2 (c = 0.30; MeOH)
62
264-266
+40.5 (c = 0.30; MeOH)
63
128-130
+61.9 (c = 0.32; MeOH)
64
185-187
+81.9 (c = 0.30; MeOH)
65
329-331
+45.9 (c = 0.29; MeOH)
66
242-244
+8.4 (c = 0.31; MeOH)
67
284-286
—
68
—
69
291-293
—
The compounds of the invention were subjected to a series of pharmacological trials which demonstrated their importance as substances with therapeutic activity.
Study of the Transport of Glycine in SK-N-MC Cells Expressing the Native Human Transporter glyt1.
The capture of [ 14 C]glycine is studied in SK-N-MC cells (human neuroepithelial cells) expressing the native human transporter glyt1 by measuring the radioactivity incorporated in the presence or in the absence of the test compound. The cells are cultured in a monolayer for 48 h in plates pretreated with fibronectin at 0.02%. On the day of the experiment, the culture medium is removed and the cells are washed with a Krebs-HEPES ([4-(2-hydroxyethyl)piperazine]1-ethanesulfonic acid) buffer at pH 7.4. After a preincubation of 10 min at 37° C. in the presence either of buffer (control batch), or of test compound at various concentrations, or of 10 mm glycine (determination of the nonspecific capture), 10 μM [ 14 C]glycine (specific activity 112 mCi/mmol) are then added. The incubation is continued for 10 min at 37° C., and the reaction is stopped by 2 washes with a Krebs-HEPES buffer at pH 7.4. The radioactivity incorporated by the cells is then estimated after adding 100 μl of liquid scintillant and stirring for 1 h. The counting is performed on a Microbeta Tri-lux™ counter. The efficacy of the compound is determined by the IC 50 , the concentration of the compound which reduces by 50% the specific capture of glycine, defined by the difference in radioactivity incorporated by the control batch and the batch which received the glycine at 10 mM.
The most active compounds of the invention, in this test, have an IC 50 of the order of 0.001 to 10 μM.
The individual results for some compounds are as follows (IC 50 in μM):
Compound No. 3 0.017 Compound No. 4 0.004 Compound No. 14 0.07 Compound No. 17 0.001 Compound No. 26 0.07
Ex Vivo Study of the Inhibitory Activity of a Compound on the Capture of [ 14 C]Glycine in Mouse Cortical Homogenate
Increasing doses of the compound to be studied are administered by the oral route (preparation by trituration of the test molecule in a mortar in a solution of Tween/Methocel™ at 0.5% in distilled water) or by the intraperitoneal route (dissolution of the test molecule in physiological saline or preparation by trituration in a mortar in a solution of Tween/Methocel™ at 0.5% in water, according to the solubility of the molecule) to 20 to 25 g Iffa Crédo OF1 male mice on the day of the experiment. The control group is treated with the vehicle. The doses in mg/kg, the route of administration and the treatment time are determined according to the molecule to be studied.
After the animals have been humanely killed by decapitation at a given time after the administration, the cortex of each animal is rapidly removed on ice, weighed and stored at 4° C. or frozen at −80° C. (in both cases, the samples are stored for a maximum of 1 day). Each sample is homogenized in a Krebs-HEPES buffer at pH 7.4 at a rate of 10 ml/g of tissue. 20 μl of each homogenate are incubated for 10 min at room temperature in the presence of 10 mM L-alanine and buffer. The nonspecific capture is determined by adding 10 mM glycine to the control group. The reaction is stopped by filtration under vacuum and the retained radioactivity is estimated by solid scintillation by counting on a Microbeta Tri-lux™ counter.
An inhibitor of the capture of [ 14 C]glycine will reduce the quantity of radioligand incorporated into each homogenate. The activity of the compound is evaluated by its ED 50 , the dose which inhibits by 50% the capture of [ 14 C]glycine compared with the control group.
The most potent compounds of the invention, in this test, have an ED 50 of 0.1 to 5 mg/kg by the intraperitoneal route or by the oral route.
Study of the Transport of Glycine in Mouse Spinal Cord Homogenate
The capture of [ 14 C]glycine by the transporter glyt2 is studied in mouse spinal cord homogenate by measuring the radioactivity incorporated in the presence or in the absence of the compound to be studied.
After the animals have been humanely killed (Iffa Credo OF1 male mice weighing 20 to 25 g on the day of the experiment), the spinal cord of each animal is rapidly removed, weighed and stored on ice. The samples are homogenized in a Krebs-HEPES ([4-(2-hydroxyethyl)piperazine]1-ethanesulfonic acid) buffer, pH 7.4, at a rate of 25 ml/g of tissue.
50 μl of homogenate are preincubated for 10 min at 25° C. in the presence of Krebs-HEPES buffer, pH 7.4 and of compound to be studied at various concentrations, or of 10 mM glycine in order to determine the nonspecific capture. The [ 14 C]glycine (specific activity=112 mCi/mmol) is then added for 10 min at 25° C. at the final concentration of 10 μM. The reaction is stopped by filtration under vacuum and the radioactivity is estimated by solid scintillation by counting on a Microbeta Tri-lux™ counter.
The efficacy of the compound is determined by the concentration IC 50 capable of reducing by 50% the specific capture of glycine, defined by the difference in radioactivity incorporated by the control batch and the batch which received the 10 mM glycine.
The most active compounds of the invention in this test have an IC 50 of the order of 0.02 to 10 μM.
The IC 50 of the compound No. 17 is 0.69 μM.
The results of the trials carried out on the compounds of the invention of general formula (I) show that they are inhibitors of the glycine transporters glyt1 which are predominantly present in the brain, and of the glycine transporters glyt2, which are predominantly present in the spinal cord.
The compounds according to the invention can therefore be used for the preparation of medicaments, in particular of medicaments inhibiting the glycine transporters glyt1 and/or glyt2.
Thus, according to another of its aspects, the subject of the invention is medicaments which comprise a compound of formula (I), or an additional salt thereof with a pharmaceutically acceptable acid, or a hydrate or a solvate of the compound of the formula (I).
The compounds of the invention may be used in particular for the treatment of behavioral disorders associated with dementia, psychoses, in particular schizophrenia (deficient form and productive form) and acute or chronic extrapyramidal symptoms induced by neuroleptics, for the treatment of various forms of anxiety, panic attacks, phobias, obsessive-compulsive disorders, for the treatment of various forms of depression, including psychotic depression, for the treatment of disorders due to alcohol abuse or to withdrawal from alcohol, sexual behavior disorders, food intake disorders, and for the treatment of migraine.
Moreover, the compounds of the invention may be used for the treatment of painful muscular contractures in rheumatology and in acute spinal pathology, for the treatment of spastic contractures of medullary or cerebral origin, for the symptomatic treatment of acute and subacute pain of mild to moderate intensity, for the treatment of intense and/or chronic pain, of neurogenic pain and rebellious algia, for the treatment of Parkinson's disease and of Parkinsonian symptoms of neurodegenerative origin or induced by neuroleptics, for the treatment of primary and secondary generalized epilepsy, partial epilepsy with a simple or complex symptomatology, mixed forms and other epileptic syndromes as a supplement to another antiepileptic treatment, or in monotherapy, for the treatment of sleep apnea, and for neuroprotection.
The subject of the present invention is also pharmaceutical compositions containing an effective dose of at least one compound according to the invention, in the form of a pharmaceutically acceptable base or salt or solvate, and in the form of a mixture, where appropriate, with one or more suitable excipients.
Said excipients are chosen according to the pharmaceutical dosage form and the desired mode of administration.
The pharmaceutical compositions according to the invention may thus be intended for oral, sublingual, subcutaneous, intramuscular, intravenous, topical, intratracheal, intranasal, transdermal, rectal or intraocular administration.
The unit forms for administration may be, for example, tablets, gelatin capsules, granules, powders, oral or injectable solutions or suspensions, patches or suppositories. For topical administration, it is possible to envisage ointments, lotions and collyria.
By way of example, a unit form for administration of a compound according to the invention in tablet form may comprise the following components:
Compound according to the invention
50.0 mg
Mannitol
223.75 mg
Croscarmellose sodium
6.0 mg
Corn starch
15.0 mg
Hydroxypropylmethylcellulose
2.25 mg
Magnesium stearate
3.0 mg
Said unit forms contain doses in order to allow a daily administration of 0.01 to 20 mg of active ingredient per kg of body weight, according to the galenic form.
There may be specific cases where higher or lower dosages are appropriate; such dosages do not depart from the scope of the invention. According to the usual practice, the dosage appropriate for each patient is determined by the doctor according to the mode of administration, the weight and the response of said patient.
The present invention, according to its other aspects, also relates to a method for treating the pathologies indicated above, which comprises the administration, to a patient, of an effective dose of a compound according to the invention, or one of its pharmaceutically acceptable salts or the hydrates or solvates.
Although the invention has been illustrated by certain of the preceding examples, it is not to be construed as being limited thereby; but rather, the invention encompasses the generic area as hereinbefore disclosed. Various modifications and embodiments can be made without departing from the spirit and scope thereof.
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The invention relates to use of compositions in therapeutics containing a compound having general formula (I):
Wherein R, R1, R2, X and n are as described herein.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a vacuum station for storing sewage from a vacuum sewage pipe and then delivering the sewage to a sewage treatment plant or the like, and to a method for operating such vacuum station.
2. Description of the Related Art
Heretofore, there has been known a vacuum sewage system which includes a vacuum station having a collection tank and delivers sewage stored in the collection tank to a sewage treatment plant or the like by a pump in the vacuum station. The vacuum station is the equipment in which vacuum serving as a driving force for collecting sewage is created, and the collected sewage is temporarily stored and then transported to a sewage treatment plant, a sewage relay pump station, or a gravity trunk sewer. The vacuum station comprises a vacuum generating apparatus for generating vacuum, a collection tank for temporarily storing collected sewage, a sewage pump for transporting the sewage from the collection tank, and a controller for controlling these equipment.
As a form of vacuum station, there has been a vacuum station in which equipment including a collection tank, a sewage pump, a vacuum pump and the like is provided on the first basement of independently reinforced concrete construction (first story and first basement), and equipment including a controller, a feed tank, a deodorizing device and the like is provided on the first story of the independently reinforced concrete construction. However, this type of vacuum station causes a clogging problem of the sewage pump by foreign matter and a problem of high equipment cost.
On the other hand, in a small-scale vacuum sewage system (for example, expected to be used for about 3 hundred residents), there has been known a unit-type vacuum station which incorporates an ejector in place of a vacuum pump and a sewage circulating pump installed in a manhole because the facility structure is simple and a site for the vacuum station is not required. The ejector-type vacuum station has the advantage of eliminating the need for a vacuum pump, and omitting a sewage pump because a collecting tank without an enclosed structure allows the collected sewage to be discharged therefrom by gravity, thus simplifying the facility structure. However, there is a possibility that the ejector is clogged with foreign matter because an ejector nozzle allows only small-diameter foreign matter to pass therethrough, and the ejector has a low ultimate pressure ranging from −60 kPa to −50 kPa and a low operating efficiency.
Therefore, in a small-scale vacuum station, there has been demanded a vacuum station which is hardly clogged with foreign matter in sucking and discharging sewage, requires a reduced facility cost, and has a good operating efficiency.
For example, in the vacuum sewage system disclosed in Japanese Patent Publication No. 2684526, a single roots-type multistage vacuum pump is used, and normal rotation and reverse rotation of such vacuum pump are automatically controlled, whereby suction of sewage into a collection tank and discharge of the sewage from the collection tank are performed alternately. In this vacuum sewage system, since sewage can be collected or discharged without using a sewage pump, clogging of the system caused by foreign matter hardly occurs, an ultimate pressure is high and operating efficiency is also high because the vacuum pump is employed.
However, in the vacuum sewage system disclosed in Japanese Patent Publication No. 2684526, since only a single collection tank and a single roots-type multistage vacuum pump are provide, if the vacuum pump breaks down, then collection and discharge of sewage cannot be performed. Since the vacuum sewage system is used for the public, it is essential to ensure the safety to prevent the entire system from malfunctioning owing to a breakdown of the vacuum pump, or the like.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a vacuum station in which clogging by foreign matter is unlikely to occur in sucking and discharging sewage, facility costs are reduced, and operating efficiency and stability in system operation are increased.
Another object of the present invention is to provide a method for operating the above vacuum station.
According to a first aspect of the present invention, there is provided a vacuum station comprising: a collection tank for collecting sewage; a plurality of vacuum pumps for depressurizing and pressurizing an interior of the collection tank; a sewage inlet pipe connected to the collection tank; a sewage discharge pipe connected to the collection tank; and a controller for controlling the plurality of vacuum pumps; wherein the controller controls at least one of the vacuum pumps so as to rotate in normal direction so that the interior of the collection tank is depressurized to collect sewage into the collection tank through the sewage inlet pipe, and at least one of the vacuum pumps so as to rotate in reverse direction when the sewage in the collection tank reaches a predetermined sewage level so that the interior of the collection tank is pressurized to discharge the sewage from the collection tank through the sewage discharge pipe.
According to the present invention, by operating the vacuum pump so as to rotate in reverse direction, the interior of the collection tank is pressurized to discharge sewage from the collection tank, and hence a sewage pump can be omitted and clogging caused by foreign matter can be avoided. Further, by using a plurality of vacuum pumps, the safety of the operation of the apparatus can be enhanced. Furthermore, since the vacuum pump is employed in the system, the ultimate pressure is high and the operation efficiency is high.
In a preferred aspect of the present invention, the vacuum pump comprises a roots-type vacuum pump.
The roots-type vacuum pump comprises a casing and a pair of roots rotors, and each of the roots rotors has a plurality of lobes. As the roots rotors rotate, a gas which is drawn from an inlet port into the casing is confined between the roots rotors and the casing and delivered toward an outlet port.
In a preferred aspect of the present invention, a power control panel having the controller therein and the plurality of vacuum pumps are unitized to form an integrated unit structure, and the collection tank is installed in a manhole to form an integrated unit structure.
According to the present invention, since a power control panel and a plurality of vacuum pumps are unitized to form an integrated unit structure, and a collection tank is incorporated in a manhole to form an integrated unit structure, the facility structure is simplified and a site for the building is not required, unlike the conventional vacuum-pump type vacuum station.
In a preferred aspect of the present invention, the controller has an operating speed control device for increasing an operation speed of each of the vacuum pumps.
According to the present invention, since an operating speed control device such as an inverter for increasing the operational speed of the vacuum pump is provided in the controller, the speed increasing operation of the vacuum pump can be performed by the operating speed control device. Further, by using a PLC, a small-sized control panel can be constructed, and setting of operation range of the vacuum pump can be varied, and thus the system can cope with wide range of design conditions and the system can operated efficiently.
According to a second aspect of the present invention, there is provided a method for operating a vacuum station, comprising: the vacuum station comprising: a collection tank for collecting sewage; a plurality of vacuum pumps for depressurizing and pressurizing an interior of the collection tank; a sewage inlet pipe connected to the collection tank; a sewage discharge pipe connected to the collection tank; and the method comprising: operating at least one of the vacuum pumps so as to rotate in normal direction so that the interior of the collection tank is depressurized to collect sewage into the collection tank through the sewage inlet pipe; and operating at least one of the vacuum pumps so as to rotate in reverse direction when the sewage in the collection tank reaches a predetermined sewage level so that the interior of the collection tank is pressurized to discharge the sewage from the collection tank through the sewage discharge pipe.
According to the present invention, a sewage pump can be omitted and clogging caused by foreign matter can be avoided. Further, by using a plurality of vacuum pumps, the safety of the operation of the apparatus can be enhanced. Furthermore, since the vacuum pump is employed in the system, the ultimate pressure is high and the operation efficiency is high.
In a preferred aspect of the present invention, wherein a sewage collecting operation mode for operating the at least one of the vacuum pumps so as to rotate in normal direction so that the interior of the collection tank is depressurized to collect the sewage into the collection tank through the sewage inlet pipe, and a sewage discharging operation mode for operating the at least one of the vacuum pumps so as to rotate in reverse direction when the sewage in the collection tank reaches the predetermined sewage level so that the interior of the collection tank is pressurized to discharge the sewage from the collection tank through the sewage discharge pipe are performed alternately.
In a preferred aspect of the present invention, the vacuum pump comprises a roots-type vacuum pump.
In a preferred aspect of the present invention, the plurality of vacuum pumps are operated alternately in the sewage collecting operation mode.
According to the present invention, since the vacuum pumps which are to be operated in the sewage collecting operation mode can be switched alternately, the safety of the operation of the apparatus can be enhanced.
In a preferred aspect of the present invention, after one of the vacuum pumps is operated for a predetermined period of time, when the degree of vacuum in the collection tank does not reach a predetermined value, another vacuum pump is started to operate simultaneously with the one of the vacuum pumps.
According to the present invention, only one of the vacuum pumps is not excessively used, but all of the vacuum pumps are evenly used, and hence the safety of the operation of the apparatus can be enhanced.
In a preferred aspect of the present invention, when switching between the sewage collecting operation mode and the sewage discharging operation mode is performed, the vacuum pump which is in operation is operated so as to rotate in a direction opposite to the direction in which the vacuum pump has been rotated before the switching.
According to the present invention, the time required for pressure fluctuation at the time of switching the mode can be shortened.
The above and other objects, features, and advantages of the present invention will be apparent from the following description when taken in conjunction with the accompanying drawings which illustrates preferred embodiments of the present invention by way of example.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view showing an overall structure of a vacuum station according to an embodiment of the present invention;
FIG. 2 is a diagram showing the manner in which the vacuum station is operated;
FIG. 3 is a table showing an example of a list of operating range of a vacuum pump, allowable pressure loss and collectable population; and
FIGS. 4A and 4B are schematic views showing the manner in which operation of vacuum pumps 40 - 1 and 40 - 2 is controlled using a vacuum valve unit 100 provided at an end of the system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A vacuum station according to embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 is a schematic view showing an overall structure of a vacuum station according to an embodiment of the present invention. As shown in FIG. 1 , a vacuum station comprises a collection tank 20 installed in a manhole 10 , two vacuum pumps 40 - 1 and 40 - 2 installed on the ground, a power control panel 50 which is unitized together with the vacuum pumps 40 - 1 and 40 - 2 , and a deodorizing device 60 for deodorizing exhaust from the vacuum pumps 40 - 1 and 40 - 2 .
Next, components of the vacuum station will be described in detail.
The manhole 10 comprises a normal built-up manhole which is laid underground. The collection tank 20 comprises a single tank, and a sewage inlet pipe (vacuum sewage pipe) 23 is connected to the collection tank 20 through a check valve 21 , and a sewage discharge pipe 27 is connected to the collection tank 20 through a check valve 25 . Further, a level sensor 29 for detecting a sewage level in the manhole 10 is attached to the collection tank 20 . The collection tank 20 comprising a single tank is incorporated in the manhole 10 , whereby the collection tank 20 is unitized. On the other hand, the collection tank 20 and the two vacuum pumps 40 - 1 and 40 - 2 are connected to each other by supply and discharge pipes 31 , the two vacuum pumps 40 - 1 and 40 - 2 and the deodorizing device 60 are connected to each other by supply and discharge pipes 33 . The two vacuum pumps 40 - 1 and 40 - 2 are connected to these supply and discharge pipes 31 and 33 in parallel. A gate valve (motor-driven gate valve) 34 and a pressure sensor 35 are attached to the supply and discharge pipe 31 at the location near the vacuum pump 40 - 1 , and a gate valve (motor-driven gate valve) 34 and a pressure sensor 35 are attached to the supply and discharge pipe 31 at the location near the vacuum pump 40 - 2 . Further, a silencer 41 is attached to the supply and discharge pipe 33 to which the vacuum pump 40 - 1 is connected, and a silencer 41 is attached to the supply and discharge pipe 33 to which the vacuum pump 40 - 2 is connected. The vacuum pumps 40 - 1 and 40 - 2 comprise a roots-type vacuum pump (roots-type multistage vacuum pump) so that the vacuum pumps 40 - 1 and 40 - 2 can be operated in normal rotation and in reverse rotation.
The power control panel 50 comprises a control panel having a controller 55 for controlling operation of the vacuum station, and is disposed at upper part of a cabinet 51 . The two vacuum pumps 40 - 1 and 40 - 2 are housed in lower part of the cabinet 51 , whereby the power control panel 50 and the vacuum pumps 40 - 1 and 40 - 2 are unitized to achieve space savings. In order to enable the power control panel 50 and the two vacuum pumps 40 - 1 and 40 - 2 to be a unitized structure, the structure is not limited to the structure in which the cabinet 51 is used, but various modification may be made. For example, the two vacuum pumps 40 - 1 and 40 - 2 maybe installed in the space defined at the lower part of the power control panel (self-support power control panel) 50 , thereby achieving such unitized structure.
Detection signals from the level sensor 29 and the pressure sensor 35 are inputted into the controller 55 , and operation of the two vacuum pumps 40 - 1 and 40 - 2 and various valves is controlled on the basis of the detection signals. Further, the controller 55 has an operating speed control device such as an inverter for controlling operating speeds of the vacuum pumps 40 - 1 and 40 - 2 , a PLC (Programmable Logic Controller), and the like. Specifically, the two vacuum pumps 40 - 1 and 40 - 2 are controlled so as to obtain respective optimum rotational speeds in accordance with their operating conditions by the operating speed control device such as an inverter. For example, in a case where loads applied to the vacuum pump 40 -l or 40 - 2 are small, the rotational speed of the vacuum pump 40 - 1 or 40 - 2 is increased (speed increasing operation), and in a case where loads applied to the vacuum pump 40 - 1 or 40 - 2 are large, the rotational speed of the vacuum pump 40 - 1 or 40 - 2 is decreased (speed decreasing operation).
The deodorizing device 60 is connected to one end of the supply and discharge pipe 33 , and the odor of exhaust drawn in from the collection tank 20 at the time of evacuation by the vacuum pumps 40 - 1 and 40 - 2 is removed by the deodorizing device 60 comprising activated carbon or the like. The deodorizing deice 60 allows a gas to pass therethrough at the time of evacuation as well as suction.
Next, a method for controlling operation of the vacuum station will be described below.
FIG. 2 is a diagram showing the manner in which the vacuum station is operated with the lapse of time. In this operating method, a sewage collecting operation mode in which the vacuum pump 40 - 1 or 40 - 2 is rotated in normal direction to depressurize the interior of the collection tank 20 and collect sewage into the collection tank 20 and a sewage discharging operation mode in which the vacuum pump 40 - 1 or 40 - 2 is rotated in reverse direction to pressurize the interior of the collection tank 20 and discharge the sewage from the collection tank 20 are performed alternately. This operating method will be described below with reference to FIGS. 1 and 2 . In this operation control, the vacuum pumps 40 - 1 and 40 - 2 , the gate valves 34 , and the like are operated on the basis of the detection signals inputted from the various sensors into the controller 55 shown in FIG. 1 .
Specifically, in the sewage collecting operation mode, when the degree of vacuum in the collection tank 20 is lowered to a predetermined value (for example, −60 kPa), one of the vacuum pumps 40 - 1 and 40 - 2 is started to operate. Thereafter, when the degree of vacuum in the collection tank 20 increases and reaches a predetermined value (for example, −70 kPa), operation of the vacuum pump is stopped. Operation/stop of the vacuum pump 40 - 1 and operation/stop of the vacuum pump 40 - 2 are performed alternately. Specifically, in FIG. 2 , first, the vacuum pump 40 - 2 is operated (part a), then the vacuum pump 40 - 1 is operated (part b), and then the vacuum pump 40 - 2 is operated (part c). Thus, the degree of vacuum in the collection tank 20 is kept in the range of −60 kPa to −70 kPa at all times, and sewage flows into the collection tank 20 from the sewage inlet pipe 23 and is stored in the collection tank 20 . While the vacuum pump 40 - 1 or the vacuum pump 40 - 2 is operated (including normal rotation and reverse rotation), the gate valve 34 corresponding to the vacuum pump which is in operation is opened. The gate valve 34 corresponding to the vacuum pump which is not in operation is closed.
After a certain period of time (for example, 30 minutes) has passed after starting of operation of the vacuum pump 40 - 1 or 40 - 2 , if the collection tank 20 does not reach a predetermined degree of vacuum (for example, −70 kPa), then another vacuum pump 40 - 2 or 40 - 1 is simultaneously operated, whereby the system is controlled to allow the collection tank to reach the predetermined degree of vacuum.
In this manner, the sewage collecting operation mode continues to be performed, and when the sewage level in the collection tank 20 reaches a predetermined level (H.W.L), the sewage collecting operation mode is switched to the sewage discharging operation mode in which one of the vacuum pumps 40 - 1 and 40 - 2 is started to rotate in reverse direction. In an example shown in FIG. 2 , the vacuum pump 40 - 2 which has been rotating in normal direction when the sewage level in the collection tank 20 reaches the predetermined sewage level (H.W.L) is started to rotate in reverse direction. Specifically, when the vacuum pump 40 - 2 is operated, the gate valve 34 corresponding to the vacuum pump 40 - 2 is opened. Therefore, if the vacuum pump 40 - 2 in operation is rotated in reverse direction, the reverse rotation of the vacuum pump 40 - 2 is sufficient to perform the function of the system without the need for opening or closing the gate valve 34 . Thus, the operation mode can be switched quickly because the time required to open or close the gate valve 34 can be saved. Therefore, when the sewage level in the collection tank 20 reaches the predetermined sewage level (H.W.L) in such a state that any of the vacuum pumps 40 - 1 and 40 - 2 is not operated, the vacuum pump 40 - 1 or 40 - 2 which has not been rotating in normal direction just before the sewage level in the collection tank 20 reaches the predetermined sewage level should be operated so as to rotate in reverse direction.
As described above, when the vacuum pump 40 - 2 is operated so as to rotate in reverse direction, the interior of the collection tank 20 is restored to atmospheric pressure promptly, and is then pressurized to positive pressure. When positive pressure in the collection tank 20 reaches a predetermined value, sewage in the collection tank 20 is discharged from the sewage discharge pipe 27 by application of positive pressure. The discharge of the sewage from the collection tank 20 is performed without using a sewage pump, and foreign matter included in the sewage passes through only the sewage discharge pipe 27 and the check valve 25 , and hence clogging by foreign matter is unlikely to occur.
When the sewage level in the collection tank 20 is lowered to a predetermined sewage level (L.W.L) by discharge of the sewage, the sewage discharging operation mode is switched to the sewage collecting operation mode again, and one of the vacuum pumps is started to rotate in normal direction. In the example shown in FIG. 2 , the vacuum pump 40 - 2 is started to rotate in normal direction. Specifically, in this case, if the vacuum pump 40 - 2 which has rotated in reverse direction is switched to the normal rotation (part d), the gate valve 34 is not required to be opened or closed in the same manner as the above, and hence switching from positive pressure to negative pressure can be performed quickly. Thus, this operation method is suitable. Thereafter, in the same manner as the above, collection of sewage into the collection tank 20 and discharge of the sewage from the collection tank 20 are performed alternately by switching between the sewage collecting operation mode and the sewage discharging operation mode.
On the other hand, exhaust from the vacuum pump 40 - 1 or 40 - 2 is led to the deodorizing device 60 through the supply and discharge pipe 33 shown in FIG. 1 and deodorized in the deodorizing device 60 , and is then discharged to the atmosphere. In the case where the vacuum pumps 40 - 1 and 40 - 2 comprise a roots-type vacuum pump, the exhaust has a high temperature at the time of vacuum operation, and thus the supply and discharge pipe 33 and the deodorizing device 60 tend to have a high temperature. However, if the deodorizing device 60 comprises activated carbon, generally the deodorizing device 60 cannot exhibit deodorizing performance at a temperature of about 40° C. or higher. Therefore, conventionally, a cooling device is provided at the exhaust side of the vacuum pump 40 - 1 or 40 - 2 to lower the temperature of the exhaust, and the exhaust whose temperature has been lowered is allowed to flow into the deodorizing device. However, in this vacuum station, the vacuum pump which is rotatable in normal and reverse directions is used as the vacuum pumps 40 - 1 and 40 - 2 , and a gas is allowed to pass through the deodorizing device 60 at the time of evacuation and at the time of suction. Therefore, outer air is allowed to pass through the deodorizing device 60 and the supply and discharge pipe 33 to produce a cooling effect (achieving ambient temperature) at the reverse rotation of the vacuum pump (when sewage is discharged from the collection tank 20 ). Then, the cooling device is unnecessary, thus lowering the cost of the system and downsizing the system.
In this vacuum station, by switching the rotational direction of the vacuum pump 40 - 1 or 40 - 2 connected to the collection tank 20 comprising a single tank, “sewage collection” and “sewage discharge” are alternately repeated, and hence it is necessary to make the time for sewage discharge as short as possible and to make preparations for sewage collection. Particularly, since the pressure in the collection tank 20 becomes atmospheric pressure, i.e. positive pressure at the time of sewage discharge, if the pressure in the collection tank 20 reaches a predetermined vacuum pressure as soon as possible, then the time for sewage discharge can be shortened. Therefore, in this vacuum station, as described above, the controller 55 has the operating speed control device such as an inverter for increasing the operating speed of the vacuum pumps 40 - 1 and 40 - 2 , and hence the time for sewage discharge (particularly, time t 2 , t 3 and t 5 in FIG. 2 ) can be shortened. In FIG. 2 , t 1 represents the time when pressure in the collection tank 20 is changed from vacuum pressure to atmospheric pressure, t 2 represents the time when pressure in the collection tank 20 is changed from atmospheric pressure to positive pressure (positive pressure rise time), and t 3 represents the time for sewage discharge. Further, t 4 represents the time when pressure in the collection tank 20 is changed from positive pressure to atmospheric pressure, t 5 represents the time when pressure in the collection tank 20 is changed from atmospheric pressure to vacuum pressure (vacuum rise time), and T represents the operating time of the vacuum pump, i.e., the sum of t 1 , t 2 , t 3 , t 4 and t 5 .
Conventionally, the operating vacuum degree of the vacuum pump is in the range of −60 kPa to −70 kPa. However, in this vacuum station, setting of the operating vacuum degree can be changed in accordance with conditions. Next, some setting examples will be described.
Setting Example 1
Setting Example According to Topographical Conditions
In the construction plan of a small-scale vacuum sewage system, expected to be used for about 3 hundred residents, to which the present invention is applied, the houses in the area where the system is installed are located under different conditions. Some houses are located sparsely in a wide area, and others are located densely in a small area. In order to cope with conditions of location flexibly, setting of operating vacuum degree of the vacuum pump is changed and the vacuum pump is controlled on the basis of the setting. The setting of the operating vacuum degree of the vacuum pump tends to affect the operating situations of the system as follows:
1. As the operating vacuum degree of the vacuum pump is higher, the flow rate of air is smaller.
2. As the operating vacuum degree of the vacuum pump is higher, allowable pressure loss which is used for designing the piping of the vacuum sewage system is larger.
Therefore, according to control of the present invention, operating range to be a base is set in accordance with conditions of location on the basis of collectable population of design region and calculation results of loss of a vacuum sewage pipe. An example of the manner in which collectable population and allowable pressure loss are changed according to operating range of the vacuum pump is shown in FIG. 3 . As shown in this example, if the degree of vacuum in the operating range is set to a high value in a wide area where houses are located sparsely, and a low value in a small area where houses are located densely, then the system can cope with various topographical conditions.
Setting Example 2
Setting Example According to the Amount of Sewage
In a small-scale plan, since the amount of sewage generated is fluctuated largely depending on time zones, setting of operating range is changed according to the time zones, thereby achieving an economical operation of the system. Specifically, the operation of the vacuum pump is controlled so that the operating range of the vacuum pump is changed to be adjusted for a time zone when the amount of sewage is large in the morning and evening and a time zone when the amount of sewage is small at night. For example, in a time zone when the amount of sewage is large (for example, 6:00–10:00, 18:00–22:00), the degree of vacuum of starting operation of the vacuum pump is set to a high value (for example, −60 kPa) In a time zone when the amount of sewage is small (for example, 1:00–6:00, 13:00–18:00), the degree of vacuum of starting operation of the vacuum pump is set to a low value (for example, −50 kPa). In other time zone (for example, 10:00–13:00, 22:00–1:00), the degree of vacuum of starting operation of the vacuum pump is set to an intermediate value (for example, −55 kPa).
The operation control for ON-OFF of the vacuum pumps 40 - 1 and 40 - 2 is normally performed by the degree of vacuum in the collection tank 20 , as described above. However, in many cases, in a small-scale vacuum sewage system, a total extension line to the vacuum valve unit located at the end of the line is short. Therefore, as shown in FIGS. 4A and 4B , a small-sized vacuum station ST according to the present invention and the vacuum valve unit 100 located at the end of the line are connected to each other by an aerial signal line 110 (see FIG. 4A ) or an underground signal line 110 (see FIG. 4B ), whereby operation control of the vacuum pumps 40 - 1 and 40 - 2 may be performed by the pressure (pressure in the vacuum sewage pipe 23 transmitted from a pressure transmitter 103 ) of the vacuum valve unit 100 provided at the end of the line. According to the present invention, the rotational speeds of the vacuum pumps are controlled using the operating speed control device of the controller 55 so that the pressure of the vacuum valve unit 100 provided at the end of the line is kept at the degree of vacuum required for operation of the vacuum valve 101 . In this case, the following two control methods are exemplified. If there are a plurality of systems including the vacuum sewage pipes 23 , the pressure of the vacuum valve unit 100 provided at the end of each system should be detected and used for controlling.
Method 1
Starting conditions (for example, if the degree of vacuum becomes −25 kPa or less, the vacuum pump 40 - 1 or 40 - 2 is started to operate) according to the pressure of the terminal vacuum valve unit 100 are added to a control pattern based on the pressure of the collection tank 20 .
Method 2
Setting of the pressure of the terminal vacuum valve unit 100 is in the range of, for example, −25 kPa to −35 kPa, and the vacuum pump 40 - 1 or 40 - 2 is operated or stopped so that the pressure is kept within the setting range. During operation, the differential pressure between the pressure of the terminal vacuum valve unit 100 and the pressure of the collection tank 20 is used as a parameter, and the vacuum pump 40 - 1 or 40 - 2 is operated such that if the differential pressure increases, the rotational speed of the vacuum pump is increases and if the differential pressure decreases, the rotational speed of the vacuum pump decreases.
In the above embodiments, there is no limit to the number of vacuum pumps, and three or more of vacuum pumps may be provided.
Although certain preferred embodiments of the present invention have been shown and described in detail, it should be understood that various changes and modifications may be made therein without departing from the scope of the appended claims.
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A vacuum station is used for storing sewage from a vacuum sewage pipe and then delivering the sewage to a sewage treatment plant or the like. The vacuum station includes a collection tank for collecting sewage, a plurality of vacuum pumps for depressurizing and pressurizing an interior of the collection tank, and a controller for controlling the plurality of vacuum pumps. The controller controls at least one of the vacuum pumps so as to rotate in normal direction so that the interior of the collection tank is depressurized to collect sewage into the collection tank, and at least one of the vacuum pumps so as to rotate in reverse direction when the sewage in the collection tank reaches a predetermined sewage level so that the interior of the collection tank is pressurized to discharge the sewage from the collection tank.
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BACKGROUND
The present disclosure includes examples of tissue fixation devices. Specifically, the tissue fixation devices described herein may be used with a uterine manipulator to grasp, retain and release cervical tissue. It will be appreciated that the disclosed embodiments may have applications outside of uterine manipulation, and may be used on other bodily tissues.
In some surgical procedures, it is desirable to control the position and orientation of an organ, such as a uterus, to help the surgeon operate on the uterus or on other parts of the body adjacent to the uterus. Uterine manipulator devices can be used to position and orient a uterus during surgery. U.S. Patent Application Publication No. US2012/0109147 discloses an example uterine manipulator system. Typical uterine manipulator systems consist of a bell-housing or cup shaped member that fits around the cervix and a rod member that is inserted through the cervix and into the uterus. The bell housing can be sized and shaped to compress the cervical tissue against the rod member to help the surgeon grasp the cervix and manipulate the position and orientation of the uterus. The bell housing can also provide a cutting guide to facilitate incision placement, for example colpotomy incisions and incisions requiring a safe distance from the ureters and uterine arteries. However, if the cervical tissue fixation within the bell housing is insufficient, a uniform colpotomy incision is difficult to achieve. Furthermore, the risk of damaging surrounding tissues, such as the ureters and uterine arteries, will increase if the tissue fixation is insufficient. The compressive forces imparted to the cervical tissue between the bell housing and the rod member are usually not sufficient enough to tightly grasp the cervix and ensure safe incision placement. Accordingly, it has been known to include a balloon in combination with the rod member which can be inflated inside of the uterus to provide additional pressure on the cervical tissue between the balloon and the bell housing to force the cervical tissue down into the bell housing and increase the gripping force of the bell housing on the cervix. However, the internal balloon may not create optimal tissue fixation, especially in patients with anatomical abnormalities, rigid tissues, scar tissue, and the like. Additionally, the balloon may leak or become accidentally “nicked” by other surgical instruments during the surgical procedure. This may result in loss of tissue fixation that can delay and complicate surgical incisions and/or removal of the uterus through the vagina in the case of a hysterectomy procedure. Moreover, it may not be desirable to use a balloon inside of a uterus containing cancerous cells, because the cancerous cells can be broken loose by the balloon and spread to other parts of the body. Sufficient tissue fixation is typically not achieved with a balloon, as is evidenced by workarounds currently used by many surgeons. For example, surgeons are known to use adjunctive stitches through the cervix which are then tied to the instrument to increase tissue fixation. This workaround adds additional steps to the surgery and further complicates things by making it difficult to quickly remove the bell housing and/or uterine manipulator from the patient if an emergency situation arises, such as the need to defibrillate the patient's heart.
Accordingly, it is desirable to provide a device that achieves reliable tissue fixation, with or without a balloon, that will last throughout the entire surgical procedure and that will not be compromised by rigid tissue, anatomical abnormalities, scar tissue, cancerous tissue, or the like. In some cases, it may also be desirable to generate tissue fixation close to certain incision sites, such as the colpotomy incision site, to increase the control, placement and precision of the incision. It is also desirable to provide a device that employs a simple actuation mechanism to quickly and easily engage and disengage the tissue fixation mechanism during surgery.
An example of the present technology disclosed herein includes a tissue fixation assembly shaped to be attached to a uterine manipulator. The assembly includes a housing, a fixation member carriage with deployable fixation members, and a cap. The fixation member carriage and fixation members are captured between the housing and the cap. In one example, a suture is attached to the fixation member carriage and is actuatable to move the fixation member carriage to deploy or retract the fixation members. The assembly may be inserted into a vagina and receive cervical tissue within the housing. The fixation members may then be deployed inwardly from the housing to grip the cervical tissue. The fixation members may also be locked in the deployed position to maintain the grip on the tissue. The fixation members may also be easily retracted to release the tissue and remove the device as needed.
Those of skill in the art will recognize that the following description is merely illustrative of the principles of the disclosure, which may be applied in various ways to provide many different alternative embodiments and may be applicable outside the fields of surgery or medical devices. While the present disclosure is made in the context of tissue fixation related to the cervix, for the purposes of illustrating the concepts of the design, it is contemplated that the present design and/or variations thereof may be suited to other uses for grasping any bodily tissue. Moreover, the devices and methods set forth herein may be used in open, percutaneous, and/or minimally invasive procedures.
All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
Standard medical planes of reference and descriptive terminology are employed in this specification. A sagittal plane divides a body into right and left portions. A mid-sagittal plane divides the body into equal right and left halves. A coronal plane divides a body into anterior and posterior portions. A transverse plane divides a body into superior and inferior portions. Anterior means toward the front of the body. Posterior means toward the back of the body. Superior means toward the head. Inferior means toward the feet. Medial means toward the midline of the body. Lateral means away from the midline of the body. Axial means toward a central axis of the body. Abaxial means away from a central axis of the body. Ipsilateral means on the same side of the body. Contralateral means on the opposite side of the body. These descriptive terms may be applied to an animate or inanimate body.
BRIEF DESCRIPTION OF THE DRAWINGS
Various embodiments of the present disclosure will now be discussed with reference to the appended drawings. It will be appreciated that these drawings depict only typical examples of the present disclosure and are therefore not to be considered limiting of its scope.
FIG. 1 is a perspective view of a tissue fixation device according to one example of the present disclosure having a housing, a cap, and deployable fixation members;
FIG. 2 is a side view of the tissue fixation device of FIG. 1 ;
FIG. 3A is a top view of the tissue fixation device of FIG. 1 with the fixation members in a retracted position; FIG. 3B is a top view of the tissue fixation device of FIG. 1 with the fixation members in a deployed position;
FIG. 4 is an exploded view of the tissue fixation device of FIG. 1 ;
FIG. 5 is a top exploded view of the tissue fixation device of FIG. 1 ;
FIG. 6 is a bottom exploded view of the tissue fixation device of FIG. 1 ;
FIG. 7A is a top view of the housing and fixation member carriage assembly of the tissue fixation device of FIG. 1 with the fixation members in a retracted position and dashed lines indicating suture paths under the fixation member carriage assembly; FIG. 7B is a top view of the housing and fixation member carriage assembly of the tissue fixation device of FIG. 1 with the fixation member in a deployed position;
FIG. 8 is a side cross-sectional view of the tissue fixation device of FIG. 1 with the fixation members in a retracted position, taken along section line 8 - 8 in FIG. 7A ;
FIG. 9 is a perspective view of another tissue fixation device in accordance with the present disclosure with the tissue fixation members in the deployed configuration;
FIG. 10 is a perspective view of the tissue fixation device of FIG. 9 with the tissue fixation members in the retracted configuration;
FIG. 11 is an exploded view of the tissue fixation device of FIG. 9 ;
FIG. 12 is a perspective view of another tissue fixation device in accordance with the present disclosure with the tissue fixation member in the deployed configuration;
FIG. 13 is a perspective view of the tissue fixation device of FIG. 12 with the tissue fixation member in the retracted configuration;
FIG. 14 is a perspective view of another tissue fixation device in accordance with the present disclosure with the tissue fixation members in the deployed configuration;
FIG. 15 is a perspective view of the tissue fixation device of FIG. 14 with the tissue fixation members in the retracted configuration;
FIG. 16 is a perspective view of another tissue fixation device in accordance with the present disclosure with the tissue fixation members in the deployed configuration;
FIG. 17 is another perspective view of the tissue fixation device of FIG. 16 with the tissue fixation members in the deployed configuration;
FIG. 18 is a perspective view of the tissue fixation device of FIG. 16 with the tissue fixation members in the retracted configuration;
FIG. 19 is a perspective view of another tissue fixation device in accordance with the present disclosure with the tissue fixation members in the deployed configuration;
FIG. 20 is a perspective view of the tissue fixation device of FIG. 19 with the tissue fixation members in the retracted configuration;
FIG. 21 is a perspective view of a tissue fixation device having a cap attached by a snap fit, the device in a deployed configuration;
FIG. 22 is a top-down view of the tissue fixation device of FIG. 21 ;
FIG. 23 is an exploded view of the tissue fixation device of FIG. 21 showing a housing, fixation member carriage, fixation members, and cap of the device;
FIG. 24 is a perspective view of the cap of FIG. 23 ;
FIG. 25 is a side cross-sectional view of the tissue fixation device of FIG. 21 ;
FIG. 26 is a perspective view of a tissue fixation device having a cap attached by a twisting fit, the device in a deployed configuration;
FIG. 27 is a top-down view of the tissue fixation device of FIG. 26 ;
FIG. 28 is an exploded view of the tissue fixation device of FIG. 27 showing a housing, fixation member carriage, fixation members, and cap of the device;
FIG. 29 is a perspective view of the cap of FIG. 28 ;
FIG. 30 is a side cross-sectional view of the tissue fixation device of FIG. 26 ;
FIG. 31A is a perspective view of another embodiment of a tissue fixation device having a housing, a fixation member carriage assembly and a cap, with tissue fixation members in a retracted configuration; FIG. 31B is a perspective view of the device of FIG. 31B with the tissue fixation members in a deployed configuration; FIG. 31C is a side view of the device of FIG. 31A ;
FIG. 32 is an exploded view of the device of FIG. 31A ;
FIG. 33 is a perspective view of a cap of the device of FIG. 31A ;
FIG. 34 is a side cross-sectional view of the tissue fixation device of FIG. 31A ;
FIG. 35A is an inferior view of the cap and fixation members of the device of FIG. 31A ; FIG. 35B is an inferior view of the cap and fixation members of the device in the configuration of FIG. 32A ;
FIG. 36A is a superior view of a housing, carriage assembly and sutures of the device of FIG. 31A ; FIG. 36B is a superior view of the housing, carriage assembly and sutures in the deployed configuration of FIG. 32A ; dashed lines indicate the approximate paths of the sutures in a passage between the carriage assembly and the housing;
FIG. 37A is a top-down view of a fixation member captured in a fixation member carriage; FIG. 37B is a partial side cross sectional view of the fixation member carriage and fixation member of FIG. 37A and the cap of FIG. 31A ;
FIG. 38A is a perspective partial view of a fixation member carriage with a capture feature; FIG. 38B is an exploded view of the fixation member and the fixation member carriage of FIG. 38A ;
FIG. 39 is a side partial cross sectional view of a fixation member captured in a fixation member carriage;
FIG. 40A is a side view of a needle, the needle curving into the page; FIG. 40B is a top view of the needle of FIG. 40A ; FIG. 40C is a side cross-sectional view of the needle of FIG. 40A captured in a needle carriage;
FIG. 41 is a partial perspective view of a needle captured in a needle carriage;
FIG. 42A is a perspective view of a needle carriage having several pins; FIG. 42B is a partial view of a needle mounted to the carriage of FIG. 42A ; FIG. 42C is a top view of the needle of FIG. 42B ; FIG. 42D is a side view of the needle of FIG. 42B ;
FIG. 43A is a side view of a needle; FIG. 43B is a transverse cross section of the needle of FIG. 43A taken along line A-A
FIG. 44 is a partial side view of a needle captured in a carriage;
FIG. 45A is a top view of a carriage with a plurality of needles and capture features; FIG. 45B is a top view of a needle of FIG. 45A ; FIG. 45C is a perspective view of a retention block;
FIG. 46A is a perspective exploded view of a needle carriage assembly; FIG. 46B is a top view of the needle of FIG. 46A ; FIG. 46C is a partial side cross-sectional view of the needle carriage assembly of FIG. 46A ;
FIG. 47A is a top view of a needle; FIG. 47B is a side view of the needle of FIG. 47A ; FIG. 47C is a perspective view of a needle carriage having a capture feature; FIG. 47D is a partial view of the needle of 47 A mounted to the carriage of FIG. 47C by a pin;
FIGS. 48A, 48B and 48C are various views of a needle; FIG. 48D is a perspective view of the needle of FIG. 48A-48C captured in a carriage;
FIG. 49A is a side view of a needle; FIG. 49B is a transverse cross section of the needle of FIG. 49A taken along line B-B;
FIG. 50 is a perspective view of another carriage and needles stamped from a single piece of material;
FIG. 51 is a perspective view of another carriage and needles stamped from a single piece of material;
FIG. 52 is a top view of a carriage with several needles overmolded into the carriage;
FIG. 53 is a perspective view of a carriage with needles mounted in slots in the carriage;
FIG. 54 is a top view of a flexible needle captured in a carriage;
FIG. 55 is a top view of a needle carriage with needles overmolded into the carriage, hinges formed between the needles and the carriage;
FIG. 56 is a partial top view of a carriage, a needle, and suture for deploying the needle;
FIG. 57 is a partial top view of a carriage and a plurality of straight needles;
FIG. 58 is a perspective view of a carriage and an expandable capture member;
FIG. 59A is a side cross-sectional view of a tissue fixation device with two needles; FIG. 59B is a perspective view of the needles and a carriage of FIG. 59A ; and
FIG. 60 is a perspective view of a tissue fixation device having needles with compound curvature.
DETAILED DESCRIPTION
While certain embodiments are shown and described in detail below by way of illustration only, it will be clear to the person skilled in the art upon reading and understanding this disclosure that changes, modifications, and variations may be made and remain within the scope of the technology described herein. Furthermore, while various features are grouped together in the embodiments for the purpose of streamlining the disclosure, it is appreciated that features from different embodiments may be combined to form additional embodiments which are all contemplated within the scope of the disclosed technology.
Not every feature of each embodiment is labeled in every figure in which that embodiment appears, in order to keep the figures clear. Similar reference numbers (for example, those that are identical except for the first numeral) may be used to indicate similar features in different embodiments.
Any of the devices described herein may be fabricated from metals, alloys, polymers, plastics, ceramics, glasses, composite materials, or combinations thereof, including but not limited to: titanium, titanium alloys, commercially pure titanium grade 2, ASTM F67, Nitinol, cobalt chrome, stainless steel, UHMWPE, PEEK, and biodegradable materials, among others. Different materials may be used within a single part. The devices disclosed herein may also encompass a variety of surface treatments or additives, including but not limited to: anti-microbial additives, analgesics, anti-inflammatories, etc. Any device disclosed herein may include a radiographic marker for imaging purposes. Any device disclosed herein may be color-coded or otherwise marked to make it easier for the surgeon to identify the type and size of the device.
In a first aspect of the disclosure, a tissue fixation device includes a housing having an inner space configured to receive tissue therein and an enclosed section, wherein the enclosed section completely encloses at least one planar surface; and at least one fixation member movable between a retracted configuration and a deployed configuration, wherein when the at least one fixation member is in the deployed configuration, the at least one fixation member protrudes into the inner space, and wherein when the at least one fixation member is in the retracted configuration, the at least one fixation member is retracted relative to the inner space. Various embodiments of the tissue fixation device can include one or more of the following attributes:
In an embodiment, the tissue fixation device can further include a fixation member carriage engaged with the at least one fixation member and configured to move the at least one fixation member between the deployed configuration and the retracted configuration.
In an embodiment, the housing and the fixation member carriage are substantially circular, and rotational movement of the fixation member carriage along a circle defined by the housing moves the at least one fixation member between the retracted and deployed configurations.
In an embodiment, the at least one fixation member is curved, and the diameter of the curvature of the at least one fixation member is less than the diameter of the circle.
In an embodiment, the tissue fixation device can further include a cap detachable from the housing, wherein the fixation member carriage is captured between the cap and the housing.
In an embodiment, the tissue fixation device can further include a plurality of tabs and a plurality of slots, wherein the tabs are received in the slots to attach the cap to the housing.
In an embodiment, the tissue fixation device can further include a first line and a second line, the first and second lines connected to the fixation member carriage, wherein pulling the first line moves the fixation member carriage in a first direction to deploy the at least one fixation member, and wherein pulling the second line moves the fixation member carriage in a second direction to retract the at least one fixation member.
In an embodiment, the at least one fixation member is deployed inwardly toward a lengthwise central axis of the housing in a plane substantially perpendicular to the lengthwise central axis.
In an embodiment, the at least one fixation member has a sharp point capable of piercing tissue.
In an embodiment, the at least one fixation member is curved with an arch shape that substantially lies in a single plane.
In an embodiment, the at least one fixation member is connected to the fixation member carriage by a hinge type connection, about which the fixation member pivots.
In an embodiment, the at least one fixation member is deflected by the cap as it moves to the deployed configuration.
In an embodiment, the tissue fixation device includes three fixation members, each of the three fixation members being substantially coplanar with each other.
In an embodiment, the at least one fixation member is helically shaped.
In an embodiment, the housing is frustoconical in shape.
FIGS. 1-8 illustrate one example of a tissue fixation device 10 . The tissue fixation device 10 can include a housing 12 , a cap 14 , and a fixation member carriage assembly 16 (shown first in FIG. 4 ) which carries at least one fixation member 18 . In some examples, the fixation member 18 may be a needle. The fixation member carriage assembly 16 can be captured between the housing 12 and cap 14 , and may be rotatable within a track 26 ( FIG. 4 ) formed in the housing 12 and/or the cap 14 . It is appreciated that in other embodiments, the cap 14 may be integral with the housing 12 and not formed as a separate element.
The cap 14 and housing 12 may be referred to as a bell cap or a bell housing, as they may form a bell shape in some examples. In some examples, the housing 12 can have at least one enclosed section that completely encloses at least one planar surface. The at least one planar surface can be defined by a cross-sectional plane through the housing that results in a planar surface that is completely enclosed or surrounded by a portion of the housing. In other words, the planar surface is an empty plane that is completely bounded by the housing 12 . For example, with reference to FIG. 2 , if a cross section of the housing 12 is taken perpendicular to the longitudinal central axis 35 and through the top portion of the housing, or the cap 14 , a circular planar surface would be created which lies within the opening, or inner space 33 of the housing 12 and which is completely bounded by or surrounded by the housing 12 or cap 14 . On the other hand, if the perpendicular cross-sectional plane were moved lower on the housing to where it crosses the struts 22 , housing inner space 33 , and windows 23 , then this would result in a planar surface that is not completely bounded on all sides, or surrounded by the housing 12 because the windows 23 are open.
In other examples, the housing 12 may not have at least one enclosed section. In these examples there may be discontinuities or breaks in the housing (not shown) of any size or shape. In these examples, the at least one fixation member can be deployed away from an inner surface 42 of the housing and into the opening, or inner space 33 to grip tissue. The at least one fixation member can be also be retracted away from the opening toward an inner surface of the housing to release the tissue.
Referring to FIGS. 3A and 3B , the device can be actuable between a fixation member 18 retracted configuration, and a fixation member 18 deployed configuration. From the top or bottom perspective, the device can be radially symmetric. The embodiment shown in FIGS. 1-8 includes three curved fixation members 18 . It will be appreciated that other embodiments may include more or fewer fixation members 18 .
Referring to FIGS. 4 and 5 , housing 12 can be substantially circular or cylindrical in shape. However, the housing 12 can also be conical, frustoconical, funnel, ovoid, or polygonal in shape, or any combination of shapes thereof. The shape of the housing is not as important as the ability of the housing to enclose tissue to be grabbed by one or more fixation members, as will be apparent from the present disclosure. Continuing with FIGS. 4 and 5 , housing 12 may include an attachment portion 20 which may be shaped to connect to a uterine manipulator (not shown). A plurality of struts 22 can project superiorly from the attachment portion 20 and terminate at a carriage support 24 . Windows 23 may be interspersed between the struts 22 . However, in other embodiments, the housing may not include struts 22 or windows 23 . The carriage support 24 can be ring-shaped, and include a carriage track 26 , which may be substantially circular. An outer rim 28 can circumscribe the outer diameter of carriage track 26 , and a step 30 may be formed intermediate the track 26 and the outer rim 28 . One or more apertures 32 can open through the carriage support 24 , and may pass through at least a portion of the outer rim 28 and step 30 . A housing inner wall 34 can circumscribe the inner diameter of the carriage track 26 , and may include a plurality of discontinuations, or wall gaps 36 . At least one edge 38 of each wall gap 36 may be beveled. When operatively assembled, the fixation members 18 are deployable through the wall gaps 36 ; the beveled edges 38 may promote smooth deployment of the fixation members 18 and prevent the fixation members 18 from hanging up or being caught in the wall gaps 36 .
Housing 12 may be generally stepped in outer profile, wherein the carriage support 24 has the widest outer diameter, struts 22 form a circle of intermediate diameter, and attachment portion 20 has the narrowest outer diameter ( FIG. 2 ). The inner wall 34 , struts 22 , and attachment portion 20 , may surround and define a housing inner space 33 . A lengthwise central axis 35 may extend through the housing inner space 33 , also defined by the inner wall 34 , struts 22 , and attachment portion 20 . The number and width of struts 22 and windows 23 may vary, and in some embodiments the housing 12 may be formed as a continuous piece extending between the attachment portion 20 and the carriage support 24 , with no struts 22 or windows 23 present. The embodiment depicted in FIGS. 1-8 is generally bell shaped; however in other embodiments the housing 12 and/or the device 10 may have a cylindrical shape and may include a tapered portion at either end. In other embodiments the device 10 may be cup or bowl shaped, or polygonal.
Cap 14 may have a ring-shape, and may include an outer side 40 opposite an inner side 42 . An outer surface 44 ( FIG. 5 ) of the outer side 40 may be positioned as an upper surface, and may include a plurality of steps, ridges and/or grooves which may facilitate gripping and manipulating the cap 14 . As seen in FIG. 6 , the inner side 42 may have circular outer and inner diameters. A cap inner wall 43 forms the inside diameter of the cap 14 , and may include a plurality of tabs 46 which project inferiorly from the inner wall 43 . Each tab 46 may include at least one beveled edge 48 . A cap outer wall 50 may extend inferiorly, intermediate to and adjoining cap inner wall 43 and cap outer wall 50 and form a track cover 52 . A plurality of cap bosses 54 can project inwardly from the cap outer wall 50 . Each cap boss 54 may include a ramp feature 56 which urges the fixation member 18 inward as it is deployed. The cap 14 can also have beveled edges 48 which can also help urge the fixation member 18 inward as it is deployed. Cap outer wall 50 can include a plurality of recessed alcoves 58 which allow space for the curved fixation members 18 to be retained within the cap outer wall 50 when the fixation members 18 are in the retracted position. Housing 12 and cap 14 may be formed of plastic, or other materials listed herein.
Fixation carriage assembly 16 can include a generally circular fixation carriage 60 . A plurality of mounting features 62 can project superiorly from the fixation carriage 60 . Each mounting feature 62 may include a recess 64 through which an opening 66 is formed. Openings 66 can be sized to allow passage of a suture 90 . Each mounting feature 62 can further include a fixation member mount 68 . In the embodiment shown, fixation member mount 68 includes two pin holes 70 through which a mounting pin 72 passes. Fixation member carriage 60 can have a first or superior side 74 and a second or inferior side 76 . A circular setback or groove 78 can be formed on the inferior side 76 , and be sized to receive a suture.
Each fixation member 18 can be curved, rigid, and may terminate at a beveled point. The rigid fixation members may be formed of stainless steel, or other materials disclosed herein. Other embodiments may include flexible fixation members, which may be straight or curved, and may be made of Nitinol, for example. The fixation member curvature may be non-concentric with the curvature of the carriage track 26 , for example the fixation member curvature may have a smaller diameter than the diameter of the carriage track ( FIG. 7A ). Each fixation member 18 may include a base portion 80 , a shaft 82 , and a point 84 , which may also be referred to as a tip. The point 84 may be sharpened and/or serrated in order to reduce the forces necessary to pierce the tissue, or deploy the fixation member. Any of the fixation members disclosed herein may also include a sharp tip or point for the same purpose. The fixation member 18 may have an arch shape that lies substantially in a single plane in some examples, in other examples, the fixation member can be substantially straight. In yet further examples, the fixation member can have a curved shape in multiple planes or in an infinite number of planes. When assembled into the fixation member carriage assembly 16 , base portion 80 is received in fixation member mount 68 , and a mounting pin 72 may pass through the fixation member mount 68 and base portion 80 to form a hinge type connection, about which the fixation member 18 may pivot.
Referring to FIGS. 7A, 7B, and 8 , fixation member carriage assembly 16 may be mounted in the upper portion of housing 12 , such that fixation member carriage 60 is received in carriage track 26 . A line passage or suture passage 86 may be formed between the groove 78 and outer rim 28 . A first line, or suture 90 may be threaded through one opening 66 , along suture passage 86 in a first direction 100 and through one aperture 32 . A knot 92 may be formed in the suture end remaining at opening 66 , the knot residing in recess 64 immediately adjacent opening 66 , and the knot preventing withdrawal of the first suture through the opening 66 . A second suture 94 may be threaded through a second opening 66 , along suture passage 86 in a second direction 102 opposite the first direction, and through another aperture 32 . The second suture 94 may also be knotted, forming knot 96 to prevent withdrawal. In another example, the first line 90 and/or second line 94 may be secured in one or more crimp tubes which reside in openings 66 , the crimp tube(s) preventing withdrawal of the first and/or second suture through the corresponding opening 66 . When the first and second sutures are thus placed, pulling on the first suture 90 will pull the fixation member carriage assembly 16 in the first direction 100 , and pulling on the second suture will pull the fixation member carriage assembly 16 in the second, or opposite, direction 102 . The sutures 90 , 94 may be replaced by another type of line, flexible member, rigid member, filament, braid, yarn, cable, wire, chain, strap, lacing, or the like.
In an alternative threading embodiment, a single suture can be used. A first end of the suture is passed down through one opening 66 , along suture passage 86 and out one aperture 32 . The first end is then passed partially around the housing 12 , up into a second aperture 32 , along suture passage 86 and up through a second opening 66 . The suture is knotted at both of the openings 66 , and a length of suture is left along the housing 12 , between the two openings 32 . With this threading, pulling on the first end of the length of suture will pull the fixation member carriage assembly 16 in one direction, and pulling on the second end of the length of suture will pull the fixation member carriage assembly 16 in the opposite direction.
The sutures or portions of the sutures may be color-coded. For example, the first suture may be colored green and the second suture may be colored red; of course any color scheme may be used so long as the sutures are visually distinct. Similarly, if one suture is used, different portions of the one suture may be color coded differently. In one example, the green color may be used to indicate that pulling on the green suture (or green portion) will deploy the fixation members and the red color may be used to indicate that pulling on the red suture (or red portion) will retract the fixation members. Also, portions of the suture(s) may be colored to a specific length in order to be used as visual indicators to show when the fixation members are fully deployed or retracted. For example, if all the red color is hidden because it has been drawn into the suture passage 86 , that may provide indication that the fixation members are fully deployed. In some examples, only one suture, or one portion thereof, may be colored, a second portion or a second suture retaining its natural color.
In other embodiments, one or more sliding tabs, levers or other actuation features may be used instead of the sutures to move the fixation member carriage and/or deploy the one or more fixation members. The actuation features may push, pull, twist, or otherwise urge movement of the fixation member carriage and/or fixation members.
When the cap 14 is fitted to the housing 12 , tabs 46 may fit into wall gaps 36 , although inferior to each tab 46 an open portion of each gap can remain, the open portion sized to permit passage of the fixation member tip 84 and shaft 82 . Fixation member carriage assembly 16 can thus be captured in an enclosure formed between the carriage track 26 and track cover 52 . When the tissue fixation device 10 is in the retracted configuration, each fixation member 18 is substantially contained in a fixation member retention space 88 bounded by fixation member carriage 60 , track cover 52 , housing inner wall 34 and cap outer wall 50 . In this configuration, each fixation member tip 84 is adjacent to, but not extending beyond, a wall gap 36 . To move the device 10 into the deployed configuration, the appropriate suture is pulled, for example suture 90 , and fixation member carriage assembly 16 will be pulled along carriage track 26 in direction 100 . As the carriage assembly 16 travels along the circle defined by the housing, carrying fixation members 18 , fixation member tips 84 will encounter ramp features 56 of bosses 54 and be forced, or deflected, through the open portions of wall gaps 36 , thus being inwardly deployed. It is appreciated that a single movement, for example, pulling the suture 90 , may deploy some or all of the fixation members simultaneously. The deployment paths of fixation members 18 may be coplanar in some embodiments, and the fixation members 18 may be deployed along a plane perpendicular to a lengthwise central axis 35 of the housing 12 . The plane may also be described as transverse to the lengthwise central axis 35 . The plane may also be coplanar with or parallel to the planar surface which is completely enclosed by the housing. When the fixation members 18 are deployed into tissue along paths transverse to the lengthwise central axis 35 , this can advantageously result in fixing the position of the tissue within the housing 12 , and preventing the tissue from subsequently translating relative to the device 10 along the lengthwise central axis. In other words, gripping the tissue from a lateral or transverse direction can prevent the tissue from moving longitudinally within, or even out of, the housing inner space 33 .
In other embodiments, the fixation members 18 may move up and/or down out of a plane perpendicular to a lengthwise central axis 35 of the housing 12 . In these embodiments, the deployment paths of the fixation members 18 may be parallel to the central housing axis, or at an acute angle to the axis; the paths themselves may be nonlinear, curved, helical, or the like.
The fixation members 18 may pierce tissue, such as cervical tissue, positioned in the housing inner space 33 . Deployment can stop when the fixation member bases 80 become wedged between housing inner wall 34 and cap ramp feature 56 . Another stop to the carriage motion may be formed when mounting feature 62 of the carriage assembly 16 encounters cap boss 54 . Because of the wedging engagement of the fixation member bases between the housing 12 and cap 14 , the deployed fixation members can be locked in the deployed configuration and remain deployed until they are intentionally retracted.
The fixation member tips 84 can be shaped similar to a hypodermic needle such that, minimum penetration force is needed to deploy the fixation members 18 into the tissue. Furthermore, in this example, when the three fixation members 18 are fully deployed, the fixation members 18 can engage with over 280 degrees of tissue, creating strong tissue fixation. Moreover, this embodiment allows the fixation members 18 to be close to the outer surface 44 of cap 14 which may serve as a cutting guide during colpotomy incisions. This allows the tissue fixation members to be less than about 0.25 inches from the cutting guide and the interiorly located fixation members 18 will not impinge on the cutting path. It will be appreciated that other size cutting guide tip designs can be made to adjust the distance and orientation of the cutting guide to achieve different incision placements as desired.
To move the device 10 into the retracted configuration, the second suture 92 is pulled. The fixation member bases 80 will be disengaged from the inner wall 34 and ramp feature 56 , and fixation member carriage assembly 16 will be pulled in the opposite direction, or direction 102 . As the carriage moves, the inner curved side of the shaft 82 of each fixation member will be forced outward as it encounters inner wall 34 , and fixation members 18 will be retracted in through wall gaps 36 .
FIGS. 9-20 show alternative embodiments of tissue fixation devices. FIGS. 9-11 show a tissue fixation device 110 having a housing 112 , a cap 115 , fixation member carriage 116 and at least two fixation members 114 which rotate into the deployed position in opposite directions. In this example, tissue fixation device 110 has four fixation members 114 . Two of the fixation members rotate into the deployed position in the same direction and the other two fixation members rotate into the deployed position in the opposite direction; the second set of fixation members is also axially offset from the first set of fixation members. However, it will be understood that more or less fixation members 114 can be used in other embodiments without departing from the spirit or scope of the present disclosure. Similar to the example of FIGS. 1-8 , the fixation members 114 can have beveled tips 118 which interact with ramp features (not shown) to force the fixation members inward toward the tissue as the fixation members 114 rotate into the deployed position, similar to other embodiments disclosed herein. The cap 115 can also have beveled edges 156 which may also help urge the fixation member 18 inward as it is deployed.
Operation of this tissue fixation device can be similar to that described above with reference to FIGS. 1-8 , except that multiple fixation member carriages 116 , 117 can be stacked on top of each other, with each of the fixation member carriages 116 , 117 being free to rotate in opposite directions. In this example, two fixation member carriages 116 , 117 are used. However, in other embodiments, more than two fixation member carriages can be used. Actuation of the fixation members 114 into the deployed position can be accomplished by any mechanical means disclosed herein. In one embodiment, a first suture (not shown) with one end split into two suture portions, or limbs, can be used with one of the split ends connected to the first fixation member carriage 116 in a first direction and the other split end connected to the second fixation member carriage 117 in a second direction. When the first suture is pulled, the two fixation member carriages 116 , 117 will rotate in opposite directions relative to each other. A second suture (not shown) with one end split into two suture portions can be used to reverse the rotation of the two fixation member carriages with the split ends of the second suture connected to the fixation member carriages 116 , 117 in opposite directions relative to the split ends of the first suture. Thus, when the second suture is pulled, this causes the two fixation member carriages to rotate in opposite directions relative to pulling the first suture.
FIGS. 12-13 show a tissue fixation device 210 having a housing 212 , and a helical fixation member 214 which may be formed of a material such as Nitinol. FIG. 12 shows the helical fixation member 214 in the deployed position, and FIG. 13 shows the helical fixation member 214 in the retracted position. The helical fixation member 214 can be engaged with a rotatable carriage member 216 . The helical fixation member can have a sharp beveled tip 218 that is angled upward toward the inserted tissue to help draw the fixation member 214 into the tissue as the fixation member is rotated into the deployed position.
In use, tissue may be received within housing 212 , and the helical fixation member 214 can be rotatably advanced into the tissue by rotating carriage member 216 to engage and hold the tissue relative to the housing 212 . It will be appreciated that helical fixation member 214 advances along a deployment path which includes a rotational component and an axial component relative to the center housing axis.
FIGS. 14-15 show a tissue fixation device 310 having a housing 312 , and multiple helical fixation members 314 , 315 which may be formed of a material such as Nitinol. FIG. 14 shows the helical fixation members 314 , 315 in the deployed position, and FIG. 15 shows the helical fixation members 314 , 315 in the retracted position. The helical fixation members 314 , 315 can be engaged with a rotatable carriage member 316 . The helical fixation members 314 , 315 can have sharp beveled tips 318 that are angled upward toward the inserted tissue to help draw the fixation members 314 , 315 into the tissue as the fixation members 314 , 315 are rotated into the deployed position. The sharp beveled tips 318 of each of the helical fixation members 314 , 315 can be positioned out of phase with each other by 180 degrees.
In use, tissue may be received within housing 312 , and the helical fixation members 314 , 315 can be rotatably advanced into the tissue by rotating carriage member 316 to engage and hold the tissue relative to the housing 312 . It will be appreciated that helical fixation members 314 , 315 advance along a deployment path which includes a rotational component and an axial component relative to the center housing axis. It will be appreciated that other embodiments may include more than two helical fixation members without departing from the spirit or scope of the present disclosure.
FIGS. 16-18 show a tissue fixation device 420 having a housing 422 and at least one curved fixation member 424 . In this embodiment there are three curved fixation members 424 , however, other embodiments may include more or fewer curved fixation members 424 . FIGS. 16 and 17 show the curved fixation members 424 in the deployed position and FIG. 18 shows the curved fixation members 424 in the retracted position. The curved fixation members 424 may be flexible, semi-flexible, or rigid. The curved fixation members 424 may be advanced upward from the housing 422 , through tissue, and the tips 418 of the curved fixation members 424 may then be received in capture features 426 formed in the housing 422 to hold the tissue relative to the housing 422 . Other embodiments may reverse the deployment direction of the curved fixation members 424 . For example, the curved fixation members 424 may be advanced downward from the housing 422 , through tissue, such that the tips 418 of the curved fixation members 424 are received in capture features 426 formed in the lower portion of the housing 422 . In this embodiment, the position of the apertures where the curved fixation members 424 exit the housing and the capture features 426 are reversed. In other embodiments, the curved fixation members 424 may be advanced sideways from the housing 422 and into capture features 426 formed on the sides of the housing 422 such that the apertures where the curved fixation members 424 exit the housing and the capture features 426 lie in a plane substantially perpendicular to the lengthwise central axis of the housing 422 .
FIGS. 19-20 show a tissue fixation device 510 having a housing 522 and one or more fixation members 524 . In this example there are three fixation members, however in other examples there may be more or fewer fixation members 524 . FIG. 19 shows the tissue fixation device 510 with the fixation members 524 in the deployed position. FIG. 20 shows the tissue fixation device 510 with the fixation members 524 in the retracted configuration. The housing can have angled ramps 528 formed near the beveled tips 518 of the fixation members 524 which force the fixation members toward the center of the tissue fixation device 510 and into the tissue as the fixation members 524 are moved into the deployed position. The fixation members 524 can be moved between the deployed and retracted positions by means discussed herein including sutures, levers, sliding tabs, translating members or any other suitable mechanical means.
FIGS. 21-25 illustrate an alternative embodiment of a tissue fixation device 610 . The tissue fixation device 610 includes a housing 612 , a cap 615 , and a fixation member carriage assembly 616 which carries at least one fixation member 614 . In the example, the fixation members 614 are needles formed from round stock and have pointed tips. In some embodiments, the needles may be hypodermic needles. The fixation member carriage assembly 616 is captured between the housing 612 and cap 615 , and is rotatable within a track 626 formed in the housing 612 and/or the cap 615 to deploy and retract the fixation members, in the same manner as described for device 10 . The housing may be referred to as a bell housing. The fixation members 614 are movable between a deployed configuration seen in FIGS. 21 and 22 and a retracted configuration seen in FIGS. 23 and 24 . The cap 615 attaches to the housing 612 via an interference fit which is a snap fit. To provide the interference fit, at least one flange 620 on the cap 615 engages with a shoulder 622 and recess 624 on the housing 612 . During assembly, the cap 615 is aligned with housing 612 with flange 620 adjacent shoulder 622 . The cap is pushed against the housing so that flange 620 moves past shoulder 622 and snaps into the recess 624 immediately below the shoulder 622 . Cap 615 includes one or more bosses 654 with ramps 656 which deflect portions of the fixation members out of the track and housing when the carriage assembly 616 is rotated.
FIGS. 26-30 illustrate an alternative embodiment of a tissue fixation device 710 . The tissue fixation device 710 includes a housing 712 , a cap 715 , and a fixation member carriage assembly 716 which carries at least one fixation member 714 . In the example shown, the fixation members 714 are needles stamped from flat stock, and have pointed tips. The fixation member carriage assembly 716 is captured between the housing 712 and cap 715 , and is rotatable within a track 726 formed in the housing 712 and/or the cap 715 to deploy and retract the fixation members, in the same manner as described for device 10 . The housing may be referred to as a bell housing. The fixation members 714 are movable between a deployed configuration seen in FIGS. 26 and 27 and a retracted configuration seen in FIGS. 28 and 30 . The cap 715 attaches to the housing 712 via an interference fit which is a twisting fit. To provide the interference fit, at least one flange 720 on the cap 715 engages with shoulders 722 and recesses 724 on the housing 712 . The shoulders 722 may alternate with the recesses 724 . During assembly, the cap 715 is aligned with housing 712 with flanges 720 fitting into recesses 724 . The cap 715 is twisted so that upon rotation, each flange 720 moves out of its respective recess 724 and is captured under shoulder 722 . If the cap is twisted the opposite direction, the flanges are released from under the shoulders and the cap may be detached. Cap 715 includes one or more bosses 754 with ramps 756 which deflect portions of the fixation members out of the track and housing when the carriage assembly 716 is rotated.
A method of use may be the same for devices 610 and 710 . In a method of use of device 710 , tissue is positioned in a central opening 708 of housing 712 . Carriage 716 is rotated in a first direction to deploy fixation members 714 . One or more sutures 90 , 94 or other lines may be used to rotate the carriage and deploy the needles, as described herein with regard to device 10 and FIGS. 7A and 7B . Fixation members 714 deflect circumferentially inward of the housing 712 and pierce the tissue, capturing the tissue and fixing it relative to the device 710 . At this point, the device 710 may be moved to manipulate the tissue as desired. After desired tissue movement has been carried out, the carriage 716 is rotated in a second direction to retract the fixation members 714 . The needles are pulled out of the tissue and back into the needle track 726 , and the tissue is released from capture.
In some examples of use, the tissue is cervical tissue. The method of use may further include inserting a rod, tube or other elongated member (not shown) through the opening in the bottom of the housing, and into the cervix, with a portion of the elongated member extending out of the opening. After the needles are deployed, and the tissue is fixed relative to the device 610 or 710 , the portion of the elongated member extending out of the opening may be manipulated to move the attached device and cervical tissue.
FIGS. 31A-36B illustrate another embodiment of a tissue fixation device. Device 810 can include a housing 812 , a cap 815 , and a fixation member carriage assembly 816 which carries at least one fixation member 814 . In some examples, the fixation member 814 may be a needle. The fixation member carriage assembly 816 can be captured between the housing 812 and cap 815 , and may be rotatable within a track 826 formed in the housing 812 and/or the cap 815 . It is appreciated that many of the features and characteristics described for device 10 are found on and also apply to device 810 .
The cap 815 and housing 812 may be referred to as a bell cap or a bell housing, respectively, as they may form a bell shape in some examples. The housing 812 includes at least one enclosed section that completely encloses at least one planar surface. The at least one planar surface can be defined by a cross-sectional plane through the housing that results in a planar surface that is completely enclosed or surrounded by a portion of the housing. In other words, the planar surface is an empty plane that is completely bounded by the housing 812 . For example, with reference to FIG. 31C , if a cross section of the housing 812 is taken perpendicular to the longitudinal central axis 35 and through the top portion of the housing, or the cap 815 , a circular planar surface would be created which lies within the opening, or inner space 33 of the housing 812 and which is completely bounded by or surrounded by the housing 812 or cap 815 .
Referring to FIGS. 32 and 34 , housing 812 is substantially frustoconical and circular in shape. However, the housing 812 can also be conical, cylindrical, funnel, ovoid, or polygonal in shape, or any combination of shapes thereof. The housing may include a base 822 which may be circular, and a peripheral support wall 822 which terminates at a carriage support 824 . In the example shown, the base 822 has the narrowest diameter of the housing, and the housing slopes outward to a widest diameter at the carriage support 824 . Housing 812 may include an opening 823 which may be shaped to engage with uterine manipulator (not shown). The peripheral wall 834 and base 822 may surround and define a housing inner space 833 . The lengthwise central axis 35 may extend through the housing inner space 833 , also defined by the peripheral wall 834 and base 822 .
The carriage support 824 can be ring-shaped, and include a carriage track 826 , which may be substantially circular. An outer rim 828 circumscribes the outer diameter of carriage track 826 , and a step 830 may be formed intermediate the track 826 and the outer rim 828 . One or more apertures 832 can open through the carriage support 824 , and may pass through at least a portion of the outer rim 828 and step 830 . A housing inner wall 834 can circumscribe the inner diameter of the carriage track 826 , and may include a plurality of discontinuations, or wall gaps 836 . At least one edge 838 of each wall gap 836 may be beveled. When operatively assembled, the fixation members 814 are deployable through the wall gaps 836 ; the beveled edges 838 may promote smooth deployment of the fixation members 814 and prevent the fixation members 814 from hanging up or being caught in the wall gaps 836 . Several slots 839 are formed in the housing 812 near the juncture of the peripheral support wall 822 and carriage support 824 . The slots 839 receive tabs 846 on the cap 815 to lock the cap to the housing 812 . Adjacent each slot 839 is a housing lip 841 formed along a portion of the peripheral wall 822 .
Cap 815 may be annular, and may include an outer wall 50 generally opposite an inner wall 843 . An outer surface 844 of the cap 815 may be positioned as an upper surface, and may include a plurality of steps, ridges and/or grooves which may facilitate gripping and manipulating the cap 815 . The cap 815 may have circular outer and inner diameters, formed by the outer wall 850 and inner wall 843 respectively. The cap inner wall 843 includes a plurality of tabs 846 which project inferiorly from the inner wall 843 , alternating with a plurality of gaps 847 . Each tab 846 may include a cap lip 848 projecting from the tab. Tabs 846 and lips 848 may be semicircular to follow the outer shaped of the peripheral wall 822 . The cap outer surface 844 may extend between cap inner wall 43 and cap outer wall 50 and form a track cover 852 . A plurality of cap bosses 854 can project inwardly from the cap outer wall 850 . Each cap boss 854 may include a ramp feature 856 which urges one of the fixation members 814 inward as it is deployed. The cap track cover 852 includes one or more cap grooves 857 , which may be semicircular, and which guide the path of fixation members 814 as they are deployed and retracted. Housing 812 and cap 815 may be formed of plastic, or other materials listed herein.
Fixation carriage assembly 816 can include a substantially circular fixation carriage 860 . Fixation member carriage 860 can have a first or superior side 874 and a second or inferior side 876 . A plurality of mounting features 862 can project superiorly from the fixation carriage 860 . Each mounting feature 862 may include a recess 864 through which an opening 866 is formed. Openings 866 can be sized to allow passage of a suture 90 , but may also be small enough to retain a knotted suture, not permitting the knot to pass through the opening. A circular setback or groove 878 can be formed on the inferior side 876 similar to groove 78 of device 10 , and be sized to receive a suture.
Each fixation member 814 can be curved, rigid, and may terminate at a beveled point. The rigid fixation members may be formed of stainless steel, or other materials disclosed herein. Other embodiments may include flexible fixation members, which may be straight or curved, and may be made of Nitinol, for example. The fixation member curvature may be non-concentric with the curvature of the carriage track 826 , for example the fixation member curvature may have a smaller diameter than the diameter of the carriage track ( FIG. 36A ). Each fixation member 814 may include a base portion 880 , a shaft 882 , and a point 884 , which may also be referred to as a tip. The point 884 may be sharpened and/or serrated in order to reduce the forces necessary to pierce the tissue, or deploy the fixation member. Any of the fixation members disclosed herein may also include a sharp tip or point for the same purpose. The fixation member may have an arch shape that lies substantially in a single plane in some examples; in other examples, the fixation member can be substantially straight. In yet further examples, the fixation member can have a curved shape in multiple planes or in an infinite number of planes. When assembled into the fixation member carriage assembly 816 , a mounting pin 872 may pass through the fixation member base portion 880 and through carriage 860 to form a hinge type connection, about which the fixation member 814 may pivot.
Cap 815 may be operatively assembled to housing 812 by insertion of cap tabs 846 into housing slots 839 . When the tabs 846 are fully inserted into the slots 839 , each cap lip 848 may snap over and positively engage a housing lip 841 to lock the cap 815 to the housing 812 . Fixation member carriage 816 and the attached fixation members 814 may be captured between the housing and the cap. In the example shown in FIG. 34 , cap tabs 846 are exterior to housing peripheral wall 822 . In another embodiment, the tabs 846 may be interior to the peripheral wall. Attachment of the cap 815 to the housing 812 encloses a fixation member retention space 888 bounded by fixation member carriage 816 , track cover 852 , housing inner wall 834 and cap outer wall 850 . The mounting pins 872 project superiorly to the fixation carriage assembly 816 and are captured in the cap grooves 857 .
A line passage or suture passage 886 may be formed between the groove 878 and outer rim 828 . Suture 90 may be threaded through one opening 866 , along suture passage 886 in the first direction 100 and through one aperture 832 . A knot 92 may be formed in the suture end remaining at opening 866 , the knot residing in recess 864 immediately adjacent opening 866 , and the knot preventing withdrawal of the first suture through the opening 866 . A free end 93 of suture 90 remains outside of the device 810 . The second suture 94 may be threaded through a second opening 866 , along suture passage 886 in the second direction 102 opposite the first direction, and through another aperture 832 . The second suture 94 may also be knotted, forming knot 96 to prevent withdrawal. In another example, the first line 90 and/or second line 94 may be secured in one or more crimp tubes which reside in openings 866 , the crimp tube(s) preventing withdrawal of the first and/or second suture through the corresponding opening 866 . A free end 95 of suture 94 remains outside of the device 810 . When the first and second sutures are thus placed, pulling on the first suture free end 93 will rotate the fixation member carriage assembly 816 in the first direction 100 , and pulling on the second suture free end 95 will rotate the fixation member carriage assembly 816 in the second, or opposite, direction 102 .
With reference to FIGS. 36A and 36B , device 810 may be deployed in the same manner as device 10 . The device may be place in the retracted configuration, with the fixation members 814 retracted into the fixation member retention space 888 . Device 810 may be positioned so that tissue, for example cervical tissue, is received in housing inner space 833 , with cap 815 and housing peripheral wall 822 enclosing the tissue. The free end 93 of suture 90 may then be pulled, rotating fixation member carriage assembly 816 in first direction 100 . As the fixation member carriage assembly 816 rotates, the fixation member tips 884 will encounter the ramps 856 on the cap 815 , and be deflected and forced inward through wall gaps 836 to protrude into the housing inner space 833 , thus attaining the deployed configuration. Pins 872 translate in grooves 857 , further guiding the fixation member deployment. The deployment paths of fixation members 814 may be coplanar in some embodiments, and the fixation members 814 may be deployed along a plane perpendicular to the lengthwise central axis 35 of the housing 812 . The plane may also be described as transverse to the lengthwise central axis 35 . The plane may also be coplanar with or parallel to the planar surface which is completely enclosed by the housing. The fixation members 814 may pierce and grip the tissue captured in the housing inner space 833 . As described for device 10 , this can advantageously result in fixing the position of the tissue within the housing 812 , and preventing the tissue from subsequently translating relative to the device 810 along the lengthwise central axis. A stylus, tubular member, rod, or other elongated member (not shown) may be inserted into device 810 through housing opening 823 and pass through the tissue, and may pass out of device 810 through cap 815 , leaving a free end of the elongated member exterior to the housing end 820 . For example, an elongated tubular member may pass through housing opening 823 and into a cervix captured in housing inner space 833 . The elongated tubular member free end may be manipulated to move the device 810 and the tissue gripped within. Instruments, bodily tissues, or fluids may be passed through the elongated tubular member into or out of the tissue. When desired, free end 95 of suture 94 may be pulled to rotate the fixation member assembly 816 in the second direction 102 and withdrawing the fixation members 814 from the tissue and back into the retracted configuration.
FIGS. 37-60 disclose embodiments of fixation members, fixation member carriages and carriage assemblies which may be used in tissue fixation devices 10 , 110 , 210 , 310 , 410 , 510 , 610 , 710 , 810 or other tissue fixation devices. For example, a fixation member carriage and the fixation members carried thereon can be substituted for fixation member assembly 816 in device 810 , or substituted for fixation member assembly 16 in device 10 . In each example, the fixation member(s) are deployable between a retracted configuration in which they are retracted and the tissue fixation device may be positioned relative to tissue to be captured, and a deployed configuration in which the fixation members are deployed to contact and capture the tissue, and subsequent movement of the device will move or manipulate the captured tissue. The fixation members may be needles. It is understood that each fixation member disclosed herein may have a sharp tip for piercing and/or engaging tissue such as cervical tissue. Each fixation member disclosed herein may be curved. The fixation members disclosed herein may be stamped, formed from round stock, formed from rod stock, or manufactured from materials and methods known in the art for making needles.
FIGS. 37A and 37B show a fixation member or needle 1314 mounted in a carriage 1316 . A cap 1315 can capture needle 1314 in carriage 1316 . Fixation member 1314 includes a convex attachment feature 1320 shaped as a portion of a circle, which is received in a concave capture feature 1322 to form a ball joint. The ball joint allows polyaxial movement of the fixation member 1314 . Fixation member 1314 has a sharp tip 1326 .
FIGS. 38A and 38B show a fixation member or needle 914 mounted in a carriage 916 . An attachment feature 920 on the needle 914 is shaped as a cylinder. A pin 924 within a capture feature 922 on carriage 916 receives the needle 914 . When captured as shown, needle 914 can rotate about a single axis. Pin 924 may be molded into carriage 916 . In other embodiments, pin 924 and other pins disclosed herein may be molded, press fit, glued, or welded.
FIG. 39 shows a needle 1014 mounted on a carriage 1016 in a capture feature 1022 . The needle 1014 is pre-formed with bends 1030 , 1032 and attachment feature 1020 folded into the needle. As carriage 1016 is rotated, attachment feature 1020 swings to allow the needle to deploy and retract. A cap (not shown) may hold needle 1014 in capture feature 1022 .
FIGS. 40A-40C show a needle 1114 , cap 1115 and carriage 1116 . In FIG. 40C , the needle 1114 is captured in between the cap 1115 and carriage 1116 . The needle 1114 includes an attachment feature 1120 wherein the needle end is bent approximately 90° to allow capture in a capture feature 1122 . When captured, needle 1114 can rotate about at least one axis. Needle 1114 may be formed from stainless steel round stock, and sharpened.
FIG. 41 shows a needle 1214 mounted on a carriage 1216 in a capture feature 1222 . The needle 1214 is pre-formed with bends 1230 , 1232 and attachment feature 1220 folded into the needle. As carriage 1216 is rotated, attachment feature 1220 swings within capture feature 1222 to allow the needle to deploy and retract. A cap (not shown) may hold needle 1214 in capture feature 1222 .
FIGS. 42A-42D show a metal carriage 1416 with pins 1424 press fit or welded to the carriage. One or more needles 1414 include an attachment feature 1420 which is a hole shaped to receive pin 1424 . One end of pin 1424 may be deformed to retain the needle. The metal carriage 1416 may be stamped or machined.
FIGS. 43A and 43B show a needle 1514 which may be created by stamping out of flat stock. The needle 1514 may then be bent or folded to create the V-shape seen in the cross-section of FIG. 20B . The needle 1520 may include one or more attachment features 1520 , which may be shaped as pegs or posts, to attach to a carriage and/or cap as disclosed elsewhere herein. The needle 1514 may be described as a stylet.
FIG. 44 shows a needle 1614 mounted on a carriage 1616 . Carriage 1616 includes a capture feature 1622 formed as a tab which extends over the carriage 1616 to capture a pin 1624 . Needle 1614 includes an attachment feature shaped to receive the pin 1624 so that when mounted, the needle 1614 is captured on the pin 1624 , between the carriage 1616 and the capture feature 1622 . In an embodiment formed from steel, capture feature 1622 may be connected to the carriage 1616 at a hinge 1626 . In an embodiment formed from plastic, capture feature 1624 may be folded over and/or formed around a mold, and welded to carriage 1616 . Needle 1614 may be a stylet, sharing the same features as needle 1514 .
FIGS. 45A-45C show a carriage 1716 with capture features 1722 and a needle 1714 having a hole 1720 . A cap is not shown, but includes a number of retention blocks 1725 equal to the number of capture features 1722 on the carriage 1716 . Each capture feature 1722 includes a pin 1724 and two holes 1726 . Each retention block 1725 includes two pins 1734 and one hole 1717 , plus a bore 1719 . When assembled, needle 1714 is captured between carriage 1716 and cap 1715 , with pin 1724 extending from carriage 1716 through needle hole 1720 and bore 1719 . Retention block pins 1724 extend into holes 1726 . In another embodiment, the retention block 1725 may be part of the carriage 1716 instead of the cap 1715 .
FIGS. 46A-46C show an embodiment including a stamped carriage 1816 , a needle 1814 and a pin 1824 . Pin 1824 includes a head 1826 and a shoulder 1828 . Needle 1814 includes an attachment feature which is a hole 1820 . Pin 1824 may be received in hole 1820 to mount needle 1814 to carriage 1816 ; head 1826 retains the needle 1814 on the pin 1824 . The carriage 1816 include capture features 1822 which may be holes to receive pins 1824 .
FIGS. 47A-47C show an embodiment including a carriage 1916 and a needle 1914 , the needle having an attachment features which is a pin 1924 . A capture feature 1922 on the carriage 1916 includes a slot 1926 and a hole 1928 . The needle can be snapped or rocked into the capture feature 1922 , with pin 1924 moving through slot 1926 into hole 1928 . The edges 1930 , 1932 of the slot 1926 may deform slightly as the pin 1924 is pushed in, then act as interference to keep the pin 1924 in place in the capture feature.
FIGS. 48A-48D shows an embodiment similar to FIGS. 47A-47C . A needle 2014 includes a pin 2024 for attachment. Carriage 2016 includes a capture feature 2022 having a slot 2026 . The pin 2024 is captured in the slot 2026 as shown. Not shown, a cap 2015 includes an inner wall 2017 which holds the pin 2024 in the slot 2026 .
FIGS. 49A and 49B show an embodiment similar to FIGS. 43A and 43B . Needle 2114 includes an attachment feature 2120 . A separate pin 2124 can attach the needle to a carriage. Needle 2114 may be formed in the same way as described for needle 1514 .
FIG. 50 shows another carriage and needle assembly stamped from a single piece of stock. The assembly includes carriage 2316 and needles 2314 . The stock metal may be stamped, then the needles bent and sharpened. The needles 2314 project upward from carriage 2316 .
FIG. 51 shows another carriage and needle assembly stamped from a single piece of stock. The assembly includes carriage 2416 and needles 2414 . The stock metal may be stamped, then the needles bent and sharpened. The needles 2414 project inward from carriage 2416 . A hinge 2420 is formed where each needle 2414 projects from carriage 2416 ; each hinge 2420 may be formed by cutting away portions of the material between the needle and the carriage. The hinge 2420 may be described as a living hinge. In FIGS. 50-51 , the needles bend out of the plane of the carriage.
FIG. 52 shows an embodiment of a carriage assembly including a carriage 2516 and needles 2514 . The carriage is formed from molded material such as polymer. Pins 2524 attach the needles to the carriage. In this embodiment, the pins 2524 and needles 2514 are in place when the carriage 2516 is molded; the pins and needles are over-molded into the carriage assembly.
FIG. 53 shows an embodiment of a carriage assembly including a carriage 2616 and a needle 2614 . When deployed, needle 2614 slides in a slot 2622 on carriage 2616 along axis 2601 .
FIG. 54 shows another carriage and needle assembly including carriage 2816 and needles 2814 . The needles may be formed from flexible steel, and may be insert molded into the carriage. A hinge 2820 is formed where each needle 2814 projects from carriage 2816 at capture feature 2822 ; each hinge 2820 may be formed by cutting away portions of the needle. The hinge 2820 may be described as a living hinge, and may result in a springy needle. Capture feature 2822 may be rigid.
FIG. 55 shows another carriage and needle assembly including carriage 2916 and needle 2914 . Carriage 2916 include capture feature 2922 having a living hinge 2926 . Needle 2914 is attached to the capture feature 2922 through overmolding; the needle is overmolded directly into the carriage.
FIG. 56 shows another carriage and needle assembly including carriage 3116 and at least one needle 3114 . A suture 90 is attached to the needle and can be manipulated to activate the needle. In this embodiment, the carriage 3116 does not move within a housing such as housing 3012 , but instead the needles 3114 are deployed by one or more sutures.
FIG. 57 shows another carriage and needle assembly including carriage 3216 and a plurality of needles 3214 . Carriage 3222 includes a plurality of capture features 3222 , and each needle includes an attachment feature 3220 which may be received in a capture feature. Unlike other embodiments herein, needles 3214 are straight. When deployed, the needles rotate approximately 90° and project straight into a center opening 3208 of the carriage 3216 . When retracted, the needles may point up.
FIG. 58 shows a tissue fixation carriage 3416 with a tissue fixation member 3414 attached to the carriage by a plurality of attachment features 3420 . Tissue fixation member 3414 is expandable and may include an expandable mesh which encircles a central opening 3408 . Small teeth or barbs 3426 are formed on the edges of the fixation member 3414 . When carriage 3416 is rotated in a first direction, fixation member 3414 expands and tissue may be positioned in the central opening 3408 . When the carriage 3416 is rotated in a second direction, fixation member 3414 contracts and the tissue is captured in the opening 3408 . The barbs 3426 help prevent withdrawal of the tissue.
FIGS. 59A and 59B are views of a tissue fixation device 3700 including housing 3712 , cap 3715 , and two needles 3714 captured in needle carriage 3716 . Instead of deploying circumferentially inward, when deployed the needles drop down into the center opening 3008 of the device, capturing tissue positioned therein.
FIG. 60 shows a tissue fixation device 3800 including housing 3812 , and several needles 3814 captured in needle carriage 3816 . Each needle 3814 is compoundly curved, having at least one convex portion and one concave portion. When deployed, needles 3814 trap tissue between the needle 3814 and the carriage 3816 .
It should be understood that the present apparatuses and methods are not intended to be limited to the particular forms disclosed. Rather, they are intended to include all modifications, equivalents, and alternatives falling within the scope of the claims. They are further intended to include embodiments which may be formed by combining features from the disclosed embodiments, and variants thereof.
The claims are not to be interpreted as including means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) “means for” or “step for,” respectively.
The term “coupled” is defined as connected, although not necessarily directly, and not necessarily mechanically.
The use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims and/or the specification may mean “one,” but it is also consistent with the meaning of “one or more” or “at least one.” The term “about” means, in general, the stated value plus or minus 5%. The use of the term “or” in the claims is used to mean “and/or” unless explicitly indicated to refer to alternatives only or the alternative are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and “and/or.”
The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”) and “contain” (and any form of contain, such as “contains” and “containing”) are open-ended linking verbs. As a result, a method or device that “comprises,” “has,” “includes” or “contains” one or more steps or elements, possesses those one or more steps or elements, but is not limited to possessing only those one or more elements. Likewise, a step of a method or an element of a device that “comprises,” “has,” “includes” or “contains” one or more features, possesses those one or more features, but is not limited to possessing only those one or more features. Furthermore, a device or structure that is configured in a certain way is configured in at least that way, but may also be configured in ways that are not listed.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. It is appreciated that various features of the above-described examples can be mixed and matched to form a variety of other alternatives. For example, fixation members, needles, hooks or barbs may be interchangeable in any of the embodiments set forth herein, as may the actuation means for deployment. As such, the described embodiments are to be considered in all respects only as illustrative and not restrictive. Similarly, manufacturing, assembly methods, and materials described for one device may be used in the manufacture or assembly of another device. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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Tissue fixation members 18 interact with a housing 12 to hold tissue relative to the housing and allow the orientation and position of the grasped tissue to be manipulated with improved efficacy. The tissue fixation members can be easily and quickly moved between deployed and retracted positions to reversibly grasp and release tissue.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from German Patent Application No. 10 2012 108 919.1, filed on Sep. 21, 2012, which application is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The invention relates to a coating apparatus for coating a substrate with a plasma generator.
[0003] Furthermore the invention relates to a method for coating a.
BACKGROUND OF THE INVENTION
[0004] The complex requirements of modern engineering and material challenges implies, to a growing extent, the use of material combinations, amongst them compound materials and layered systems. Such layered systems may for example be used as protective or functional layers on objects against corrosive, thermal, chemical, or biological stresses in many ways. For making such material or layer compounds currently various technologies are employed. Therein often chemical vapor deposition (CVD) or physical vapor deposition (PVD) are used, Further established methods are soldering, diffusion welding, or powder metallurgical compound pressing with possible subsequent smithing. Therein the layers are either applied onto a compact substrate via the melted phase (thermal spraying) or via the vapor (PVD) or gas (CVD) phase, or are directly connected with a compact substrate material as compact parts by means of an auxiliary substance (soldering) or by simultaneous application of pressure and temperature (diffusion welding).
[0005] These known techniques have method specific limitations, however. Unfavorable layer properties like for example open porosity and cracks in the layer reduce the protective effect against reactive media. Due to temperature gradients between the materials during production of the layer compounds often stresses remain in the thermally affected regions of the parts. Therefore often laborious additional processes are required.
[0000] These disadvantages can often be reduced or completely eliminated by the direct application of layers by means of a plasma jet to which powder is supplied. Such a method for example is known from U.S. Pat. No. 5,853,815. In this document it is proposed to homogeneously coat a substrate with a plasma stream covering the entire width of the substrate. A particle reservoir is directly connected with a plasma generator via a pipe. A large pressure difference between the plasma gun and the plasma generator creates a shock pattern, causing the coating stream to fan out widely and also resulting in a thorough distribution of the coating material in the plasma stream.
[0006] Various material combinations can be applied onto a substrate in this way. To this end for example a powder consisting of a mixture of several types of material is used. In this way many material combinations can be applied even on substrates of complex shape, given a corresponding control of the nozzles. For example, in this way a very wear resistant but brittle material can be embedded into an elastic matrix. It is furthermore possible to sinter powders comprising a mixture of plural fine grained metallic components during the coating process.
[0007] From DE 199 58 473 A1 a method and an apparatus are known wherein by means of a plasma a multilayered structure is applied onto a substrate. Therein the properties of the individual layers can be chosen from within a wide range. To this end it is proposed to supply to the plasma jet exiting from the plasma generator the species forming the layer, so called precursor materials, in the form of powder, gases, or liquids, which then are chemically or physically changed in the plasma in such a way that they are deposited as a cluster in the nano or microscale range on the substrate. In this way a composite layer system can be applied if precursor materials with different properties are supplied to the plasma jet at different locations. A disadvantage of this method of applying layers to substrates is that the property of the layer to be applied is fixed in the process.
[0008] The international application PCT/DE2006/000638, published as WO 2006/108395 A1 describes an apparatus and a method for plasma coating. A plasma generator with plural expansion stages is disclosed, wherein each expansion stage exhibits an inlet for a coating material. Downstream from the expansion stages a mixing chamber is provided, in which the coating materials are mixed with each other and with the plasma.
[0000] The German patent document DE 10 2008 053 640 B3 discloses a coating method in which a layer is sprayed onto an object. The spray material is melted from wires by an electric arc. A filler material can be supplied to the spray jet via an injector.
SUMMARY OF THE INVENTION
[0009] The object of the present invention is to provide an apparatus for coating a substrate, wherein the properties of the coating to be applied are changeable during the coating process.
[0010] According to the invention this object is achieved by a coating apparatus tier coating a substrate, comprising
a plasma generator for generating a plasma jet; which exits from a coating head of the plasma generator from which the plasma jet exits; a first particle reservoir connected with a transport pipe for supplying particles stored in the first particle reservoir to the plasma jet: at least a second particle reservoir is provided and configured to supply particles from the second reservoir via the transport pipe to the plasma jet in a particle mixture with the particles from the first particle reservoir; and a supply control device for setting an amount of the particles fed from the first particle reservoir into the transport pipe relative to the amount of the particles fed from the second particle reservoir into the transport pipe.
[0016] A further object of the invention is to provide a method by which the possibilities of coating substrates become more varied.
[0017] With respect to the method the object is achieved by a method for coating a substrate comprising the following steps:
generating a plasma jet with a plasma generator having at least one coating head from which the plasma jet exits; feeding particles from at least a first particle reservoir and from at least a second particle reservoir via a transport pipe to a supply control device in which they are mixed; supplying a particle mixture of particles from the first particle reservoir and of particles from the second particle reservoir from the supply control device to the plasma jet via the transport pipe; and directing the plasma jet together with the particle mixture onto a surface of the substrate in order to form the coating.
[0022] A coating apparatus for coating a substrate is proposed. The coating apparatus comprises a plasma generator for generating a plasma jet, wherein the plasma jet exits from a coating head of the plasma generator. Particles from a first particle reservoir can be supplied to the plasma jet via a transport pipe. A second particle reservoir is provided from which particles can also be supplied via the transport pipe to the plasma jet. A supply control device in the transport pipe allows setting the amount of particles from the first particle reservoir relative to the amount of particles from the second particle reservoir. Advantageously this ratio of amounts of particles can be varied even during the coating process. This also makes possible the generation of a changing layer profile on the surface of the substrate.
[0023] In a preferred embodiment of the coating apparatus a controller for controlling the amount of particle mixture supplied to the plasma jet is provided. Therein the controller may be configured in such a way that the amount of supplied particles can be varied over a wide range, even during the coating process. Moreover, the controller may be a switch or configured to exhibit a switching function so that by this switch the supply of particles to the plasma jet may be allowed or interrupted.
[0024] In a further embodiment of the invention a plurality of particle reservoirs is provided. The particle reservoirs therein may be mixed with respect to their relative amounts by a common supply control device or may be applied onto the surface of the substrate with corresponding separate coating heads.
[0025] Preferentially for each particle reservoir there is provided at least one separate process by which a fluidized powder is generated from the particle reservoirs. The particle reservoir and the corresponding process gas form a respective particle supply unit. The particle supply unit may comprise a process gas control unit for controlling the mixing relation between the particles and the process gas.
[0026] In a further embodiment of the invention the coating apparatus may comprise at least a second coating head and a further particle supply unit corresponding to the second coating head. The particle supply unit therein exhibits a further particle reservoir, a process gas, and a process gas control unit. With this embodiment of the invention it is also possible to provide a plurality of coating heads and respectively corresponding particle supply units,
[0027] In the method for coating a substrate in a first embodiment the coating is done with a coating apparatus having a plasma generator for generating a plasma jet and also having a coating head, from which the plasma jet exits. For coating the substrate particles are supplied to the plasma jet from a first particle reservoir via a transport pipe. Also, particles from a second particle reservoir are mixed with those from the first particle reservoir by a supply control device and then fed into the transport pipe together and supplied to the plasma jet as a particle mixture. The plasma jet, together with the particle mixture, is then directed onto the surface of the substrate for forming the coating. Therein the particles from the first particle reservoir may be fluidized with a first process gas and the particles from the second particle reservoir may be fluidized with a second process gas. The fraction of particles from the first particle reservoir within the mixture can be set between 10% and 90%, and the fraction of particles from the second particle reservoir can be set between 10% and 90%. Furthermore it is possible to vary the amount of particles from the first particle reservoir relative to the amount of particles from the second particle reservoir during the coating of the substrate by changing the mixing ratio between the first and second particles during the application.
[0028] In a further embodiment of the method according to the invention the coating is done with a coating apparatus having a plasma generator for generating a plasma jet and also having a coating head from which the plasma jet exits. Therein the substrate is coated by supplying particles from a first particle reservoir via a transport pipe to the plasma jet at a first supply location and supplying particles from a second particle reservoir to the plasma jet at a second supply location in such a way that on the substrate a first layer of particles from the first particle reservoir and a second layer of particles from the second particle reservoir are formed. As an alternative, the first and second supply location may also be chosen in such a way that a gradient layer or a compound layer is formed on the substrate.
[0029] The second layer or gradient layer or compound layer in a further embodiment of this method is covered with a further layer, wherein particles from a third particle reservoir are fed into a further transport pipe, then are supplied to the second plasma jet of a second coating head, and then are applied onto the second layer of particles from the second particle reservoir or onto the gradient layer or onto the compound layer.
[0030] With the method according to the invention and the apparatus according to the invention the properties of the layer to be applied may be varied over a wide range. By specific controlled supply of coating materials into the plasma coating process functional compound layers may be applied. The thickness and the composition of the compound layer therein may be controlled in such a way that the desired electrical, mechanical and chemical properties can be tailored. Also plural layers, including with different properties, and gradient layers may be generated on the substrate.
[0031] According to an additional object of the invention a coating apparatus for coating a substrate is provided. The coating apparatus has at least a first plasma generator and at least a second plasma generator each of which generating a plasma jet. The first plasma generator has a coating head from which the plasma jet exits. The second plasma generator has a coating head from which the plasma jet exits. A first particle reservoir is connected with a transport pipe for supplying particles stored in the first particle reservoir to the plasma jet of the first plasma generator. At least a second particle reservoir is provided and configured to supply particles from the second reservoir via the transport pipe to the plasma jet of the first plasma generator in a particle mixture with the particles from the first particle reservoir. A least a third particle reservoir is connected with a transport pipe for supplying particles stored in the third particle reservoir to the plasma jet of the second plasma generator. A supply control device is provided for setting an amount of the particles fed from the first particle reservoir into the transport pipe to a first injector relative to the amount of the particles fed from the second particle reservoir into the transport pipe to a second injector, wherein the first injector and the second injector are arranged in relation to the plasma jet of the first plasma generator. A further supply control device is provided for setting an amount of the particles fed from the third particle reservoir into the transport pipe to a third injector arranged in relation to the plasma jet of the second plasma generator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] Additional advantages and advantageous embodiments are presented in the subsequent figures and pertaining description, where
[0033] FIG. 1 is a schematic coating apparatus with a plasma module for providing a plasma jet;
[0034] FIG. 2 is a schematic further embodiment of a coating apparatus with two plasma modules, wherein each of which provides a plasma jest;
[0035] FIG. 3 a through c are examples of layers that may be formed with the coating apparatus, in schematic representation;
[0036] FIG. 4 is a schematic representation of a possible layered structure on a substrate after a coating;
[0037] FIG. 5 is a schematic representation of the principle of a gradient layer by a depth profile; and
[0038] FIG. 6 is a schematic representation of an example of a conductive coating formed with the coating apparatus.
DETAILED DESCRIPTION OF THE INVENTION
[0039] FIG. 1 schematically shows a coating apparatus 10 for coating a substrate The coating apparatus 10 has a plasma module with a coating head 26 , a source for a plasma process gas 56 and a power supply 58 .
[0040] The coating head 26 has a plasma chamber 60 in which an electric arc 20 is started between two electrodes 62 and 64 . Electrical energy is supplied to this electric arc 20 from the power supply 58 for sustaining it, so that, depending on the modulation of the power supply 58 , a continuous plasma jet 22 or a pulsed plasma jet 22 is generated, which exits on the exit side 26 A of the coating head 26 . At the feed side 26 E of the coating head 26 a plasma process gas 56 may be supplied, so that the plasma process gas 56 streams through the plasma chamber 60 in a controlled manner. A mixture of process gas 30 , 32 and particles may be supplied to the plasma jet 22 via an injector 66 , which here is shown as an external injector. The particles may be partially molten by the high energy density in the plasma jet 22 . In this way they can be deposited on the surface 12 a of the substrate 12 as first layer 50 . As the substrate 12 and the coating head 26 are moveable relative to each other, a continuous layer 50 can be formed on the substrate 12 .
[0041] The particle mixture supplied to the injector 66 in the embodiment of the invention shown in FIG. 1 is provided by a first particle supply unit 34 and a second particle supply unit 36 . A process gas control unit 38 , 42 is provided in the particle supply units 34 , 36 , respectively. By the process gas control unit the fractions of particles in the respective process gas 30 , 32 can be controlled independently of each other. if necessary different process gases 30 , 32 may be used in each particle supply unit 34 , 36 , the process gases being adapted to the particles in the particle reservoirs. From the mixture of particles and process gases 30 , 32 fluids are generated, which can be mixed in varying amounts relative to each other by a supply control device 18 . The mixture depends on the layer 50 desired on the substrate 12 . Usually the mixing ratio of the particles is chosen such that the fraction of the particle mixture with particles from the first particle reservoir 14 is set between 10% and 90%, and that the fraction of particles from the second particle reservoir 16 is set between 10% and 90%.
[0042] The supply control device 18 therein is configured such that a ratio which is constant in time between the amount of particles from the first particle reservoir 14 and the amount of particles from the second particle reservoir 16 can be set for the particle mixture. Furthermore also supply control devices 18 may be employed by which in addition or exclusively a time-varying mixing relation can be set. During the supply of particles it is also possible, at least temporarily, to set the relative amount of one of the particle types to 0 , so that for a specific part of the surface of the substrate 12 the applied first layer 50 contains only particles from one particle reservoir.
[0043] The supply control device 18 may for example be media adder. Therein two fluids may be supplied as two or more partial streams to one or more mixing chambers within the media adder, in which the mixing occurs. The mixing reaction may be controlled, wherein also a time-varying mixing ratio can be set, The mixture is then usually released through an opening in the bottom or top of the mixing chamber and supplied to the transport pipe 24 , which for example may be a system of hoses. For the transport pipe 24 also materials different from hoses can be used, like for example metal pipes, depending on the particles which are to be used for coating the substrate 12 . Via the transport pipe 24 the particle mixture reaches the injector 66 . Upstream of the injector 66 a controller 28 may be provided, by which the amount of particle mixture supplied to the injector 66 is controlled. Control may include a throttling of the particle stream or a dynamical switching process, i.e. controlled blocking and opening of the path to the transport pipe 24 in the controller 28 .
[0044] With this apparatus dynamically changeable layers 50 may be applied. Thickness and material composition can be dynamically set via the supply rates of the particle supply units 34 , 36 and the controller 28 . In this way the composition of a layer may also be dynamically changed during an active coating process.
[0045] FIG. 2 schematically shows a further embodiment of the apparatus for coating a substrate 12 . According to this embodiment of the invention plural, in the example shown two, injectors 66 , 68 correspond to the coating head 26 . Again the particles from the particle supply units 34 , 36 are fluidized in the desired fractions. Afterwards the particles from the particle supply unit 34 are separately supplied to a first injector 66 and enter the plasma jet 22 at a first supply location 46 . The particles from the particle supply unit 36 are supplied to a second injector 68 and enter the plasma jet 22 at a second supply location 48 . Upstream from the injectors 66 , 68 respective supply control devices 18 may be provided, the action of which has already been described in the context of FIG. 1 . Through this arrangement two separate layers 50 , 52 (double layer), independent of each other, can be generated on the surface 12 a of the substrate 12 , the properties of which may be different (see FIG. 6 ).
[0046] There is also the possibility to form a so called gradient layer 54 (see FIG. 3 c ) with this apparatus. This is particularly advantageous, as both the double layer and the gradient layer 54 can be applied onto the substrate 12 in one process step. Depending on the arrangement of the injectors 66 , 68 and therefore depending on the position of the supply locations 46 , 48 relative to the plasma jet 22 a wide range of effects can be achieved. These depend on the injection taking place in different regions of the plasma jet 22 . These regions differ by jet velocity, temperature, and plasma composition. Depending on the fluid dynamical mixing of the material streams, multi layers or mixed layers result ( FIG. 3 ).
[0047] In FIG. 2 there is furthermore schematically shown that the process carried out with the coating head 26 can be extended, To this end a further coating head 27 can be added to the coating apparatus 10 . In the simplest case a plasma process gas 56 and a power supply 58 are provided for this coating head 27 on its feed side 27 E. Furthermore there corresponds to it a third particle supply unit 37 , which in turn has a particle reservoir 15 and a process gas 33 . With the process gas control unit 44 the ratio of process gas 33 and particles from the particle reservoir 15 can be set. By means of an already described supply control device 18 the amount of particles from the particle reservoir 15 can be controlled. Thus a third layer 53 can be deposited onto the second layer 52 .
[0048] In order to form a layer system with more than three layers or a layer system with two or more gradient layers, the coating apparatus 10 may be provided with a further coating head 26 and two injectors 66 , 68 , which correspond to the one described above, instead of the simple coating head 27 described.
[0049] FIG. 3 a schematically shows a layered structure which may be formed with a coating apparatus 10 according to FIG. 2 . Therein a first layer 50 , a second layer 52 , and a third layer 53 have been applied onto the substrate 12 .
[0050] FIG. 3 b schematically shows a so called compound layer 55 , which may be formed with a coating apparatus 10 according to FIG. 1 or 2 . Therein the particles from the particle reservoirs 14 , 16 are mixed by a mixing process ( FIG. 1 ) or by an adequate choice of the supply locations 46 , 48 in such a way that an as homogeneous as possible distribution of the particle types within the volume of the applied compound layer 55 results.
[0051] FIG. 3 c schematically shows a gradient layer 54 which can be formed with the coating apparatus 10 according to FIG. 2 . Therein the supply locations 46 , 48 are chosen in such a way that the amount of particles in y-direction decreases or increases, respectively.
[0052] FIG. 4 schematically shows that it is possible to create various transitions in the sequence of layers to be applied onto the substrate 12 . To this end the shown sequence of layers is formed during a single coating run through a suitable configuration of the coating apparatus 10 .
[0053] In segment A three different materials with the particles r, s, t are deposited with a fixed ratio onto the substrate as a layer. In segment B, later in time during the same coating process, the layer thickness of the compound layer 55 is reduced continuously, and a cover layer of phase u applied on the compound layer 55 . in segment C the layer thickness of the entire multilayer is reduced, until in segment D the layer is interrupted completely and thus the substrate 12 is not covered by a layer at this location. In segment E the layer thickness of the phase u is increased continuously and in regions F transitions into a gradient layer 54 , in which at the surface of the phase u the material r is embedded at the highest concentration.
[0054] FIG. 5 schematically shows the principle of the design of a gradient layer by means of a depth profile. The material composition starts from a layer material S 1 having the highest concentration at the transition point to the substrate 12 . Towards the surface the layer material S 1 decreases continuously, reaching essentially the value zero at the surface. The layer material S 2 essentially has the value 0 at the transition point to the substrate 12 and continuously increases towards the surface. In the example shown there is a transition region U, in which the layer material S 1 and the layer material S 2 have an essentially equal concentration.
[0055] FIG. 6 shows a particular application of the coating apparatus 10 according to the invention and the method according to the invention for coating a substrate 12 with the example of a conductive layer 74 and an insulating layer 72 . Both layers are applied onto a substrate 12 with the coating apparatus 10 . Therein the conductive layer 74 is applied onto the substrate 12 as a strip-like structure. The conductive strip formed this way is to be protected towards the outside by an insulating layer 72 in the region KO. Therein the insulating layer may be interrupted in the regions K 1 and K 2 to facilitate the formation of a contact.
[0056] The invention has been described with reference to preferred embodiments. It is obvious for the skilled person that changes and modifications can be made to the invention without leaving the scope of the subsequent claims.
LIST OF REFERENCE SIGNS
[0057] 10 coating apparatus
[0058] 12 substrate
[0059] 12 a surface of the substrate
[0060] 14 particle reservoir
[0061] 15 particle reservoir
[0062] 16 particle reservoir
[0063] 18 supply control device
[0064] 20 electric arc
[0065] 22 plasma jet
[0066] 23 second plasma jet
[0067] 24 transport pipe
[0068] 25 second transport pipe
[0069] 26 coating head
[0070] 26 A exit side
[0071] 26 E feed side
[0072] 27 second coating head
[0073] 27 E feed side
[0074] 28 controller
[0075] 30 process gas
[0076] 32 process gas
[0077] 33 process gas
[0078] 34 first particle supply unit
[0079] 36 second particle supply unit
[0080] 37 third particle supply unit
[0081] 38 process gas control unit
[0082] 40 particle supply unit
[0083] 42 process gas control unit
[0084] 44 process gas control unit
[0085] 46 first supply location
[0086] 48 second supply location
[0087] 50 first layer
[0088] 52 second layer
[0089] 53 third layer
[0090] 54 gradient layer
[0091] 55 compound layer
[0092] 56 plasma process gas
[0093] 58 power supply
[0094] 60 plasma chamber
[0095] 62 electrode
[0096] 64 electrode
[0097] 66 first injector
[0098] 68 second injector
[0099] 70 third injector
[0100] 72 insulating layer
[0101] 74 conductive layer
[0102] A, B, C, D, E, F segments of a layer
[0103] r, s, t particles
[0104] S 1 layer material
[0105] S 2 layer material
[0106] U transition region
[0107] K 1 region
[0108] K 2 region
[0109] K 3 region
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For improving the variability in the coating of substrates a coating apparatus is proposed having a plasma generator for generating a plasma jet which exits from a coating head of the plasma generator. A first particle reservoir and a second particle reservoir are provided. The particles from the first particle reservoir and the second particle reservoir are supplied to the plasma jet as a particle mixture via a transport pipe. A supply control device is provided for setting the amount of particles from the first particle reservoir fed into the transport pipe relative to the amount of particles from the second particle reservoir.
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[0001] This application is a continuation of U.S. application Ser. No. 11/192,852, filed Jul. 29, 2005; which is a continuation-in-part of U.S. application Ser. No. 09/708,186, filed Nov. 7, 2000, now U.S. Pat. No. 6,959,708; which claimed the benefit of U.S. Provisional Patent Application Nos. 60/164,125, filed on Nov. 8, 1999 and 60/185,495, filed on Feb. 28, 2000. The contents of the above-identified 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 drug delivery. More particularly, the present invention relates to methods and apparatus for delivering physiologically active agents to mucosal and other tissue surfaces in the presence of adjuvant gases.
[0004] Drug delivery to mucosal surfaces, such as the mucosa of the nose, is well known. While in some cases drugs delivered to the nose and other mucosal surfaces are intended to have local effect, more often such transmucosal drug delivery is intended for systemic administration. In either case, penetration of the drug into or through the mucosa is limited by the ability of the particular drug to pass into or through the mucosal cell structure. Such resistance from the mucosal cell structure can result in slowing of the delivery, the need to use higher dosages of the drug, or in the case of larger molecules, the inability to deliver via a nasal or other mucosal route.
[0005] For these reasons, it would be desirable to provide improved methods and systems for transmucosal drug delivery in the nose and other organs. It would be desirable if the concentration of drug being delivered could be lowered while achieving an equivalent local or systemic physiologic effect. It would be further desirable if the activity or effective delivery of the drug could be enhanced without the need to raise the dosage or drug concentration. At least some of these objectives will be met by the invention described and claimed hereinbelow.
[0006] 2. Description of Background Art
[0007] Inhalation devices, systems and methods for delivering carbon dioxide and other gases and aerosols to patients, with and without co-delivery of a drug are described in U.S. Pat. Nos. 3,776,227; 3,513,843; 3,974,830; 4,137,914; 4,554,916; 5,262,180; 5,485,827; 5,570,683, 6,581,539; and 6,652,479. While some methods and devices provide for co-delivery of a drug and carbon dioxide or other gases, the purpose is usually not potentiation. For example, carbon dioxide may be used as a safe propellant, as shown in Wetterlin, U.S. Pat. No. 4,137,914. See also copending application Ser. Nos. 09/614,389; 10/666,947; and 10/666,562, the full disclosures of which are incorporated herein by reference.
[0008] Additional background art may be found in the following references: Guyton A C, Hall J E. Textbook of Medical Physiology . Ninth Ed., W.B. Saunders Co., Philadelphia, 1996; Tang A, Rayner M, Nadel J. “Effect of CO 2 on serotonin-induced contraction of isolated smooth muscle. Clin Research 20:243, 1972; Qi S, Yang Z, He B. An experiment study of reversed pulmonary hypertension with inhaled nitric oxide on smoke inhalation injury. Chung Hua Wai Ko Tsa Chih 35(1):56-8, January 1997; Loh E, Lankford E B, Polidori D J, Doering-Lubit E B, Hanson C W, Acker M A. Cardiovascular effects of inhaled nitric oxide in a canine model of cardiomyopathy. Ann Thorac Surg 67(5): 13 80-5, May 1999; Pagano D, Townend J N, Horton R, Smith C, Clutton-Brock T, Bonser R S. A comparison of inhaled nitric oxide with intravenous vasodilators in the assessment of pulmonary haemodynamics prior to cardiac transplantation. Eur J Cardiothorac Surg 10(12):1120-6, 1996; and Sterling G, et al. Effect of CO2 and pH on bronchoconstriction caused by serotonin vs. acetylcholine. J of Appl. Physiology , vol. 22, 1972.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention provides methods and systems for delivering physiologically active agents to tissue. The methods rely on contacting a tissue surface, typically a mucosal tissue surface, with the physiologically active agent while simultaneously and/or sequentially (either before or after) suffusing the same tissue surface with an adjuvant gas which promotes the uptake of the agent by the tissue and/or which promotes an activity of the agent. Mucosal surfaces targeted for drug delivery by the methods and apparatus of the present invention include the nasal mucosal surface, oral mucosal surfaces, ocular mucosal surfaces, auricular mucosal surfaces, and the like. The adjuvant gas may be any vasoactive, myoactive, or neuroactive gas or vapor which is capable of enhancing the efficacy of the agent being delivered and/or which is capable of reducing the dosage or concentration of agent being delivered while achieving an activity equivalent to a higher dosage and/or concentration. Preferred adjuvant gases include carbon dioxide, nitric oxide, nitrous oxide, and dilute acid gases, such as dilute hydrochloric acid, hydrofluoric acid, and the like. Particularly preferred are carbon dioxide gases having a relatively high concentration, typically greater than 10% by volume, usually greater than 20% by volume, and preferably greater than 25% by volume and often being as great as 80% by volume, 90% by volume, and in many instances being substantially pure. The adjuvant gases may be used in combinations of two or more adjuvant gases and/or may be combined with physiologically inert gases such as nitrogen, to control concentration of the active gases.
[0010] The physiologically active agent will be in a form which is capable of being delivered to the mucosal or other tissue surface, usually being in the form of a gas, vapor, liquid, mist, or powder. In certain instances, however, the drug can be in the form of a pill or other conventional solid dosage form which may be placed on the mucosal or other surface, e.g., beneath the tongue when the oral cavity is to be suffused with the adjuvant gas. Physiologically active agents which may be delivered include drugs selected from the group consisting of nitroglycerin, triptans, imidazopyridines (such as zolpidem available under the brand name Ambein®), 5-HT3 antagonists (such as ondansetron available under the brand name Zofran®), epinephrine, angiotensin II, atrophine, apomorphine, opioids, and the like.
[0011] Systems according to the present invention for delivering physiologically active substances to a mucosal surface comprise a source of an adjuvant gas and a source of the physiologically active substance, typically in fluid or other deliverable form. The systems may comprise some mechanism, structure, or the like, for delivering both the adjuvant gas and the physiologically active substance to the mucosal surface. Usually, the delivering structure will comprise a hand-held dispenser, for example where the dispenser includes a pressurized source of the adjuvant gas and a valve assembly for releasing the gas at a controlled flow rate, typically in the range from 0.5 cc/sec to 20 cc/sec in the case of high concentration of carbon dioxide. The physiologically active substance may be dissolved or suspended in the pressurized adjuvant gas for simultaneous delivery. Alternatively, the physiologically active substance may be delivered from a separate receptacle, either through the same or a different delivery path. Often, the adjuvant gas and the physiological gas, even when stored in separate receptacles, will be delivered through a common conduit and nozzle to allow for both simultaneous and sequential delivery. The exemplary adjuvant gases and physiologically active agents incorporated into these systems are the same as those set forth above with respect to the method.
[0012] The co-application of a drug with the adjuvant gas can be performed in at least three different ways. First, the drug and gas can be applied together locally by co-infusion and transmucosal co-absorption nasally, orally, and/or via the eye or ear. The form of the drug, of course, would need to be suitable for such infusion, for example, a fine powder or liquid. If the combination of the drug and gas is applied nasally or orally for local transmucosal absorption, the individual would preferably substantially inhibit passage of the drug and gas into his lungs and trachea by limiting inhalation of the gas and drug. Second, the drug and gas may be applied separately. The drug will be applied to infuse a nostril or nostrils, mouth, eye or ear or other body cavity having a mucosal surface with the gas before, during or after application of the drug.
[0013] As an example of the first method, a drug previously infused into the oral cavity, mouth, eyes, or ears by entraining with air, e.g., as an aerosol, powder, or spray, can be applied according to the present invention by entraining with CO 2 , e.g., through aspiration of a drug-containing liquid or powder by CO 2 . In particular, the action of drugs developed and presently used for relieving respiratory and headache symptoms may be improved by their co-infusion with CO 2 , NO, or other adjuvant gases identified herein. The vasodilation which may be induced by CO 2 or NO may improve the speed and extent of absorption and distribution of the drug in the tissue in which it is co-absorbed with CO 2 or NO. This is beneficial through more rapid relief being obtained, and/or through reduction in the quantity of drug required to obtain the relief. Reduction in the required quantity of drug reduces the cost of treatment per dose and particularly reduces the side effects of such drugs, which are severe restrictions to their present use.
[0014] With respect to the second method, a particular benefit of co-application of such drugs with CO 2 or other adjuvant gases is that, in addition to the reduction of the total amount of drug required, the effect of the drug can be controlled or “modulated” in the course of its action after application. Infusion of CO 2 prior to drug application can increase the effectiveness and reduce the required quantity of the drug. Alternatively, infusion of CO 2 after application of a drug can enhance the effect of the drug at a controlled rate; i.e., if a more rapid or more intense effect of the drug is desired, CO 2 can be infused at the rate required to obtain the desired degree of enhancement. A particular advantage of such control is that the drug enhancement effect can be abruptly terminated, by ceasing CO 2 infusion, at the optimum level of beneficial drug effect that minimizes side or overdose effects. Also, since CO 2 is rapidly eliminated from the body via the bloodstream and respiration, the enhancement is reversible after CO 2 application is ceased, allowing continuous chronic adjustment of the drug effect.
[0015] An example of the beneficial regulation of the effect of a powerful drug by CO 2 inhalation or infusion is the co-application of CO 2 and nitroglycerin for the relief of acute angina and during onset of a heart attack (myocardial infarction). Nitroglycerin is a powerful vasodilator. Ordinarily persons suffering from angina or from symptoms of heart attack place a nitroglycerin tablet under their tongue (transmucosal delivery). If this is not adequate to relieve the symptoms within three minutes, another tablet is similarly ingested. After another three minutes, if relief is not obtained, this process is again repeated. If the symptoms then persist, a person should be taken immediately to a hospital for emergency treatment. Some persons are extremely sensitive to the side effects of nitroglycerin however, including severe blood pressure reduction that can result in dizziness and fainting, especially after ingesting the second tablet, at a time when good judgment and deliberate corrective action are required. A few minutes of delay can be crucial after the onset of a heart attack. With co-application, CO 2 can be infused after the first tablet to rapidly enhance and sustain its effects, possibly reducing the need for subsequent tablets. The effects of a second tablet of nitroglycerin can be initiated gradually and reversibly with CO 2 application to maintain and extend the optimum degree of pain relief without severe blood pressure reduction.
[0016] In all three methods cited only one physiologically active or other adjuvant gas is used; however, physiologically active gases may be used together, with or without drugs. For example, CO 2 has been found to relax both central and peripheral airways in asthmatic adults (Qi et al. (1997) supra). Similarly, in both in vivo and clinical tests, inhaled low dose NO has been found to be as effective as sodium nitroprusside and prostacyclin in reducing transpulmonary gradient and pulmonary vascular resistance, and is highly pulmonary vasoselective (Sterling et al., (1972) supra). NO has also been found to reverse pulmonary hypertension (Loh et al. (1999) and Pagano et al. (1996), supra). Therefore, NO and CO 2 can be co-applied to potentiate their respective actions or otherwise interact.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 illustrates an exemplary co-infusion device, illustrating the charge/dose and dose rate adjustment features.
[0018] FIG. 2 is a schematic illustration of a delivery system incorporating separate receptacles for the adjuvant and the physiologically active agent, where the receptacles are joined through valves into a common delivery conduit.
[0019] FIGS. 3A-3E show application of the adjuvant gas optionally in combination with the physiologically active agent to the nose, mouth, both nostrils, eye, and ear, using a gas dispenser according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] An exemplary carbon dioxide dispenser 100 comprising a carbon dioxide cartridge 101 is illustrated in FIG. 1 . The embodiment of FIG. 1 is described in greater detail in parent application Ser. No. 09/708,186, now U.S. Pat. No. 6,959,708, the full disclosure of which has previously been incorporated herein by reference. A user delivers a dose of carbon dioxide (optionally carrying the physiologically active agent to be delivered) by applying the top of the dispenser 608 to the user's nose or mouth and pushing a button 600 which releases an internal mechanism to allow the CO 2 to flow from the top of the dispenser 608 . The internal mechanism will lower the pressure of CO 2 in the cartridge and will control the flow rate within suitable ranges, typically from 2 to 10 cc/sec. The flow rate may be maintained for a suitable time period, typically at least 2 seconds when suffusing the nasal and sinus passages. The device is cocked by rotation as shown by arrow 602 and pushing the button 600 to deliver the dose by an automatic counter-rotation. The user may select the specific carbon dioxide flow rate by setting at a set screw through aperture 609 .
[0021] The hand-held dispenser 100 of FIG. 1 may be used to deliver any of the adjuvant gases in accordance with the principles of the present invention. The adjuvant gases may be delivered with or without the physiologically active agent incorporated in the canister 101 . In cases where the adjuvant gas is to be delivered by itself, at some suitable concentration, the physiologically active agent will have to be delivered to the target mucosal or other tissue surface in some other manner. The physiologically active agent, for example, could be delivered by separate suffusion or infusion, by placing a liquid, powder, or the like over the tissue surface, by introducing a vapor, mist, or the like using conventional drug delivery vapor sources and misters, or the like. In some instances, such as the delivery of nitroglycerin, it would be possible to simply place a solid dosage form at the mucosal surface through which the drug is to be delivered. The adjuvant gas can be delivered before, during, and/or after any of the steps taken to deliver the physiologically active agent.
[0022] FIG. 2 is a schematic illustration showing a system for simultaneous or sequential delivery of the adjuvant gas and physiologically active agent. The adjuvant gas is held in a separate cartridge or other container 202 while the physiologically active agent is held in a cartridge or other container 204 . Both the gas and the physiologically active agent will be in a gaseous, vapor, mist, or other flowable form which permits them to pass through associated valves 206 and 208 respectively, and thereafter through a conduit 210 which receives flow from both valves. The valves will be suitable for controlling both flow rate and pressure of the adjuvant gas and the physiologically active agent. It will be appreciated that more complex delivery systems can be provided including flow rate measurement, feedback control, temperature control, timers, and the like.
[0023] Referring now to FIGS. 3A to 3E , a variety of ways for effecting mucosal infusion with the adjuvant gas, optionally combined with the physiologically active agent, are illustrated. The adjuvant gas is preferably infused at a flow rate in a range from 0.5 cc/sec-20 cc/sec, depending on the tolerance of the individual being treated. In some instances, the selected drug or other physiologically active agent can be delivered separately by suffusion, infusion, misting, the application of powder, or the like. As shown in FIG. 3A-B , the individual P then infuses oral and nasal mucous membranes by placing the source of low flow rate CO 2 or other appropriately physiologically active gas or vapor in or around a facial orifice, such as the mouth or nostril, while substantially inhibiting the flow of the CO 2 into the trachea and lungs by limiting inhalation of the CO 2 . If the mouth is infused the gas is allowed to exit from the nostrils. Alternatively, one or both nostrils may be infused either by using the dispenser head shown in FIG. 3B or by use of a cup or similar device that covers both nostrils as shown in FIG. 3E . The gas is allowed to flow from a remaining open orifice, i.e., either the mouth, the uninfused nostril, or both as appropriate. Completely holding the breath is not necessary to substantially prevent inhalation of the CO 2 . With practice, it is possible for the individual to breathe through an uninfused orifice: for example, if one nostril is infused and the gas is allowed to exit though the other nostril, it is possible for the individual to breathe through the mouth without substantial inhalation of the infused gas. The eye or eyes may also be infused using a cup as shown in FIG. 3C or merely by holding a hand over the eye and releasing the gas between the hand and the eye. Persons of ordinary skill in the art will appreciate that a double cup could be developed to infuse both eyes simultaneously, and similarly appropriate heads could be developed to infuse the mouth and one nostril. The ear or ears may also be infused as shown in FIG. 3D . Note that a similar process may be used with the first embodiment to infuse a mixture of a drug and gas into various facial orifices.
[0024] Infusion can be continued to the limit of tolerance or until the desired potentiation effect is realized. Since most individuals develop a temporary increased tolerance after extended applications or repeated applications, it may be possible and desirable to increase the duration of additional infusions after a few applications when all applications occur within a short time of each other, i.e., approximately 1 to 20 minutes between each application.
[0025] While the above is a complete description of the preferred embodiments of the invention, various alternatives, modifications, and equivalents may be used. Therefore, the above description should not be taken as limiting the scope of the invention which is defined by the appended claims.
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Apparatus and methods deliver physiologically active agents in the presence of adjuvant gases. The adjuvant gases can enhance the effectiveness of the drug, lower the dosage of drug or concentration of drug necessary to achieve a therapeutic result, or both. Exemplary adjuvant gases include carbon dioxide, nitric oxide, nitrous oxide, and dilute acid gases.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to processing signals, and more particularly to a system and method for performing duty-cycle correction of clock and other frequency signals.
[0003] 2. Background of the Related Art
[0004] Synchronous chips often use a latch design in which a logic path propagates in one phase (high or low) of a clock signal. In chips of this type, phase paths are influenced by duty-cycle distortion of the clock signal. This mainly occurs because of process variations and/or changes in the level of the voltage supply (e.g., changes in transistor characteristics with voltage supply level). As a result, if one of the clock phases in a synchronous chip is reduced, data may be sampled earlier than expected and this may lead to phase-path failure.
[0005] To overcome this problem, the frequency of the clock signal can be reduced to a value that compensates for and thus restores the original phase duration. For example, a 2% duty-cycle distortion in a 2 GHz clock frequency results in a 10 ps reduction of the clock phase. Thus, to restore the original clock phase period of 250 ps, the clock frequency may be reduced to 1920 MHz.
[0006] In higher frequency CPUs, phase-path designs have increasingly been used. As presently implemented, this design has a number of drawbacks, not the least of which include increasing the sensitivity of the maximum operating frequency of the CPU relative to duty-cycle distortion of a core clock signal. In fact, core clock duty-cycle distortion is one of the main factors that limits the maximum frequency of the CPU.
[0007] Conventional high-performance CPUs use static duty-cycle correction circuits. These circuits are based on a digitally controlled phase shifter that varies the clock phase duration with a predetermined resolution. The clock phase is shifted in automatic test equipment based on test programs to optimize the maximum frequency of the CPU. This approach is undesirable for at least two reasons. First, valuable tester time is wasted which makes the procedure inefficient. Second, testing is performed at only one voltage point, which tends to diminish the effectiveness of the overall process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a diagram of a duty-cycle correction loop in accordance with one embodiment of the present invention.
[0009] FIG. 2 is an equivalent block diagram of one possible implementation of a single-input charge pump which may be included in the duty-cycle correction loop.
[0010] FIGS. 3 ( a )-( c ) are graphs showing waveforms produced by the duty-cycle correction loop at respective ranges of duty-cycle values.
[0011] FIG. 4 is a functional block diagram of one possible implementation of a single-input charge pump which may be included in the duty-cycle correction loop.
[0012] FIG. 5 is a diagram showing one possible implementation of a voltage-controlled buffer which may be included in the duty-cycle correction loop.
[0013] FIG. 6 is a graph showing an exemplary level of performance that may be attained by at least one embodiment of a duty-cycle correction loop of the present invention.
[0014] FIG. 7 is a graph showing loop convergence that may be obtained by the duty-cycle correction loop for the illustrative case of a ±30 ps duty-cycle increment.
[0015] FIG. 8 is a diagram showing a processing system which may include one or more embodiments of the duty-cycle correction loop of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0016] FIG. 1 shows a duty-cycle correction loop according to one embodiment of the present invention. The loop includes a duty-cycle correction circuit 100 and a global clock network 110 . The duty-cycle correction circuit includes a voltage-controlled buffer (VCB) 120 , a startup circuit 121 , and a bias generator 122 as well as a loop filter 123 and a single-input charge pump (CP) 124 . Using these elements, the duty-cycle correction circuit generates a corrected output clock signal from an input clock signal.
[0017] The global clock network distributes the signal output from the correction circuit to other circuits. This may be accomplished using one or more buffers which control the timing and distribution of the correction circuit signal. The global clock network may therefore be considered a distribution network (i.e., one that takes the clock signal output from the correction circuit and merely distributes where needed), as opposed to one which changes the frequency of the clock signal. The signal output from the global clock network may be referred to as a core clock signal because, for example, it may be supplied to one or more logic blocks of a host circuit (e.g., chip, microprocessor, or system) as well as other areas.
[0018] The global clock network is usually a main source of duty-cycle distortion. The output of the global clock network (core clock) may therefore be used as a basis for measuring duty cycle distortion. The correction circuit ensures that the duty cycle of the core clock signal is maintained at a predetermined value (e.g., as close to 50% as possible) by continuously monitoring the core clock signal to detect duty cycle distortion and then correcting that distortion. Monitoring is performed by feeding the core clock signal back to the single-input CP 124 in a manner that will be described in greater detail below.
[0019] In addition to the core clock signal, the CP may optionally receive a bias voltage from bias generator 122 . Using the feedback clock signal (or a combination of the feedback signal and bias voltage), the CP generates a current that is injected into loop filter 123 and the loop filter converts the charge pump current into a correction voltage V 1 for input into the bias generator. The bias generator then generates an analog control voltage V cntl for input into the voltage-controlled buffer based on a predetermined bias. The voltage-controlled buffer then processes the input clock signal based on the analog control voltage to produce a output clock signal with a corrected duty cycle.
[0020] The duty cycle of the output clock signal depends on the control voltage provided by the bias generator, which control voltage is preferably applied to correct the duty cycle of the VCB output clock. on a continuous basis, not only during testing procedures but also during active operation of the global network clock. The output clock signal is then used as a basis for generating the core clock signal. As shown, the control voltage and bias voltage fed back to the charge pump may be the same signal.
[0021] In the foregoing embodiment, the voltage-controlled buffer is shown as being included in an input stage of the global clock network, that generates the core clock signal for driving the entire chip. To ensure stable performance, the core clock signal is fed back to the correction circuit for detecting duty-cycle distortion. This distortion is measured as a function of the output of the charge pump. More specifically, the average output current of the charge pump taken over a predetermined time (e.g., one core clock cycle) is proportional to and thus may be used as a basis for determining the duty-cycle distortion of the core clock signal.
[0022] Once the average output current of the charge pump has been determined, it is converted into a correction voltage (V 1 ) by the loop filter 123 . The bias generator 122 converts correction voltage V 1 to a proportional change in the control voltage of the voltage-controlled buffer. This correction process is continued until the average output current of the charge pump is zeroed, which occurs, for example, when the duty cycle of the core clock signal is at a predetermined value, e.g., 50%. Bias generator 122 generates the self-bias voltage of the CP circuit 124 and a startup circuit 121 is used to generate an initial DC bias voltage to the CP.
[0023] FIG. 2 shows an equivalent block diagram of one possible implementation of the single-input charge pump. The charge pump includes a control signal generator 200 , a positive current source 210 , a negative current source 220 , and two switches 230 and 240 which selectively connect the current sources to a node 250 . This node outputs the aforementioned correction voltage V 1 to loop filter 123 (shown here as including Vcc and capacitor C) and then to the bias generator. Generation of correction voltage V 1 will now be explained in greater detail.
[0024] The core clock signal (shown as gclk in FIG. 2 ) drives the charge pump by initially being input into control signal generator 200 . The control signal generator then generates two signal pulses (gclkpl and gclkph) to control the charge pump switches, which in turn respectively connect the positive and negative current sources Icp(+) and Icp(−) to node 250 . The gclkpl signal has a duration equal the low phase of the gclk signal, while gclkph has a duration equal to the high phase of gclk. Whether or not duty-cycle distortion exists in the gclk signal may therefore be determined based on a comparison of the durations of the gclkpl and gclkph pulses.
[0025] When the gclk signal has a 50% duty cycle and thus no distortion exists, the two pulses, gclkph and gclkpl, have the same duration. Thus, the total charge injected into the loop filter capacitor is zero: Icp(+)=Icp(−). Put differently, Icp(+) and Icp(−) have equal absolute values but are opposite in sign, so that the average output current from node 250 is zero. Moreover, if gclk has a 50% duty cycle, then THIGH(gclkph)=THIGH(gclkpl). So, Icp(+)*THIGH(gclkpl)=Icp(−)*THIGH(gclkph). A distortion exists when the gclk signal does not have a 50% duty cycle.
[0026] When the duty cycle distortion of the core clock signal is below 50%, gclk may be considered to have a low value. The control signal generator then generates gclkpl to have a longer duration than gclkph. When the duty cycle distortion of the core clock signal is above 50%, gclk may be considered to have a high value. The control signal generator then generates gclkph to have a longer duration than gclkpl.
[0027] FIGS. 3 ( a )-( c ) are graphs showing waveforms obtained for each of three duty-cycle ranges and how correction is or is not performed during each case. In each of these figures, the gclkph pulse used to control connection of the Icp(−) source to node 250 may correspond to a copy of the gclk signal and the gclkpl used to control connection of the Icp(+) source to node 250 may be an inverted copy of the gclk signal. The duration each current source is connected is reflected in the graph corresponding to the Icp output current.
[0028] In FIG. 3 ( a ), the duty cycle of the core clock signal gclk is at a desired value, e.g., 50% corresponding to the case where half of the core clock signal has a high-level voltage and half is at a low-level voltage. The high-level voltage may be a value close to a power supply voltage and the low-level voltage a value close to ground. In this case, the time positive current source Icp (+) 230 is connected to node 250 equals the time negative current source Icp(−) 240 is connected. As a result, the average output current of the charge pump Icpavg is zero. Consequently, the average voltage V 1 does not change (ΔV 1 =0). Since the control voltage into VCB is proportional to V 1 , no duty cycle correction is required or performed under these circumstances.
[0029] In FIG. 3 ( b ), the duty cycle of the core clock signal gclk is measured to be less than 50%, corresponding to a case where less than half of the core clock signal has a high-level voltage and more than half has a low-level voltage. In this case, the time positive current source Icp (+) 230 is connected is greater than the time negative current source Icp(−) 240 is connected. As a result, the average output current of the charge pump Icpavg is greater than zero. Consequently, the average voltage V 1 changes to a value greater than zero (ΔV 1 >0). This value drives the bias generator to generate a control voltage for the VCB to be greater than zero by a proportional amount, thereby correcting the duty cycle of the input clock signal. The corrected duty cycle is reflected in the output clock signal, which is used by the global clock network as a basis for generating the core clock signal.
[0030] In FIG. 3 ( c ), the duty cycle of the core clock signal gclk is measured to be greater than 50%, corresponding to a case where less than half of the core clock signal has a low-level voltage and more than half a high-level voltage. In this case, the time positive current source Icp (+) 230 is connected is less than the time negative current source Icp(−) 240 is connected. As a result, the average output current of the charge pump Icpavg is less than zero. Consequently, the average voltage V 1 changes to a value less than zero (ΔV<0). This value drives the bias generator to generate a control voltage for the VCB to be less than zero by a proportional amount, thereby correcting the duty cycle of the input clock signal. The corrected duty cycle is reflected in the output clock signal, which is used by the global clock network as a basis for generating the core clock signal.
[0031] In each of the cases discussed above, the gclkph pulse has a duration equal to the time the gclk signal has a high-level value. This is reflected in the duration of Icp(−) in the graphs. Thus, in this sense gclkph may be said to correspond to a copy of the gclk signal. The gclkpl pulse has a duration equal to the time the gclk signal has a low-level value. This is reflected in the duration of Icp(+) in the graphs. Thus, in this sense gclkpl may be said to correspond to an inverted copy of the gclk signal.
[0032] The average change in voltage ΔV 1 is proportional to the average current at the charge pump output and therefore is proportional to the duty cycle distortion of the core clock signal. The control voltage of the voltage-controlled buffer VCB 120 is, in turn, inversely proportional to V 1 , e.g., V cntl decreases when V 1 increases. The voltage-controlled buffer functions to correct the duty cycle of the input clock signal to thereby correct the duty cycle in the core clock signal. This may be accomplished in the following exemplary manner.
[0033] The VCB may have a fixed delay for the rising edge of the input clock signal (rise-rise delay) and a voltage-controlled delay for the falling edge of the input clock signal (fall-fall delay). The fall-fall delay is directly proportional to the control voltage input into the VCB. Thus, if the control voltage increases (e.g., to a value greater than zero as shown in FIG. 3 ( b )), the fall-fall delay will increase. This will cause the duty cycle of the clock signal to increase, which is desirable in the case of FIG. 3 ( b ) where the duty cycle was measured to be less than 50%. If the control voltage decreases (e.g., to a value less than zero as shown in FIG. 3 ( c )), the fall-fall delay will decrease. This will cause the duty cycle of the clock signal to decrease, which is desirable in the case of FIG. 3 ( c ) where the duty cycle was measured to be greater than 50%.
[0034] FIG. 4 is a functional block diagram of one possible implementation of the single-input charge pump. The charge pump preferably includes a CP buffer 410 and a high-performance charge pump 420 . The buffer receives the core clock signal gclk and selectively generates one of two complementary control signals gclkb and gclkb# to operate the high-performance CP. The first signal (gclkb) is high when gclk has a high-level voltage, while gclkb# is high when gclk has a low-level voltage. Operation of the single-input charge of FIG. 4 is equivalent to the operation of the control signal generator explained with reference to FIGS. 2 and 3 ( a )-( c ), where gclkb and gclkb# operate in a manner similar to gclkph and gclkpl. The single-input CP preferably has the same steady-state input phase offset as the high-performance CP (<2 pS). Accordingly, the single-input CP is a high accuracy duty-cycle distortion measurement circuit.
[0035] FIG. 5 shows one possible implementation of voltage-controlled buffer 120 . The buffer includes a cascode amplifier 510 which generates a bias voltage for two serial bias-controlled buffers 520 and 521 . The cascode amplifier includes a diode-connected transistor 522 serving as an active load, two (always-on) transistors 523 and 524 connected in series, and an current-source transistor 525 . Transistor 525 acts as a current source controlled by control voltage V cntl output from bias generator 122 , however those skilled in the art can appreciate that this control voltage may be connected to one of the other two transistors if desired. All transistors may be implemented in NMOS except transistor 522 where PMOS is preferable.
[0036] Both bias-controlled buffers are constructed from a bias-controlled inverter followed by a regular inverter. In the first bias-controlled buffer, the bias-controlled inverter is formed from two complementary transistors, PMOS transistor 527 and NMOS transistor 528 . The PMOS transistor 526 and NMOS transistor 529 set the drive current (“strength”) of the inverter. (PMOS 526 and NMOS 529 act as current sources controlled by bias voltage). In the second bias-controlled buffer, the bias-controlled inverter is formed from complementary transistors 533 and 534 and the bias control is performed by transistors 532 and 535 .
[0037] In operation, the bias circuit affects the drive strength of the inverter, by controlling the amount of current the inverter can drive in the up or down transition. More specifically, the control voltage V cntl from bias generator 122 determines up and down transition currents of the bias-controlled inverter in the first buffer stage and therefore affects the output slope of the bias-controlled buffers. When V cntl decreases, the bias voltage increases, the up-transition slope at the bias-controlled inverter output is increased and the down-transition slope decreases. Thus, the high-phase width of the inverter output clock 530 is decreased and the low-phase width of the inverter output clock 530 is increased. After a second inverter 531 , the duty cycle of the VCB output clock increases. When V cntl voltage increases, the low-phase width of the output clock is increased and the high-phase width is reduced. Accordingly, the duty cycle of the VCB output clock decreases.
[0038] To achieve this operation, NMOS transistor 525 acts as a current source and is never off. When V cntl increases, the current of transistor 525 increases and bias (in FIG. 5 ) decreases (transistor 522 acts as a diode, and as the current increases the voltage drop across it increases, as Vbias decreases).
[0039] Transistors 526 and 532 serve as current sources whose current is controlled by the bias signal, and transistors 529 and 535 also act as current sources controlled by the bias signal. When the bias signal decreases, the currents of current sources 526 and 532 increase, while the currents of current sources 529 and 535 decrease. The up transition in nodes 530 and 536 is faster, the down transistor is slower. Thus, the up transition slope of inverter 531 ( 537 respectively) is slower, and the down transition is faster. The high phase at the output is decreased, and the low phase is increased. The voltage-controlled buffer affects the delay of the rise transition and the fall transition by different amounts, compensating for the duty-cycle distortion. If the core clock signal has a short high phase (duty cycle <50%), the voltage-controlled buffer acts to increase the high phase (faster slope up, slower slope down).
[0040] Performance-wise, the correction circuit dynamically adjusts the output clock signal (and thus the core clock signal) to reduce or eliminate duty-cycle distortion or corrects duty cycle back to any value desired based on the intended application of the host circuit. This dynamic control is implemented through the generation of an analog control signal V cntl , which is unlike other proposed correction circuits which attempt to reduce duty-cycle distortion by making adjustments in predetermined discrete increments, e.g., in increments of 5 ps. This approach is undesirable because it limits accuracy and the extent to which correction can be made. For example, when duty-cycle distortion is only 2 ps, a digital system which makes adjustments in discrete 5 ps increments will at best leave a distortion of 3 ps for one phase that cannot be compensated for. At least one embodiment of the duty-cycle correction circuit of the present invention can, through its continuous (e.g., non-discrete) and dynamic approach, generate an analog correction value that can eliminate substantially all 5 ps of distortion.
[0041] Other proposed correction circuits are also dependent on process characteristics, voltage, and temperature. Because of this dependence, the accuracy of correction may be affected. One or more embodiments of the duty-cycle correction circuit of the present invention are independent of these influences and thus can achieve superior performance. Also, other proposed correction circuits have only been implemented during testing processes, not during operation of the host circuit or in otherwise real system applications. One or more embodiments of the correction circuit of the present invention corrects duty-cycle distortion continuously and automatically, irrespective of whether the host system is operating our under test.
[0042] FIG. 6 is a graph showing a level of performance attainable by at least one embodiment of a duty-cycle correction circuit according to the present invention. The graph plots output clock signal duty cycle as a function of input clock signal duty cycle for a 2 GHz clock frequency measured over a wide range of duty-cycle distortion (40%-60%) at the input loop. In this example, the output clock duty-cycle distortion is less than ±1% for 40%-60% duty-cycle distortion in the input clock. Moreover, for a narrow interval, a 45%-55% (duty-cycle distortion due to process variability) output clock duty cycle distortion is less than ±0.1%.
[0043] For example, a 40% input clock duty cycle (200 ps HIGH, 300 ps LOW) produces an output clock duty cycle of 49.2% (246 ps HIGH, 254 ps LOW). These and other plot points on the curve show that the duty-cycle correction circuit (and more specifically the voltage-controlled buffer) achieves steady state performance, which is a level of performance which cannot be obtained with discrete solutions. The graph also shows that the same level of performance may be obtained for different supply voltages (and adjusts when the supply voltage varies). In contrast, other circuits perform correction at a single-voltage/single-frequency point.
[0044] FIG. 7 is a graph showing an example of a loop convergence that may be obtained for a ±30 ps duty-cycle increment at the input clock. More specifically, a ±30 ps increment is corrected to a less than 2% duty cycle distortion in approximately 50 core clock cycles.
[0045] FIG. 8 is a diagram of a processing system which includes a processor 810 , a power supply 820 , and a memory 830 which, for example, may be a random-access memory. The processor 810 may include an arithmetic logic unit 812 and an internal cache 814 . In addition to these elements, the processing system may optionally include a graphical interface 840 , a chipset 850 , a cache 860 , and a network interface 870 .
[0046] The duty cycle correction circuit 100 may be used to generate timing and/or clock signals for controlling operations of the chipset or processor, or for controlling the transfer of data between either of these elements and the memory. Those skilled in the art can appreciate that these applications are only illustrative, as the duty-cycle correction circuit may be applied in such a processing system to generate or correct any type of timing or clock signals required. Also, in accordance with at least one embodiment, duty-cycle correction is performed continuously and dynamically, i.e., correction is not performed in discrete increments like many digital systems which have been proposed but rather involves performing analog control which preferably results in precisely matching and thus altogether eliminating duty-cycle distortion.
[0047] One or more embodiments of the present invention have been described in the exemplary case where duty cycle of a clock signal is corrected to 50%. Variations include correcting the duty cycle to values other than 50%, for example, when the intended application and/or host system incorporating the duty cycle correction circuit requires performance of this type.
[0048] The description is merely exemplary and not to be construed as limiting of any one or more of the embodiments of the present invention described herein. Rather, the description is merely intended to be illustrative and not to limit the scope of the claims in any way. Many alternatives, modifications, and variations will be apparent to those skilled in the art. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures.
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A control circuit corrects duty-cycle distortion of clock signals accurately and with a fast and continuous response over a wide dynamic range. In one embodiment, the duty-cycle correction circuit includes a self-biased loop that corrects duty-cycle distortions to preferably less than ±1%. The duty-cycle correction circuit also compensates for changes in a supply voltage. These corrections may take place on a continuous basis, not only during a testing period but also during normal operation of the host system driven by the clock signals.
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SCOPE OF THE INVENTION
The invention concerns an enclosure (hereinafter a “unit”) incorporating electronic components, which produce considerable quantities of waste heat (hereinafter “heat”) when in operation. To dissipate this heat the unit is furnished with a plurality of cooling fins or ribs.
STATE OF THE EXISTING TECHNOLOGY
As is already known, a predominate number of electronic components produce considerable amounts of heat during operation. This heat should be advantageously dissipated into the ambient environment. Electronic, load carrying elements, such as transistors or impedances produce especially great quantities of heat.
Importantly, if a multiplicity of electronic components is applied within a tight enclosure without atmospheric circulation so that protection is provided to combat undesirable environmental properties including humidity and air-borne dust the generated heat, can produce high temperatures in the immediate area of circuitry. An increase in temperature degrades the efficiency of the circuit elements, cuts down the operating life of components or, in some cases, can destroy the electronic component itself.
A conventional practice in providing cooling means for the avoidance of overheating may include the formation of ribs in the unit which carries the electronic component for the pickup and radiation of heat. Resulting from the placement of such ribs, a unit must be must be of such a character, that on an inner section a heat producing electronic component is present and on a section distant therefrom, cooling ribs be installed. In this type of manufacture, generated heat is transferred to cooling ribs and is dissipated into the surrounding air.
To develop a solution to unwanted heat, EP 1 996 004 A1 proposes added components designed for more rapid heat dissipation. These additions are in the form of coils, which are inserted into separated areas of the unit and are simultaneously blocked off from heat transfer to supports of electronic components. EP 1 996 004 A1 is based on an application for a converter, wherein the unit is furnished with indentations to receive the said heat relieving coils. This arrangement restricts heat transfer to sensitive elements. Cooling ribs are installed on an exposed outer section of the enclosing unit to remove heat from the inserted coils. The described separation of elements also provides a lower temperature in the interior of the unit.
The disadvantages of the above described cooling lies in disadvantageous changes in the shape of the unit housing. Manufacturing costs of housings are increased by valley-like indentations and their presence results in a bulky appearance of the finished unit.
DE 10 2004 030 457 A1 discloses another solution, in accord with which, unit housing is divided into two chambers. The first chamber is sealed off and possesses a high degree of protective measures. The second chamber is provided with air passage slits. The electronic operational components employ a partitioning wall between the two chambers as a heat transfer surface. Sensitive electronic components, which are to be guarded from environmental influences, are placed in the first chamber. Other components—here, for instance, self protected electronic components immersed in congealed plastic—are secured in the second chamber. The components of first chamber make use of the partition as a heat transfer means. The separating partition extends into the second chamber. Air slits in the second chamber permit captured heat to escape. This method again results in a lower temperature in the first chamber in spite of the heat of operating components, even though heat is generated in substantial quantities
This heat removal system carries inherent disadvantages. The double chamber arrangement contributes to a loss of space otherwise used for ribs. Consequently, optimal cooling of the electronic components in the first chamber cannot be assured.
Further, in the double chamber system, the cooling system and the components in the second chamber, can be subjected to unwanted environmental effects finding entry through air passage slits.
SUMMARIZATION OF THE PRESENT INVENTION
Given the above background, the purpose of the invention is to make available an improved cooling system for electronic components with smallest possible space requirements. In this way, simultaneously, a better protection of the cooling system from undesirable environmental conditions can be achieved.
This purpose is attained by means of the presentation of an invented unit in accord with claim 1 . The dependent claims concern advantageous modes of construction of the invention.
The invented unit comprises several electronic components, which, when in operation, generate heat, which is dissipated into the immediately surrounding ambience. As an example, the invented unit could hold a frequency transverter or another kind of electronic converter. This is not a limitation as the invention is applicable for use in other optional electronic circuits.
The invented unit for electronic components includes a carrier plate. On a first section of the carrier plate, in accord with the invention, is to be found a first group of assembled components. Upon a second section are located a second group of electronic components. In a preferred design, the first group incorporates such components as may be sensitive to foreign influences and which are not shielded by individual housings nor are these components distanced from portions of the circuit. To the second group belong electronic components which can generate first, large quantities of heat and also possess high quality, individual protection. For example, superior protection can be achieved if a component is encased in its own individual housing and immersed in insulating, congealed plastic. Thus, for example, converters and other electronic components of the second group can be self-protected against invasion without great expense or effort.
As part of the protective design, the invented unit possesses a housing, which corresponds in dimensioning to the carrier plate. This carrier plate has two sections, which respectively carry installed electronic components. In at least one version, the carrier plate is so positioned in the said housing, that the housing may be spoken of as being in two parts. As an alternative version to this, each section of the carrier plate can be an integral part of the housing. In an alternative design, each section of the carrier plate can form its own housing. In accord with either version, that part of the housing, which is equipped with the first group of electronic components is provided with a high degree of protection to protect the therein installed electronic components from, for example, environmental challenges, humidity and influx of dust. Contrary to this there are frequent instances in which no, or at least minimal protection, such as a special housing, or an additional housing would be found necessary to block the ingress of damaging environmental conditions. Consequently, the second section of the carrier plate, in one version, may be regarded as a part of the outer wall of the housing and, in this state, further protection is not required. Differing from this, a version is available wherein a housing, or part thereof, is equipped with air passage slots. Such slots allow a simple ventilation of the interior and an exit path for heat. In yet another version of the invented unit, even the second group of electronic components is protected by a special housing or part thereof to provide a superior type of protection.
The above described separation of the electronic components into two sections of the carrier plate allows an installation wherein a substantial quantity of heat may be generated by heat-sensitive circuits positioned in that portion of the housing containing a first group of electronic components. Again, this division of situating of the first electronic component group permits a lesser order of environmental protection for heat generated in a single, integral housing. Accordingly, a major expense in time or money is saved by the elimination of a large, common covering for an assembly of electronic components. Other components, for example load transistors, remain within the first group, even though they emit relatively large quantities of heat. The reason for this type of manufacture is that individual housings for separate components is too expensive. Due to placement on the other section of the carrier plate, components of the second group do not contribute heat to increase the temperature of the sensitive circuitry of the first group in the first section of the carrier plate.
In addition to the electronic components of the second group, which are installed on the second section of the carrier plate, a conforming plurality of cooling ribs have been inserted. These ribs, with fitted curvature, are thermally united with the first group, so that these said ribs can withdraw heat also from these first components. In accord with the invention, these cooling ribs extend themselves over either their entire or partial length in a plane parallel to the surface of the carrier plate. The material and the dimensioning of the said cooling ribs is not described here or later in detail, except to the extent that both follow respective conventional standards.
Because of the curving of the cooling ribs, in comparison to straight-line ribs, a more effective cooling result is achieved within the same over-all length. This becomes possible, in that, due to the said curvature of the ribs, flowing air is caused to impact and change direction, so that lamination is broken up and turbulence increased. These properties assure a more effective thermal contact of air against the ribs. Beyond this, the offsets increase the heat conduction surface of the ribs, thus allowing a greater heat exchange to take place. This advantageous effect is common in cases where cooling ribs are fashioned in the curved manner.
Another advantage of the curved cooling ribs can be found, in that this shape offers additional protection against environmental forces for electronic components located on the second section of the carrier plate. The undesirable environmental influx could be rainwater. This is true especially for an advantageous version of the invented unit in which an installation of the protective elements has been so installed so that the ribs, as viewed from that component to be protected, are situated in that direction from which the said environmental influx is expected to flow. To clarify direction, if the invented unit possesses a hanging support, whereby one end forms a “bottom”, and the other end is the “top”, then the components to be highly protected should find themselves beneath the curves of the ribs. In such a case the rain would not fall on the components beneath a bellied out casing, but would collect itself on the curvatures from which it is easily diverted.
In some variants of the invented unit, the cooling ribs are given an S-shaped curvature, this having two or more directional reverses of equal size in both directions across the longitudinal axis of the said cooling ribs. This type of curving assures an especially effective protection from environmental interferences such as rainwater. For example, rainwater is widely spread out by the double curves and consequently, a large area under the projection of the curves is shielded. Because of the uniformity of an S-shaped curvature, the fabrication of a protective element becomes a simple operation.
In accord with another version, one or more of the narrowed ribs are tapered, so that the length of the cooling ribs in proximity to the carrier plate becomes the greatest dimension, hence, tapering off away therefrom. Thus, tapering is carried out in proximity to the heat-sensitive elements. This incline creates an improvement of the protective action in respect to rainwater. Inflowing rainwater is led by the curves along the cooling ribs to an accumulation point. Otherwise, rainwater would be distributed over the entire height of the ribs, from which it would drop away. The tapered end edges of the cooling ribs are so made and/or the heat sensitive element may be so located, that rainwater bypasses the sensitive elements.
Very often the cooling ribs are arranged in parallel, i.e. disposed at equal distances, one from the other. This is not always the case. Deviations from a parallel arrangement are purposely made to facilitate space requirements. These deviations aid turbulence or serve to direct cooling air through the passages between the ribs in a predetermined, advantageous path. Fortunately, the cooling ribs are so set, that rainwater or another disturbing inflow, which is directed to their location, can be properly captured. Rainwater can be caused to remove itself directly from the air flow passages. This is achieved by an alignment of the size and shape of the curvature regarding the separating distance between the cooling ribs.
In regard to the elements to be protected, one such element can be a fan installation, which directs cooling air along the ribs and thus increases the heat transfer capacity. For example, the fan installation (of one or more fans) is located at the bottom end of a hang mounted carrier plate. Air is blown upward through the now vertical pathways between the cooling ribs.
The cooling ribs are so disposed in relation to the fan installation, as well as being properly situated in respect to one another that, because of the said curvature as well as the tapered construction at either or both ends, protection is gained from rainwater entering from above and falling upon the fan or its motor, both being sensitive elements. Accordingly, the fan is, at least partially, protected from rainwater and damaging environmental forces such as dust entering from above.
In yet another version, for example the cooling ribs, that is to say, some of the cooling ribs are aligned in the direction of one or more components of the second group and protect these in the means and ways described above.
In accord with a preferred version of the invented unit, the components of the second group are placed on external, side sections of the carrier plate. Thus, these components do not interfere with the efficient alignment of the cooling ribs. Simultaneously, heat developed by the components dissipates itself without help into the ambient air. In this way the capacity of the cooling ribs for heat transfer and removal for the first component group is not degraded.
A BRIEF DESCRIPTION OF THE DRAWINGS
The following Figures describe and explain the invented unit by means of illustrations of approved versions of the same:
FIG. 1 A schematic diagram showing a top view of a carrier plate of an invented version, and
FIG. 2 An exploded view of an equipped carrier plate of an invented version; and
FIG. 3 A vertical sectional view of the housing enclosing the carrier plate and taken along lines 3 - 3 of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a top view of a carrier plate 2 of an invented unit 1 . The exemplary arrangement comprises a frequency transverter and provides the layout of the second section, which encompasses the cooling ribs. The first section carrying the first group is not shown in this view. Normally, the carrier plate 2 , in the illustrated version is protected by a housing 8 . Parts of the housing 8 have been omitted in the drawing to enhance clarity; the housing 8 includes a pair of side members mounted on opposite sides of the carrier plate 2 . In the following, references to “above” and “below” are in reference to the alignment of FIGS. 1 and 2 , which is the alignment of an invented unit in a hanging mode. The carrier plate 2 in the depicted view divides the housing into two halves 10 , 11 (see FIG. 3 ), whereby that half 10 , in which the second section 13 of the carrier plate 2 lies, possesses air openings 14 (see FIG. 3 ) which can be arranged in a circumferential manner or possibly also placed on the upper and the lower sections. These openings assure heat interchange with surrounding ambient air. The other half 11 of the housing, in which the first carrier plate section 15 is found, is designed to be air tight and corresponds to a high order of protection.
The unit 1 shown in FIG. 1 is described in a hanging mode. Each housing side 9 includes a mounting lug 16 having a through hole; the lugs 16 define a device for hung mounting of the housing 8 . Such a mounting using the lugs 16 permits the installation of unit 1 on a wall with the arrangement of carrier plate 2 and mounted components remaining unchanged. The drawing of FIG. 1 shows a wall mounting alignment and section 1 , as pictured, is in an upward position with an upper or top housing end 23 above a lower or bottom housing end 24 such that gravity urges rainwater or other environmental contaminents entering the housing 8 towards the lower or bottom housing end 24 .
In this version, the upper, right area (as per drawing) of the carrier plate 2 supports the electronic components 4 of the second electronic component group. Advantageously, the components 4 are in thermal union with the carrier plate 2 . This is accomplished by means of small, evenly spaced pins being placed between component 4 and the carrier plate. This avoids a transfer of heat from these components to the first section of the carrier plate 2 .
In the case of the second group of components 4 , which are shown as being a generally prismatic component 25 and the components 17 circular in outline, these are sine-wave chokes 17 , which, in the case of the frequency transverter, are employed for the production of a sine wave shaping of outgoing voltage, wherein square wave formation is subjected to harmonic tuning. Such choking operations give rise to considerable heat when in operation. Thus, the arrangement of the sealed-off first section 15 of the carrier plate 2 clearly reduces the output of its heat. Generated heat from the second section 13 can easily be removed by air slits 14 .
In the case of the version shown, all components 4 of the second group are placed in respective individual housings 18 in a manner compliant with current degrees of protective methods. Briefly, it can be said that a component 4 is encompassed by its own individual housing 18 and is sealed therein by an insulating cast plastic which has congealed. As a result, no damage to the so sealed components can result from subjection to air from the said slits 14 .
The cooling ribs 3 run through the middle zone of the carrier plate 2 . These are responsible for the removal of heat from the first section 15 of the carrier plate 2 . In particular, in the illustrated FIG. 3 , are shown the first group of components, which group contains a set of load components 19 , for instance Insulated Gate Bipolar Transistors (IGBT's) which are not detailed but are located in the first section 15 of the carrier plate 2 . The heat from these devices is conducted through the carrier plate 2 to the cooling ribs 3 and from those, dissipated into the ambient air. For an optimal removal of the heat from the cooling ribs 3 , in the lower area of the carrier plate 2 , two fans 5 have been installed. The output flow from these fans 5 is so directed against the cooling ribs 3 , that the air can move along the ribs from below through the passageways 6 , which are interstitially located between the ribs. These air passageways 6 terminate in the illustrated version at the sine wave chokes 17 , which also allows the cooling air to flow over these components.
The pictured placement area for the large middle area of the carrier plate 2 , which is devoted to the cooling ribs 3 has been made possible by the placement of the components 4 in the edge zones of the carrier plate 2 . This arrangement provides an extensive, free running installation of the cooling ribs 3 . Thus there is only a minimal heat contribution of the sine wave chokes 17 to the cooling capacity of the cooling ribs 3 . This has the result that the quantity of heat which is conducted to and through the cooling ribs 3 can be additionally increased.
As may be seen in FIG. 1 , the cooling ribs, in their upper area make a reverse offset in away from and back to their longitudinal axes. These particular ribs ( 3 ) which lie above the fans 5 and their motors (not shown) at the lower section of the invented unit 1 lie in a plane parallel to the surface of the carrier plate 2 and possess within this plane, as shown in the illustrated version, an shape with curvatures of approximately equal extent in both directions from and to their longitudinal axes. Counter to this arrangement, in the right hand section of FIG. 1 , the cooling ribs 3 are shown as bending in only one direction. This lies, first, within the appointed cooling rib 3 space allotment, and second within the highly necessary protective area spatially located beneath them. Because of this deviant curving of individual cooling ribs 3 , these ribs are only partially included in the above said parallel alignment.
In order to attain a complete shielding, especially in regard to rainwater, in the illustrated arrangement, the separating distance of the cooling ribs 3 and consequently the width of the air passages 6 is so dimensioned in respect to the rib curving, that no rainwater from above can migrate directly through the flow passages onto the fans 5 . Instead of this, rainwater, which has penetrated inside of the housing, falls on the said S-curves of cooling ribs 3 and consequently flows along these, until it finds an exit path due to the tapered ends 7 of the cooling ribs and removes itself at a preselected point.
Concerning the offset cooling ribs 3 as well as the illustrated version, especially where an invented unit 1 of equal dimensions is concerned, these S-curved ribs, in cooling capacity, exceed straight ribs by 50%. This superiority lies first, in that the forced diversion of path of the cooling air leads to better turbulence and additionally the heat transfer area of the cooling ribs 3 is increased. Alternate versions of the cooling ribs comprise ribs that are curved over their entire length or over a predominate extent thereof. This arrangement further increases the cooling efficiency.
FIG. 2 shows an exploded view of another version of an invented unit 1 , whereby the components lying on the first section of the carrier plate 2 are again not shown and, for clarity, parts of the housing 8 are removed. The same reference numbers are used for elements, which correspond to those in FIG. 1 .
In spite of the described characteristics of the cooling ribs 3 in FIG. 1 , the ribs in FIG. 2 clearly denote the tapered incline of the narrowed end edges proximal to the fans. This tapering is such, that as the height above the carrier plate 2 increases, the overall length of the ribs decreases. This tapered contour permits a conduction of rainwater to a preselected exit in the lower section of the housing 8 . Advantageously, the fans 5 are so arranged, that the edges 7 of the ribs divert rainwater from fan motors.
In the exploded view, side parts 9 of the housing 8 are visible. Normally, the housing 8 completely encloses carrier plate 2 with the thereon mounted components. FIG. 3 illustrates the housing 8 formed from the side walls 9 , front cover plate 20 , back cover plate 21 , top cover plate 22 and a bottom cover plate (not shown) opposite the top cover plate 22 . To simplify the drawing, only the carrier plate 2 , the components 19 and 25 mounted on the carrier plate 2 , and one rib 3 are shown in the drawing. The housing 8 completely encloses the carrier plate 2 and cooperates with the carrier plate 2 to define the housing halves 10 , 11 . In the illustrated embodiment the air openings 14 are formed in the front cover plate 20 and the top cover plate 22 . To achieve this, the housing 8 , in relation to the carrier plate 2 is in a two-part construction, that is, the housing 8 and the carrier plate 2 cooperate to define the housing halves or compartments 10 , 11 that are separated from each other by the carrier plate 2 . The so separated housing part 11 , in which the first section of the carrier plate 2 is located, possesses a high degree of protective means and, accordingly, is free of air or water intrusion, that is, the portion of the housing 8 defining the housing half 11 is airtight and watertight as previously described and so does not include openings or air passages.
The other housing part, shown as being above that in which the cooling ribs are present, due to air slits, has a lesser degree of protective means.
The other housing part 10 , shown as being above that in which the cooling ribs are present, due to air slits 14 , has a lesser degree of protective means and would allow environmental contaminants, such as rainwater, to enter the housing half 10 .
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The invention concerns a unit with electronic components, which, when in operation, generate heat. The unit comprises a carrier plate, upon the first section of which a first group of electronic components is placed. Upon a second section thereof is installed a plurality of cooling ribs for the removal of heat produced by the electronic components. The cooling ribs are designed to be curved to a predetermined extent along their longitudinal axis and to lie in a plane parallel to the said carrier plate.
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RELATED APPLICATIONS
[0001] This application is an improvement to the invention described in Provisional Patent Application Ser. No. 60/359,489 filed on Feb. 25, 2002 and which is now expired.
INCORPORATION BY REFERENCE
[0002] Applicant(s) hereby incorporate herein by reference, any and all U.S. patents, U.S. patent applications, and other documents and printed matter cited or referred to in this application.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates generally to skate boards and similar sport and utility conveyance devices, and more particularly to such a device having motor power and the ability to receive a wide range of accessories.
[0005] 2. Description of Related Art
[0006] The following art defines the present state of this field:
[0007] Brickson, U.S. Des. 150,401 describes a coaster car design.
[0008] Cohen, U.S. Des. 330,394 describes a motorized skateboard design.
[0009] Johnson, U.S. Pat. No. 4,043,566 describes a skateboard including a brake assembly for slowing and stopping the vehicle. A pivotal member on the board is provided with a depending rubber stop for engagement with the ground surface when the member is tilted by the heel of the shoe of the skater.
[0010] Spitzke, U.S. Pat. No. 4,199,165 describes a skid accessory for skateboards adapted to be mounted at the end of the board between the wheel supporting trucks and the end of the board to protect the board from engagement with the ground and to act as a braking device by frictional engagement with the ground.
[0011] Martin, U.S. Pat. No. 5,020,621 describes an electrically driven brake controlled skateboard employing an electric motor and associated battery mounted on the bottom of its foot supporting board employs a pulley arrangement whereby the initial slipping of its belt acts as a clutch for transferring rotational power from the motor to a U-grooved drive wheel of the skateboard. The U-groove is low cut so that the drive belt is partially exposed to the road surface. A dual-purpose tether mounted brake control and on/off switch is used to control the braking of the skateboard and the energizing of the drive motor.
[0012] Hsu, U.S. Pat. No. 5,330,026 describes a remote controlled electric skate-board having a motor to drive two sets of sun and planet gear units connected with a pair of rollers rotated to move the skate-board by a remote controller transmitting a signal to an electronic circuit carried on the board to start or to stop the motor so that the skate-board may be moved or stopped by electric power in addition to human force.
[0013] Kaufman, U.S. Pat. No. 5,381,870 describes a motorized skateboard including a tubular frame having a first and second axle mounted in a parallel relationship about opposed ends of the frame, with a drive motor directed through a drive belt to a rear driven sprocket. An optional configuration of the invention utilizes the rear driven sprocket mounted to a constant velocity joint to permit rear steerage of the skateboard. The skateboard is arranged with pivoted front arms as required to provide for shock-absorbing suspension to the skateboard structure. The utilization of an independent front suspension is cooperative with a tapered rear roller support wheel structure to permit steerage of the organization. The independent front suspension includes frontal steering controlled by the front boot including a tie rod and spindle configuration.
[0014] Ondrish, Jr., U.S. Pat. No. 5,950,754 describes a multi-terrain riding board including an elongate deck mounted on a chassis, a front axle assembly pivotally coupled with the chassis and including a pair of horizontal spindles rotatable about respective vertical axes, a pair of wheels mounted for rotation about the spindles, a pair of tie rods connected between the chassis and the spindles to transfer tilting movement of the chassis into rotation of the spindles about the vertical axes, a rear axle coupled with the chassis, and a rear wheel rotatably mounted on the rear axle. In one embodiment, the rear axle is fixedly connected to the chassis so that the rear wheel cambers in response to angulation of the deck; however, the rear axle can be pivotally coupled with the chassis and provide with a pair of spindles and tie rods to steer like the front axle assembly if desired. Preferably, horizontal tension springs are connected between the spindles and a bottom portion of the chassis to help stabilize the deck of the riding board. An engine or motor can be mounted within the chassis between the front and rear axle assemblies, in which case the deck is preferably hingedly connected with the chassis to permit pivotal movement of the deck from a lowered position resting on the chassis to an elevated position allowing access to the engine.
[0015] Chen, U.S. 2003/0151214 describes a skateboard comprising a board, two wheel units attached to an underside of the board, and a braking member attached to the underside of the board. The braking member includes at least one metallic braking block that is in contact with ground during braking. The metallic braking block sparks during braking to provide an amusement effect.
[0016] Our prior art search with abstracts described above teaches: a design for a coaster board having three wheels with a at least one wheel in a frontal position, a design for a motorized skateboard with two wheels, a non-motorized skateboard with three wheels, with one wheel in front, a skateboard skid accessory, an electric motor powered skateboard with integral brakes, a remote controlled electric skate board, a motorized skateboard apparatus, a three wheeled multi-terrain riding board, and a braking member for a skateboard, but does not teach a three wheeled skateboard with the at least one forward wheel powered, a board with forward and rearward receivers for accessory attachments, and a push-pull driving arrangement for a skateboard. The present invention fulfills these needs and provides further related advantages as described in the following summary.
SUMMARY OF THE INVENTION
[0017] The present invention teaches certain benefits in construction and use which give rise to the objectives described below.
[0018] A skateboard has a platform supported on a tubular frame. The frame is engaged with a pair of wheel trucks, one with a at least one wheel, the other with a pair of wheels. An electrical motor, and a power source are mounted below the platform to the frame. The at least one wheel is positioned proximate a forward end of the platform, and the pair of wheels are positioned proximate a rearward end of the platform. The motor engages the at least one wheel and is able to be tuned on and off by a remote switch accessible to a hand or foot of the rider. A front and rear receivers enable attachment of a wide range of accessories including a seat, handle bar and lights.
[0019] A primary objective of the present invention is to provide an apparatus and method of use of such apparatus that yields advantages not taught by the prior art.
[0020] Another objective is to provide such an invention capable of being driven by a front wheel drive that may be lifted from the riding surface when necessary or when desired.
[0021] A further objective is to provide such an invention capable of receiving a wide range of accessories in a snap-in arrangement for convenience.
[0022] A still further objective is to provide such an invention capable of being driven by front and rear wheels at the same time.
[0023] A further objective is to provide such an invention capable of sharp and effective turning.
[0024] A further objective is to provide such an invention capable of having less wheel surface in contact with the ground surface so as to provide less friction and resistance.
[0025] A further objective is to provide a skate board wherein the rider's weight is concentrated in the rear of a front wheel driven machine so that there is less strain on the drive system so that a less powerful motor may be applied and smaller batteries may be used with longer battery life between charges.
[0026] Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The accompanying drawings illustrate the present invention. In such drawings:
[0028] FIG. 1 is a perspective view of the invention;
[0029] FIG. 2 is similar to FIG. 1 showing a front wheel suspension arrangement thereof;
[0030] FIG. 3 is similar to FIG. 1 showing a dual drive system thereof;
[0031] FIG. 4 is an exploded perspective view showing details of a frame thereof;
[0032] FIGS. 5-7 are side elevational views thereof showing application of snap-in accessories of the invention;
[0033] FIGS. 8-10 are perspective views thereof showing application of further accessories of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0034] The above described drawing figures illustrate the invention in at least one of its preferred embodiments, which is further defined in detail in the following description. Those having ordinary skill in the art may be able to make alterations and modifications in the present invention without departing from its spirit and scope. Therefore, it must be understood that the illustrated embodiments have been set forth only for the purposes of example and that they should not be taken as limiting the invention as defined in the following.
[0035] As shown in the figures, see FIG. 1 for instance, the present invention is an improved skateboard apparatus comprising a platform 10 having a forward end 12 , an opposing rearward end 14 , a top surface 16 and an undersurface 18 . The platform 10 , preferably of wood or plastic construction, is engaged with a tubular metal frame 20 shown in FIG. 4 , and the frame 20 is further engaged with a pair of wheel trucks 30 , 40 , a means for driving 50 and an electrical power source 55 , as best seen in FIG. 4 . One of the wheel trucks 30 mounts a at least one wheel 32 positioned proximate the forward end 12 of the platform 10 while the other of the wheel trucks 40 mounts a pair of wheels 42 , 44 positioned proximate the rearward end 14 of the platform 12 . The means for driving 50 , preferably an electric motor, is engaged mechanically; by a drive belt 52 or direct meshing gears, or other drive train means, with the at least one wheel 32 and is electrically engaged by cable 62 with the electrical power source 55 for driving the at least one wheel 32 in moving the apparatus on a riding surface 5 ( FIG. 5 ). Thus, with a rider (not shown) standing on the top surface 16 of the platform 10 , the at least one wheel 32 can be driven to move the platform 10 and rider over the riding surface. The apparatus is preferably a front wheel driven skate board.
[0036] Preferably, as best shown in FIG. 4 , a means for actuating 60 is positioned proximate the top surface 16 and is electrically interconnected, by the electrical cable 62 , with either the driving means 50 or the power source 55 , enabling power control of the driving means 50 as actuated by a foot of the rider. Such an actuating means 60 , for instance, is preferably an electrical toggle switch with each actuation reversing the switching sense. Alternately, the electrical cable 62 may be of such length as to be actuated by a hand of the rider as shown in FIGS. 8-10 .
[0037] Preferably, the forward 22 and rearward 24 ends of the tubular frame 20 each provides a receiving means 26 for receiving an extension piece that is removeably engagable with either of the receiving means 26 . Such a receiving means 26 is preferably a tubular aperture with a snap-in locking feature of any type well known to those of skill in the art, or it may be a tube in tube arrangement with set screw 28 , as shown in FIG. 8 . The extension piece may be any one of several utility accessory parts including a fender brake 70 which is positioned forward of the platform 10 and proximal to the at least one wheel 32 as shown in FIG. 6 , or an upwardly extending T-bar 71 positioned forward of the platform 10 and extending upwardly so as to provide a gripping element for the rider to grasp, as shown in FIG. 7 , a hand brake actuator 82 ( FIG. 8 ) with cable actuator 82 ′ preferably enabling dynamic braking by reversing the sense of the field in the motor 50 , or alternately by an bicycle-type caliper brake (not shown) preferably engaging wheel 32 , or a wheely bar 73 positioned rearward of the platform 10 , as shown in FIG. 6 , or headlights 75 , ( FIG. 5 ), tail-lights or reflectors 76 ( FIG. 8 ). Electrical power is supplied to these lights 75 , 76 from the power source 55 by conductors (not shown) mounted within the frame 20 as would be easily enabled by one of skill in the art, so that when the lights 75 , 76 are engaged with the frame 20 ( FIGS. 5, 8 ), electrical interconnections are made as well.
[0038] Preferably, the power source 55 , as shown in FIG. 5 , comprises a heavy duty dry cell type battery 59 , which may be made up of a plurality of cells mounted in tubes as is well known in the art, and further comprises a battery charging circuit 57 , well known in the art, enabled for charging the battery 59 , preferably at 12 volts DC, from an AC utility outlet at either 115 volts, 60 Hz, or 220 volts at 50 Hz.
[0039] Preferably, a manual brake 77 ( FIG. 9 ) is positioned proximate the top surface 16 at the forward end 12 of the platform 10 and is mechanically engagable with the at least one wheel 32 for frictional braking as actuated by a foot of the rider. Spring 77 ′ is positioned to maintain the brake 77 in an “up” position until the rider presses downwardly on the brake 77 which forces a brake pad 77 ″ into contact with the wheel 32 . An alternate manual brake 78 is positioned proximate the top surface at the rearward end of the platform and mechanically engagable with one or both of the rear wheels 42 , 44 enabling frictional braking as actuated by a foot of the rider. A short leaf spring 78 ′ is engaged for maintaining a space between a brake pad 78 ″ and the wheels 42 , 44 ( FIG. 7 ).
[0040] As shown in FIG. 8 , a seat attachment 90 is mountable onto the frame 20 and extends upwardly therefrom. Accommodation is made in the platform 10 for mounting bolts 92 . Likewise, a handle bar 80 , similar to T-bar 71 is preferably mounted to frame 20 in the same manner. See FIG. 8 .
[0041] Preferably, one or both wheel trucks 30 , 40 provides a shock mounting 100 comprising at least one means for shock absorbing as shown in FIG. 2 . Such shock mounting may comprise a at least one spring or equivalent resilient material, or two or more such shock absorbing elements positioned at the center of the truck, as shown in FIG. 2 , or dual springs, etc. mounted laterally to wheel 32 , in any manner that is well known in the art. To achieve maximum effectiveness, the trucks 30 , 40 are preferably mounted as swing arms 110 (swing arm mounting means) with one end secured pivotally by a hinge member 110 ′ while the free end is clear to move against the shock mounting 100 , as shown in FIG. 2 .
[0042] Preferably, the means for driving 50 is further engaged mechanically with the pair of wheels 42 , 44 , the driving means comprising individual motors engaged individually with the at least one wheel 32 and with the pair of wheels 42 , 44 for driving all of the wheels 32 , 42 , 44 in moving the apparatus along the riding surface 5 in a push-pull arrangement. Alternately, a at least one motor is preferably engaged with both wheel 32 and at least one of the wheels 42 , 44 to achieve the same objective.
[0043] The use of a front wheel drive in the present invention is critically superior to rear wheel drive because of less resistance, less friction between the front wheel and the rider surface and results in less strain on the drive system including less drain on the battery.
[0044] The enablements described in detail above are considered novel over the prior art of record and are considered critical to the operation of the instant invention and to the achievement of the above described objectives. The words used in this specification to describe the invention and its various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification: structure, material or acts beyond the scope of the commonly defined meanings. Thus if an element can be understood in the context of this specification as including more than one meaning, then its use must be understood as being generic to all possible meanings supported by the specification and by the word or words describing the element.
[0045] The definitions of the words or elements of this described invention and its various embodiments are, therefore, defined in this specification to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the invention and its various embodiments below or that a at least one element may be substituted for two or more elements in a claim.
[0046] Changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalents within the scope of the invention and its various embodiments. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements. The invention and its various embodiments are thus to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, what can be obviously substituted, and also what essentially incorporates the essential idea of the invention.
[0047] While the invention has been described with reference to at least one preferred embodiment, it is to be clearly understood by those skilled in the art that the invention is not limited thereto. Rather, the scope of the invention is to be interpreted only in conjunction with the appended claims and it is made clear, here, that the inventor(s) believe that the claimed subject matter is the invention.
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A skateboard has a platform supported on a tubular frame. The frame is engaged with a pair of wheel trucks, one with a at least one wheel, the other with a pair of wheels. An electrical motor, and a power source are mounted below the platform to the frame. The at least one wheel is positioned proximate a forward end of the platform, and the pair of wheels are positioned proximate a rearward end of the platform. The motor engages the at least one wheel and is able to be tuned on and off by a remote switch accessible to a hand or foot of the rider. A front and rear receivers enable attachment of a wide range of accessories including a seat, handle bar and lights.
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FIELD OF THE INVENTION
[0001] The present invention relates to dual-gated transistors and, more particularly, to FinFETs.
BACKGROUND OF THE INVENTION
[0002] A field-effect transistor (FET) is a type of transistor commonly used in Ultra Large Scale Integration (ULSI). In the FET, current flows along a semiconductor path called the channel. At one end of the channel, there is an electrode called the source. At the other end of the channel, there is an electrode called the drain. The physical dimensions of the channel are fixed, but its number of electrical carriers can be varied by the application of a voltage to a control electrode called the gate. The conductivity of the FET depends, at any given instant in time, on the number of electrical carriers of the channel. A small change in gate voltage can cause a large variation in the current from the source to the drain. This is how the FET amplifies signals. In one popular type of FET, known as a MOSFET, the channel can be either N-type or P-type semiconductor. The gate electrode is a piece of metal whose surface is insulated from the channel by a dielectric layer between the gate electrode and the channel and there is little current between the gate and the channel during any part of the signal cycle. This gives the MOSFET an extremely large input impedance.
[0003] One recent technique for improving the performance of field-effect transistors involves using dual-gates. In a dual-gated transistor, a top gate and a bottom gate are formed around an active region. Specifically, the advantages for dual gate devices over their single gate counterparts include: a higher transconductance and improved short-channel effects. As a result, higher device on-current is achieved for a given off-current.
[0004] Within a dual gate device, the bottom gate must be aligned with the top gate, as well as the source and drain junctions, in order to avoid highly penalizing parasitic capacitance. Furthermore, the top and bottom gates must be connected by a low resistance path having low parasitic capacitances with the other elements present (e.g., substrate, drain, etc.). This alignment has proven very difficult with conventional fabrication techniques and a structure known as FinFET has been proposed as showing promise as a dual-gated device.
[0005] A FinFET turns the silicon channel on its side thereby yielding access to a front gate and back gate from the top of the wafer during processing. This makes self-alignment of the source and drain regions and both gates relatively straightforward using conventional lithographic techniques. In a FinFET, the width of the device is determined by the height of the fin.
[0006] When fabricating a FinFET using sidewall imaging transfer techniques, the spacer used to define the gate dimension wraps up and down the fin sidewalls. While a taller fin provides a device with more performance, it also results in a longer vertical distance over which the spacer runs. Thus, when etching the gate conductor material along the spacer's edges, the gate conductor must be etched down the entire height of the fin while maintaining a straight vertical profile and while not punching through other layers like the mask, or a protective cap. As a result, as the fins of FinFETs reach larger heights, techniques are needed that allow fabricating gate structures without requiring very long directional etching when forming dimension-critical features of the FinFET such as channel or gate length.
SUMMARY OF THE INVENTION
[0007] Accordingly, embodiments of the present invention relate to a method for forming a gate for a FinFET using a series of selectively deposited sidewalls along with other sacrificial layers to create a cavity in which a gate can be accurately and reliably formed. This technique avoids long directional etching steps to form critical dimensions of the gate that have contributed to the difficulty of forming FinFETs using conventional techniques. In particular, a sacrificial seed layer, from which sidewalls can be accurately grown, is first deposited over a silicon fin. Once the sacrificial seed layer is etched away, the sidewalls can be surrounded by another disposable layer. Etching away the sidewalls will result in cavities being formed that straddle the fin, and gate conductor material can then be formed within these cavities. Thus, the height and thickness of the resulting FinFET gate can be accurately controlled by avoiding a long direction etch down the entire height of the fin.
[0008] One aspect of the present invention relates to a method of forming a gate for a FinFET. In accordance with this aspect, a first mandrel is formed over a substrate and a gate shape substantially perpendicular to the fin, wherein the mandrel includes a first and second vertical sidewall. The fin may be a silicon fin or be formed of other semiconductor material. A first sidewall spacer is formed on the first sidewall and a second sidewall spacer is formed on the second sidewall. The first mandrel is then removed and a second mandrel, or sacrificial film, is deposited over the sidewall spacers, the fin, and the substrate. A first and a second cavity are created by removing the first and second sidewall spacers from within the second mandrel and a respective gate is formed within each of the first and second cavities. Another aspect of the present invention relates to a FinFET gate structure fabricated using the method described above.
[0009] Yet another aspect of the present invention relates to an intermediate structure formed while constructing a FinFET gate. In accordance with this aspect of the invention, the intermediate structure includes a planarized mandrel layer that covers a silicon fin formed on a substrate. This planarized mandrel layer includes a cavity that extends through the mandrel layer thereby exposing a portion of the silicon fin and substrate. More precisely, the cavity has a width that determines a channel length of a first gate portion of the FinFET. Within this cavity, a gate conductor is deposited so as to form the first gate portion over the fin. In accordance with this aspect of the invention, a second cavity can also be formed in the mandrel and filled with gate conductor so as to form a second gate portion of the FinFET.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 illustrates a conventionally formed capped semiconductor fin on a wafer.
[0011] FIG. 2 illustrates a first mandrel formed over the fin of FIG. 1 .
[0012] FIG. 3 illustrates a resist layer deposited over the ends of the mandrel of FIG. 2 .
[0013] FIG. 4 illustrates sidewalls grown on each side of the mandrel of FIG. 2 .
[0014] FIG. 5 illustrates the sidewalls of FIG. 4 after the first mandrel is removed.
[0015] FIG. 6 illustrates a planarized mandrel formed over the sidewalls on the wafer.
[0016] FIG. 7 illustrates the device of FIG. 6 after the sidewalls have been etched away leaving two cavities within the planarized mandrel.
[0017] FIG. 8 illustrates the device of FIG. 7 after the cavities have been filled with a gate material.
[0018] FIG. 9 illustrates the device of FIG. 8 after the planarized mandrel has been removed.
DETAILED DESCRIPTION
[0019] FIG. 1 depicts an initial structure in forming the FinFET. Using conventional photolithography techniques, a capped semiconductor fin 100 , such as silicon, is formed on an insulating substrate 102 . The capped semiconductor fin 100 includes protective nitride film 106 that is formed along the top of the semiconductor material 104 . Next, referring to FIG. 2 , a mandrel 202 is formed across the fin 100 . Mandrel 202 is an organic material, the surface of which is then modified by exposure to a sililating agent such as hexamethyl-cyclotrisilazane or hexamethyl-disilazane. This exposure converts the surface of the mandrel 202 to a silicon containing organic polymer. This surface layer is subsequently oxidized in a dry oxygen containing plasma, such as RIE, downstream ozone, or such. As a result, the mandrel 202 is formed so as to facilitate selective oxide growth in liquid phase oxide deposition, but can be selectively stripped with respect to the growth oxide.
[0020] The mandrel material is deposited substantially over the entire wafer 102 and fin 100 of FIG. 1 and then planarized and patterned using conventional techniques. If the mandrel material is deposited in a non-conformal manner (e.g., spun on), then no planarization is required. If conformally applied, however, chemical-mechanical polishing is used to planarize the mandrel 202 and RIE or directional etching is used to selectively remove unwanted portions of the mandrel material. Although a variety of feature dimensions can be selected within the scope of the present invention, the exemplary embodiment of FIGS. 1 and 2 , utilizes a fin having a thickness between approximately 5 to 100 nm, a height between approximately 30 to 150 nm, and a length of approximately 100 to 150 nm. The dimensions of the mandrel can vary widely but will typically be about twice as tall as the fin 100 .
[0021] One advantageous method of forming the mandrel 202 is described below although one of ordinary skill would recognize other functionally-equivalent methods are contemplated as well.
[0022] The first mandrel 202 is formed of a material that can be used as the underlying substrate for a later step of selectively depositing silicon oxide. The silicon oxide spacers will be formed on the mandrel 202 by selectively growing on the side surfaces of the mandrel 202 without growing on the silicon (or other semiconductor) surfaces of the capped fin 100 .
[0023] In particular, for oxide deposition to occur, the surfaces of the mandrel 202 should include hydroxy silicon functionalities such as would be provided if the surfaces incorporated therein some hydroxy silicon species. In general, the mandrel 202 is formed from any of a variety of organosilicon polymer materials after which the resulting organosilicon surface is treated with an oxygen plasma to create the hydroxy silicon functionality.
[0024] Referring now to FIG. 2 , one specific embodiment of the present invention includes spin applying a film 206 of organosiloxane bottom anti-reflective coating. In particular, the film 206 is spun-on to a thickness of approximately twice that of the capped fin 100 . This intermediate structure (now shown) is soft baked to remove the solvents of the film. An exemplary soft bake is one ramped from 150° C. to 250° C. for about 2 minutes.
[0025] After the soft bake, a resist layer 204 is spun over the organosiloxane. The resist layer 204 is exposed and developed to create the mandrel pattern. The organosiloxane is then etched to form the mandrel 202 shown in FIG. 2 .
[0026] After the mandrel 202 is etched, a brief oxygen RIE step is used to create hydroxy silicon species on the exposed vertical surfaces of the organosiloxane 206 . The hydroxy silicon species serve to act as nucleation sites for the selective growth of silicon dioxide. The resist layer 204 remains to act as a mask during the silicon oxide deposition process.
[0027] Additional resist areas 301 and 303 are formed over the etched mandrel 202 as shown in FIG. 3 . This figure shows a resist layer at each “end” of the substrate 102 although alternative embodiments of the present invention contemplate omitting one of these structures. To prevent intermixing between resist layers 301 and 303 with the resist layer 204 , an intermediate UV-harden process can be performed. The resist areas 301 and 303 are conventionally patterned so as to be formed in areas where it is not desired to have a sidewall spacer formed.
[0028] Once the substrate resembles that of FIG. 3 , the silicon surface of the capped fin 100 is cleaned to remove any silicon dioxide. This cleaning is typically performed by using dilute HF, or similar material, to clean the silicon substrate prior to oxide growth.
[0029] As is conventionally known, liquid phase deposition of silicon dioxide is then performed to deposit oxide on the side surfaces of the mandrel 202 . Such as, for example, by immersing the structure in an aqueous bath saturated with silicon oxide at 25-35° C. As a result, the sidewall spacers, or oxide regions, 402 and 404 are formed as shown in FIG. 4 .
[0030] The thickness of the regions 402 and 404 will determine the desired channel length or gate conductor width, of the resulting transistor and can be controlled with great accuracy. In an advantageous embodiment, each region 402 and 404 are approximately 15-100 nm thick.
[0031] After the oxide deposition is complete, the organosiloxane 206 is removed with a solvent process such as NE-98 (by ATMI) or CC-1 (by Air Products-ACT). The resist layers 204 , 301 and 303 are removed prior to this wet strip process such as by a downstream ozone stripper or other, similar process. The resulting structure is shown in FIG. 5 . As shown, the remaining sidewall spacers 402 , 404 are no longer supported by the surrounding mandrels and resist layer. Accordingly, as an intermediate step before removing the mandrel 202 , TEOS may be deposited so that it is formed between the bottom of each sidewall spacer 402 , 404 and the substrate 102 . The formation of TEOS, approximately 10-20 Å thick, in this area will adhere the sidewall spacers 402 , 404 to the substrate 102 and help stabilize the structure of FIG. 5 during subsequent steps. In the exemplary embodiment depicted in FIG. 5 , each sidewall spacer 402 , 404 extends on each side of the fin 100 for a distance of approximately 25-100 nm giving the sidewall spacers 402 , 404 a total length of between 200-350 nm.
[0032] This resulting structure is covered with a disposable layer 502 or a second mandrel that is planarized, as shown in FIG. 6 , such as by a CMP step. For example, the disposable layer 502 can be an organic fill material that offers etch selectivity with respect to the sidewall spacers 402 , 404 and withstands oxidation and high temperatures. One example of such a material is known as “Black Diamond” and is available from Applied Materials. Depending on the subsequent process steps and the temperatures likely to be encountered, disposable layer 502 may be other than an organic fill material. For example, in one alternative, the disposable layer 502 may be Germanium, if the gate process allows it. Furthermore, as FIG. 6 depicts, the planarization of the layer 502 is accomplished until the tops of the sidewall spacers 402 , 404 are exposed. Chemical-mechanical polishing (CMP) or other planarizing techniques are used to finish the disposable layer 502 to the desired height.
[0033] Referring now to FIG. 7 , with the tops of the sidewall spacers 402 , 404 exposed, a selective etch is performed which removes the sidewall spacers 404 , 402 to create respective holes 602 , 604 through the disposable layer 502 . This etch step removes the sidewall spacers 402 , 404 without disturbing the fin 100 and substrate 102 that are underneath each portion 402 , 404 . Thus, with these holes 602 , 604 opened, parts of the substrate 102 , semiconductor fin 104 and nitride film 106 are exposed.
[0034] Optionally, the nitride film 106 that is exposed in each of the holes 602 , 604 is etched away allowing for a three-sided gate. This exposes the top of the semiconductor fin 104 in each of the holes 602 , 604 and permits the depositing or growth of a gate dielectric on the exposed surfaces (i.e., top and sides) of the fin 104 . Once a gate dielectric layer has been formed, the holes 602 , 604 are filled with gate material 702 , 704 , such as polysilicon, as shown in FIG. 8 to form gates on three sides of the fin 104 . In one embodiment, the holes 602 , 604 are overfilled with gate material 702 , 704 and then planarized to the top surface of the disposable layer 502 . The disposable layer 502 can now be removed selective to the semiconductor fin 104 and cap 106 , as well as to the gate dielectric material (not shown). For example, if the disposable layer 502 is organic material then it can be dry-stripped with oxygen plasma; while if it is Germanium, then hydrogen-peroxide may be used to etch it.
[0035] The completed gate structure 800 is depicted in FIG. 9 . In particular, the semiconductor fin 104 is straddled by two vertical gate structures 702 and 704 formed atop the substrate 102 . Once the structure of FIG. 9 is complete, source and drain areas can be formed, using conventional techniques, on each side of the fin along with contacts and other features if desired. Thus, a method has been described that results in a FinFET gate structure but avoids long directional etches when forming dimension-critical features such as gate or channel length.
[0036] Various modifications may be made to the illustrated embodiments without departing from the spirit and scope of the invention. Therefore, the invention lies in the claims hereinafter appended. For example, the step of trimming the sidewall spacers can be performed so as to completely remove the sidewall on one side of the fin thereby leaving only one sidewall spacer over the fin. With this structure in place, only one cavity would be formed when the sidewall spacer is etched away, resulting in a single gate over the semiconductor fin.
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A method for forming a gate for a FinFET uses a series of selectively deposited sidewalls along with other sacrificial layers to create a cavity in which a gate can be accurately and reliably formed. This technique avoids long directional etching steps to form critical dimensions of the gate that have contributed to the difficulty of forming FinFETs using conventional techniques. In particular, a sacrificial seed layer, from which sidewalls can be accurately grown, is first deposited over a silicon fin. Once the sacrificial seed layer is etched away, the sidewalls can be surrounded by another disposable layer. Etching away the sidewalls will result in cavities being formed that straddle the fin, and gate conductor material can then be deposited within these cavities. Thus, the height and thickness of the resulting FinFET gate can be accurately controlled by avoiding a long direction etch down the entire height of the fin.
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FIELD OF THE INVENTION
The present invention relates to window assemblies, and in particular to sliding window assemblies which may be pivoted out of their plane of normal sliding for cleaning purposes.
BACKGROUND OF THE INVENTION
The prior art includes sliding windows with sashes which slide between opened and closed positions in parallel tracks. Generally, such windows include two sashes which slide in parallel, offset tracks. Weatherstripping seals the spaces between the sashes and between the sashes and tracks. Although traditional window assemblies (including sashes and tracks) have been made of wood, modern manufacturing techniques and materials have made it possible to manufacture these components from metal or plastics, or a combination, and such combined materials have thermal, esthetic and economic advantages.
Additionally, there have been windows of the sliding type which have mechanisms allowing the window sash to pivot about an axis so that the sash may be washed on both sides from within the building in which it is installed. Windows of this type have been both vertically double hung windows and horizontally sliding windows. The pivot mechanisms have included movable pins mounted on one edge of the sash which may be extended upward and downward to engage holes in the track and to form the axis about which the sash may be pivoted. At the opposite vertical edge are releasable track engaging members which may be withdrawn from the track to allow the sash to pivot.
Although such windows have worked, special steps have been required to maintain the sash steady when it is pivoted out of its usual sliding plane. For example, U.S. Pat. No. 4,222,201 shows such a window assembly, and it requires that spring loaded pins be released so that the springs push the pins into circular passages formed in the tracks. Then the sash may be pivoted. When window cleaning is complete, the pins must be retracted against the spring bias to free the pins from the circular passages, and locknuts must be secured to hold the pins in the retracted position for ordinary sliding. Not only does this mechanism require moving parts which may over time corrode or bind, but the pivoting procedure is complicated, and there may be problems with the sash not being adequately stable when pivoted open.
SUMMARY OF THE INVENTION
The present invention overcomes the difficulties of the prior art window assemblies by providing an improved sliding and pivoting mechanism for use in a sliding window which includes at least one, and preferably two, and possibly more, sashes which slide in a window frame. According to the present invention a window of the double sliding sash type has a pair of pivot members which extend in opposite directions from one edge of the sash. Each pivot member includes a first portion or leg by which it is fastened to the edge of the sash, and terminates in a short foot. The foot extends normal to the first portion and in the plane of the sash. A pair of manually releasable pins extends in opposite directions from the side of the sash opposite from the pivot members. The pivot feet and releasable pins support the sash in the track for sliding in the usual horizontal direction to open or close the window.
To pivot the sash, as for washing, the sash is first slid in the track until the feet at the top and bottom of the one side of the sash are aligned with slots or openings in the sidewalls of the track. Then the releasable pins on the other side of the sash are manually retracted and the sash is pivoted out of its usual plane of motion into the interior of the building so that both sides of the sash are simultaneously readily accessible. The slots in the sidewalls of the track accommodate the projecting ends of the feet as the sash pivots and prevent the sash from twisting diagonally and/or falling out when it is pivoted for washing.
The feet have a relatively broad contact area with the track during sliding movement, so no additional bushing or bearing is required even where the foot is made of metal and the track is extruded from polyvinyl chloride or other rigid vinyl or like material that has adequate strength and durability characteristics. Further, because the feet are permanently fixed to the sash, pivoting movement is more easily accomplished than with windows where the pins about which the sash pivots must be manually adjusted before the sash can be pivoted for cleaning.
In addition, the tracks of the window are profiled to facilitate easy pivoting of the sash back into its usual position. Specifically there are two different track profiles used. The first of the tracks readily allows the feet to slide in it; the other track blocks entrance of the feet. The openings which provide clearance for the feet as the sash pivots are formed in the first track section which is formed with heavy sectioned walls so there is adequate strength to support the pivoting of the sash. The second track section may be made of thinner material, and has inclined surfaces against which the manually releasable pins slide as the sash is returned to its normal position after cleaning. By selecting the length of the second track to be just slightly longer than the width of the one of the sashes, the track will prevent this sash from being opened too far and causing damage, e.g. to the handle of the other operating sash, etc., because the feet will not slide into such other track.
The invention, then, comprises the features hereinafter particularly pointed out and distinctly claimed in the claims. The following specification, taken together with the appended drawings, describes but a few of the various ways in which the invention may be carried out.
BRIEF DESCRIPTION OF THE DRAWINGS.
In the drawings:
FIG. 1 is a perspective illustration of a horizontally sliding window embodying the features of the present invention and viewed from the outside;
FIG. 2 is an enlarged partially sectioned view of a portion of the window of FIG. 1, and also viewed from the exterior of the window;
FIG. 3 is a view looking in the direction of arrows 3--3 of FIG. 2;
FIG. 4 is a view looking in the direction of arrows 4--4 of FIG. 3;
FIG. 5 is a view generally similar to FIG. 4 but showing the window assembly partially pivoted for cleaning; and
FIG. 6 is a partially sectioned and exploded view of a portion of the pivot mechanism of the window assembly of FIG. 1.
DESCRIPTION OF PREFERRED EMBODIMENTS
The window assembly 10 (FIG. 1) includes two sashes 12 and 14 which are horizontally slidable in tracks 18 and 20 (FIG. 2). As illustrated in FIG. 1, the sashes 12 and 14 slide horizontally, with the sash 14 mounted outside of the sash 12. The description which follows proceeds with respect to the window assembly as oriented in FIG. 1. However, it will be clear to those of ordinary skill in the art that the present invention could be embodied in other types of windows to achieve rotation of the entire window assembly approximately 90° from a closed condition. In the description that follows, the words "above", "below", "inside" and "outside" as well as "right" and "left" are used with respect to the orientation of the window assembly 10 shown in FIG. 1. This however is not intended to be limiting in any way and is merely for convenience of description.
The window assembly 10 includes tracks 18 and 20 which are mounted in a window frame 22. The window frame 22 may be formed either of metal or PVC extrusions or other similar extrusions, and in preferred embodiments of the present invention the exterior facing portion 24 of the frame 22 is formed from an aluminum extrusion while the interior facing portion 26 of the frame 22 is made of vinyl. This construction provides a thermal barrier to reduce heat loss. In any event, and whether the frame 22 is formed of metal, vinyl, plastic or even wood, the frame includes recesses 30 and 32 which mount and support the tracks 18 and 20, respectively. The recesses 30 and 32 are formed in the lower, horizontal member of the frame 22, and an identical pair of recesses (not shown) are formed in the upper member of the frame.
Each sash includes means for guiding its sliding movement in the frame 22. As illustrated in FIG. 1, there are two spring-loaded guide pins 36 and 38 which project downwardly and upwardly, respectively, from the rail of the sash 12 into the track 18. The pins 36 and 38 are essentially conventional, being spring biased to their extended positions and being retractable by means of appropriate buttons for purposes which will become clear from the discusion which follows. At the lefthand end of sash 14 there are a pair of identical pivot members 44 and 46. Inasmuch as the two pivot members are identical, only the pivot member 44 will be described in detail, it being understood that the description applies equally to the pivot member 46. The pivot member 44 (FIG. 6) includes a straight leg portion 50 which extends and fits snugly into a recess 52 formed in the vertical rail on the right side of sash 12. At the lower end portion of the pivot member 44 is a relatively short foot 54 which extends perpendicular to the straight leg portion 50 and in the plane of the glazing of the sash 12. The pivot member 44 is integrally formed from a piece of tooling steel which has a generally rectangular cross section. The width of the pivot member 44 is selected to slide easily within the tracks 18 or 20.
Means are provided for securing the pivot member 44 against unintended vertical movement with respect to the sash 12. In a preferred embodiment, the rail 56 of the sash 12 is formed, like the frame 22, of metal and plastic extrusions which are joined to each other. The recess 52 is formed in the metal portion of the rail 56 and extends its entire vertical length. In addition, the recess 52 is defined by the metal walls of the rail 56 which also define an outwardly opening slot 60. The pivot member 44 is secured in the recess 52 by means of a retaining bolt 62 and positioning and pivot pin locking pad 64. The pad 64 is formed of a relatively hard synthetic material such as a plastic material, e.g. nylon or Celcon. The pad 64 is generally shaped like a rectangular solid with a projecting tab 68 which fits into the slot 60 snugly. The pivot member 44 includes a threaded passage 70 which receives the bolt 62. When the bolt 62 is passed through the pad 64 and tightened into the passage 70, the portions of the pad 64 which extend beyond the projecting tab 68 bear tightly against the outside surface 72 of the rail 56, while the projecting tab 68 prevents rotation of the pad 64. Therefore, by tightening the bolt 62 it is possible to draw the leg portion 50 and the pad 64 toward each other to clamp the pivot member 44 against the walls of the rail 56 and into the desired position in the recess 52.
The foot 54 of the pivot member 44 preferably does not support the sash 12. Rather, a slider/glide pad assembly at all four corners, i.e. both top and bottom of the sash, supports the weight for easy sliding movement. The foot also slides in the track 18 and helps stabilize the side-to-side movement of the window during horizontal movement. Additionally, the corners of the foot 18 are slightly rounded, or at least not sharp, so that theydo not dig into the vinyl extrusion track 18.
The window assembly 10 is designed so that the sashes 12 and 14 not only may slide in a plane defined by the upper and lower tracks in which they slide and parallel to the plane of their glazing for conventional opening and closing of the window assembly, but also the sashes 12 and 14 may individually be pivoted out of their plane of sliding movement so that both sides of the glazing of each sash may be easily cleaned from one side of a wall on which the window assembly is installed. The present invention not only makes pivoting a simple operation, it also stabilzes the sash when pivoted so that it does not twist diagonally in the window frame or fall out of the frame during pivoting movement and while in a pivoted condition. To this end, openings 80 are formed in a vertical sidewall 82 of the track 18. The openings 80 have a vertical dimension the same as or slightly larger than the vertical dimension of the foot 54 (FIG. 6) of the pivot member 44 and the two openings are in vertical alignment with each other, one being formed in the exterior vertical sidewall of the track 18 and the other in alignment therewith in the track which supports the top of the sash 12.
To pivot the sash 12 inward for cleaning, the sash is first slid along the track 18 until the foot 54 and the foot of the corresponding pivot member 46 extending upward from the top of the sash are in alignment with the respective openings 80 in the tracks in which they slide. Then, the retractable pins 36 and 38 are manually retracted so that they are free of contact with their respective tracks. Thereafter, the edge of the sash 12 from which the pins 36 and 38 extend is pulled inward while the opposite edge of the sash pivots about an axis defined by the leg portions 50 of the pivot members 44 and 46. As the pivot members 44 and 46 rotate, the feet 54 project into the openings 80 as shown in FIG. 5. Of course, if the window had not first been slid into proper alignment with the openings 80, the feet would bind against the sidewall 82 of the respective tracks 18 thereby preventing the window sash from being pivoted into the room while unsecured, i.e., when the feet are not aligned and/or in the respective openings 80.
Moreover, when the sash is properly aligned, and the feet do rotate into and through the openings 80, the feet serve to stabilize the pivoted open window, preventing it from rotating catercorner in the frame and falling out. This is so because the side faces 84 and 85 of the feet 44 engage the ends 86 and 87 of the openings 80. This prevents twisting of the sash while it is pivoted out of its usual plane of sliding movement and thus assures that the pivoting will be only about the axis defined by the pivot members 49 and 46.
In addition, it should be noted that the tracks 18 and 20 may be formed with a change in profile along their axial length which serves to limit the extent to which the sash may be slid in one direction. For example, the lefthand portion (as seen in the exterior view shown in FIG. 1) of the tracks 18 and 20 may have a rectangular slot 100 through which the foot 54 of the pivot member 44 (FIG. 6) slides easily. On the other hand, the righthand portion of the tracks may have a profile with a slot 102 which is narrower than the slot 100. The slot 102 will easily accommodate sliding of the rectractable pins 36 and 38 therethrough, but is too small to allow the foot 54 to enter. By selecting the length of the righthand portion of the tracks 18 and 20 to be slightly longer than the distance between the righthand edge of the frame 22 and the pivot member 44 of the lefthand sash 12, the righthand portion of the track 18 will limit the distance through which the sash may be slid, thereby preventing the sash from being banged into the lefthand edge of the window frame.
Although the description has proceeded with respect to the lower portion of the window frame 22, the upper portion is essentially the same, and the description applies equally thereto. There is, however, one exception. To facilitate pivoting of the sash 14 inward for cleaning both sides of it, the window frame 22 forms an opening which is shorter for the outer sash 14 than for the inner sash 12. The bottom edges of the two sashes are level with each other, however the upper edge of the outer sash 14 is lower than the upper edge of the inner sash 12. In this way, the weatherstripping or the like associated with the outer sash does not contact the top of the window frame as the window is pivoted inward. In addition the openings 80 associated with the track 20 are spaced to the right (as viewed in FIG. 1) of the openings 80 in the track 18. This allows both sashes 12 and 14 to be pivoted simultaneously into the building in which the window assembly 10 is installed.
As a further feature of the present invention, the righthand portion (as seen in FIG. 1) of the tracks 18 and 20 may be provided with inclined or beveled surfaces 104 which slant in a direction to facilitate returning of the windows from their pivoted position to their normal position. To further this end, the pins 36 and 38 may be provided with beveled end surfaces 106 and 108. When pressed against the window frame 22 while pivoting the window back to its normal position, the inclined surface tends to retract the spring-loaded pins. The beveled surfaces on the tracks 18 and 20 further cooperate with the beveled surfaces on the pins 36 and 38 to ease the return of the window sashes to their usual position.
Thus, it will be appreciated that the invention may be used in connection with horizontally sliding windows in which one, two, three or even more sashes can slide generally in a horizontal fashion relative to the window frame. The sliding sash(es) will function in the usual sliding manner to enable opening or closing of the window. However, with the sash moved to the oppropriate position for rotation for cleaning purposes, for example, i.e. with the feet aligned with respective openings in the upper and lower tracks, the buttons may be operated to withdraw the retractable pins and the window may be pivoted about a generally vertical axis. During such pivoting the feet hold the window in place and prevent the same from falling out, as has been described in detail above. More than one window may be pivoted open for cleaning at a time, if desired. After cleaning, for example, the pivoted open window may be moved back into closed position fully aligned with the appropriate tracks and slides for further horizontal sliding movement in usual manner. Therefore, the invention improves efficiency and facility vis-a-vis window cleaning, for example, while also improving the overall safety of operation since the window is held rather securely in place during normal sliding operation, during pivoting, and while pivoted in the open condition.
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A pivotable and slidable window assembly includes one or more sashes slidable in parallel, coplanar horizontal tracks. Each sash carries a pair of pivot members extending in opposite directions from the sash to define a pivot axis for swinging the sash out of its usual sliding plane for cleaning or the like of both sides of the sash. Each pivot member is slidably received in a respective one of the tracks, and each includes a foot extending in the plane of sliding movement of the sash and perpendicular to the pivot axis. Each track includes an opening to receive the foot of a respective pivot member when the sash is pivoted for cleaning. Upon pivoting of the sash and movement of the feet into the respective openings, contact between the feet and the openings stabilizes the sash preventing further and unwanted sliding of the sash in the tracks. Thus the sash cannot twist catercorner with respect to the tracks and is prevented from falling out while pivoted.
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This application claims the benefit of U.S. Provisional Application No. 60/340,449, filed Dec. 14, 2001, the contents of which are hereby incorporated by reference.
This invention has been made with government support under National Institutes of Health grant HL-25848. Accordingly, the U.S. Government has certain rights in the invention.
Throughout this application, various publications are referenced by Roman numeral superscripts. Full citations for these publications may be found at the end of the specification immediately preceding the claims. The disclosures of these publications in their entireties are hereby incorporated by reference into this application in order to more fully describe the state of the art as known to those skilled therein as of the date of the invention described and claimed herein.
BACKGROUND OF THE INVENTION
Neurotrophic factors are functionally defined as molecules which promote the maintenance and growth of neurons in vitro and in vivo. 1 Among such factors are the nerve growth factor (NGF) and glial cell-derived neurotrophic factor (GDNF). Intraventricular administration of NGF to rats and primates reduces cholinergic neuronal degeneration, with potential implications for the treatment of Alzheimer's disease. 2a,3 GDNF may have consequences in the treatment of Parkinson's disease. 2b However, optimism along these lines is tempered by concerns as to the pharmacokinetics and bioavailability of polypeptidal factors. 3 It is in this connection that the discovery of non-peptidal small molecules with neurotrophic properties is potentially of great significance. 4 It seems appropriate to explore non-peptidal neurotrophic agents in detail as to their biological function and their usefulness, if any, in the treatment of neurodegenerative diseases. A mastery of the total synthesis of such small-molecule natural products could be most helpful, not only in improving access to these difficultly available agents, but in providing the basis for probing their SAR profiles.
Described below is the total synthesis of the pentacyclic sesquiterpene dilactone, merrilactone A (1). This compound had previously been obtained in 0.004% yield from the methanol extract of the pericarps of Illicium merrillianum. 5 Preliminary studies indicated that 1 greatly promotes neurite outgrowth in fetal rat cortical neurons at concentrations as low as 0.1–10 μmol. Further investigations to date have been hampered by the scarcity of the natural merrilactone A.
SUMMARY OF THE INVENTION
This invention provides a total synthesis of Merrillactone and Merrilactone analogues having the structure
wherein Z is O or >N—X, where X is H, straight or branched substituted or unsubstituted alkyl, alkenyl or alkynyl, or acyl, carbamoyl, cycloalkyl, aryl, heterocycloalkyl, heteroaryl, aralkyl, amino, alkyl amino, or dialkyl amino;
wherein each of R 1 and R 2 is H or R 1 and R 2 together are ═O;
wherein each of R 3 and R 4 is H or R 3 and R 4 together are ═O;
wherein each of R 5 and R 6 is, independently, H, alkyl, aralkyl, or aryl;
wherein each of R 7 and R 8 is, independently, H or OR 14 , where R 14 is alkyl or —C(O)—R 15 ,
where R 15 is H, —CH 2 R 16 , —CHR 16 R 16 , —CR 16 R 17 R 16 , —OR 16 , alkenyl or alkynyl, cycloalkyl, aryl, heterocycloalkyl, heteroaryl, aralkyl, amino, alkyl amino, or dialkyl amino,
wherein each R 16 is straight or branched, substituted or unsubstituted alkyl, alkenyl or alkynyl, cycloalkyl, aryl, heterocycloalkyl, heteroaryl, aralkyl, or amino; and wherein R 17 is straight or branched, unsubstituted alkyl, alkenyl or alkynyl, cycloalkyl, aryl, heterocycloalkyl, heteroaryl, aralkyl, or amino,
or wherein R 7 and R 9 together are >O;
wherein each of R 9 and R 10 is, independently, H, alkyl, OH, or OR 13 , where R 13 is an alkyl, an acyl, or an amide, or R 9 and R 10 together are ═CH 2 ,
or wherein R 8 and R 10 together are >O;
wherein if one of R 7 or R 8 and one of R 9 or R 10 is absent, a double bond is formed as indicated by the broken line; and
wherein each of R 11 and R 12 is, independently, H, OH, or OR 13 , where R 13 is an alkyl, an acyl, or an amide, or R 11 and R 12 together are ═O,
or wherein R 12 and R 10 together are >O.
The invention also provides intermediates for use in the synthesis.
The total synthesis of the title compound has been accomplished in 20 steps. The key step is a free radical cyclization of vinyl bromide 29 to afford 30. The synthesis also features an efficient Diels-Alder reaction of 2,3-dimethylmaleic anhydride with 1-(tert-butyldimethylsiloxy)-butadiene. The oxetane moiety of merrilactone A is fashioned via a Payne-like rearrangement of a hydroxyepoxide (see 2->1).
DETAILED DESCRIPTION OF THE INVENTION
In one embodiment, this invention provides a compound having the structure
wherein Z is O or >N—X, where X is H, straight or branched substituted or unsubstituted alkyl, alkenyl or alkynyl, or acyl, carbamoyl, cycloalkyl, aryl, heterocycloalkyl, heteroaryl, aralkyl, amino, alkyl amino, or dialkyl amino;
wherein each of R 1 and R 2 is H or R 1 and R 2 together are ═O;
wherein each of R 3 and R 4 is H or R 3 and R 4 together are ═O;
wherein each of R 5 and R 6 is, independently, H, alkyl, aralkyl, or aryl;
wherein each of R 7 and R 8 is, independently, H or OR 14 , where R 14 is alkyl or —C(O)—R 15 ,
where R 15 is H, —CH 2 R 16 , —CHR 16 R 16 , —CR 16 R 17 R 16 , —OR 16 , alkenyl or alkynyl, cycloalkyl, aryl, heterocycloalkyl, heteroaryl, aralkyl, amino, alkyl amino, or dialkyl amino,
wherein each R 16 is straight or branched, substituted or unsubstituted alkyl, alkenyl or alkynyl, cycloalkyl, aryl, heterocycloalkyl, heteroaryl, aralkyl, or amino; and wherein R 17 is straight or branched, unsubstituted alkyl, alkenyl or alkynyl, cycloalkyl, aryl, heterocycloalkyl, heteroaryl, aralkyl, or amino,
or wherein R 7 and R 9 together are >O;
wherein each of R 9 and R 10 is, independently, H, alkyl, OH, or OR 13 , where R 13 is an alkyl, an acyl, or an amide, or R 9 and R 10 together are ═CH 2 ,
or wherein R 8 and R 10 together are >O;
wherein if one of R 7 or R 8 and one of R 9 or R 10 is absent, a double bond is formed as indicated by the broken line; and
wherein each of R 11 and R 12 is, independently, H, OH, or OR 13 , where R 13 is an alkyl, an acyl, or an amide, or R 11 and R 12 together are ═O,
or wherein R 12 and R 10 together are >O.
In another embodiment of the compound Z is >N—X, where X is H, straight or branched substituted or unsubstituted alkyl, alkenyl or alkynyl, or acyl, carbamoyl, cycloalkyl, aryl, heterocycloalkyl, heteroaryl, aralkyl, amino, alkyl amino, or dialkyl amino.
In yet another embodiment of the compound Z is O or >N—X, where X is H, straight or branched alkyl, alkenyl or alkynyl, or acyl, carbamoyl, cycloalkyl, aryl, heterocycloalkyl, heteroaryl, aralkyl, amino, alkyl amino, or dialkyl amino;
wherein each of R 1 and R 2 is H or R 1 and R 2 together are ═O; wherein each of R 3 and R 4 is H or R 3 and R 4 together are ═O; wherein each of R 5 and R 6 is, independently, H, alkyl, or aralkyl; wherein each of R 7 and R 8 is, independently, H or OR 14 , where R 14 is alkyl or —C(O)—R 15 ,
where R 15 is H, —CH 2 R 16 , —CHR 16 R 16 , —CR 16 R 17 R 16 , —OR 16 , cycloalkyl, aryl, or aralkyl,
wherein each R 16 is alkyl, cycloalkyl, or aryl, aralkyl; and wherein R 17 is alkyl, cycloalkyl, aryl, or aralkyl,
or wherein R 7 and R 9 together are >O;
wherein each of R 9 and R 10 is, independently, H, alkyl, OH, or OR 13 , where R 13 is an alkyl, an acyl, or an amide, or R 9 and R 10 together are ═CH 2 ,
or wherein R 8 and R 10 together are >O;
wherein if one of R 7 or R 8 and one of R 9 or R 10 is absent, a double bond is formed as indicated by the broken line; and wherein each of R 11 and R 12 is, independently, H, OH, or OR 13 , where R 13 is an alkyl, an acyl, or an amide, or R 11 and R 12 together are ═O,
or wherein R 12 and R 10 together are >O.
In another embodiment, the compound hasing the structure
wherein Z is >O;
wherein each of R 1 and R 2 is H, or R 1 and R 2 together are ═O;
wherein each of R 3 and R 4 is H, or R 3 and R 4 together are ═O;
wherein each of R 5 and R 6 is, independently, H, alkyl, aralkyl, or aryl;
wherein each of R 7 and R 8 is, independently, H or OR 14 , where R 14 is alkyl or —C(O)—R 15 ,
where R 15 is H, —CH 2 R 16 , —CHR 16 R 16 , —CR 16 R 17 R 16 , —OR 16 , alkenyl or alkynyl, cycloalkyl, aryl, heterocycloalkyl, heteroaryl, aralkyl, amino, alkyl amino, or dialkyl amino,
wherein each R 16 is straight or branched, substituted or unsubstituted alkyl, alkenyl or alkynyl, cycloalkyl, aryl, heterocycloalkyl, heteroaryl, aralkyl, or amino; and wherein R 17 is straight or branched, unsubstituted alkyl, alkenyl or alkynyl, cycloalkyl, aryl, heterocycloalkyl, heteroaryl, aralkyl, or amino; and
wherein R 9 is H, alkyl, OH, or OR 13 , where R 13 is an alkyl, an acyl, or an amide.
In this embodiment, R 9 may be H, alkyl or OR 13 , where R 13 is an alkyl, an acyl, or an amide.
Also disclosed is a compound wherein R 1 and R 2 together are ═O;
wherein each of R 3 and R 4 is H; wherein each of R 5 and R 6 is, independently, H, alkyl, or aralkyl; wherein each of R 7 and R 8 is, independently, H or OR 14 , where R 14 is alkyl or —C(O)—R 15 ,
where R 15 is H, —CH 2 R 16 , —CHR 16 R 16 , —CR 16 R 17 R 16 , —OR 16 , alkenyl or alkynyl, cycloalkyl, aryl, heterocycloalkyl, heteroaryl, aralkyl, amino, alkyl amino, or dialkyl amino,
wherein each R 16 is straight or branched, substituted or unsubstituted alkyl, alkenyl or alkynyl, cycloalkyl, aryl, heterocycloalkyl, heteroaryl, aralkyl, or amino; and wherein R 17 is straight or branched, unsubstituted alkyl, alkenyl or alkynyl, cycloalkyl, aryl, heterocycloalkyl, heteroaryl, aralkyl, or amino; and
wherein R 9 is alkyl.
In yet another embodiment, the invention provides a compound having the structure
wherein Z is O or >N—X, where X is H, straight or branched substituted or unsubstituted alkyl, alkenyl or alkynyl, or acyl, carbamoyl, cycloalkyl, aryl, heterocycloalkyl, heteroaryl, aralkyl, amino, alkyl amino, or dialkyl amino;
wherein each of R 1 and R 2 is H or R 1 and R 2 together are ═O;
wherein each of R 3 and R 4 is H or R 3 and R 4 together are ═O;
wherein each of R 5 and R 6 is, independently, alkyl, aralkyl, or aryl; and
where Q is H or a silyl protecting group.
The compound may have the structure
The compound may also have the structure
The compound may further have the structure
The compound also may have the structure
In a further embodiment, this invention provides a compound having the structure
wherein each of Ra, Ra′, Rb, and Rb′ is independently H, alkyl, alkenyl, alkynyl, acyl, or carbamoyl, or either Ra and Rb or Ra′ and Rb′ together with the carbons to which they are attached form a substituted or unsubstituted five or six member ring; and
wherein each of Rc and Rc′ is, independently, H, OH or OR, wherein R is alkyl, acyl or Q, where Q is a silyl protecting group, or both Rc and Rc′ together are ═O.
This invention also provides a process for forming a cyclic ring in the compound so as to produce the compound having the structure
wherein each of Ra, Ra′, Rb, and Rb′ is independently H, alkyl, alkenyl, alkynyl, acyl, or carbamoyl, or either Ra and Rb or Ra′ and Rb′ together with the carbons to which they are attached form a substituted or unsubstituted five or six member ring; and
wherein each of Rc and Rc′ is, independently, H, OH or OR, wherein R is alkyl, acyl or Q, where Q is a silyl protecting group, or both Rc and Rc′ together are ═O,
comprising treating a compound having the structure
where M is Br or I,
with Bu 3 SnH or tris-(trimethyl silyl)-silane ((TMS) 3 SiH) and a free radical initiator so as to thereby produce the compound.
The process can produce a compound having the structure
where Q is a silyl protecting group; and
where each of R′ and R″ is independently alkyl, alkenyl, alkynyl, acyl, or carbamoyl, or R′ and R″ together form a substituted or unsubstituted five or six member ring,
by treating a compound having the structure
where M is Br or I,
with Bu 3 SnH or tris-(trimethyl silyl)-silane ((TMS) 3 SiH) and a free radical initiator so as to thereby produce the compound.
The process may also produce a compound having the structure
by treating a compound having the structure
where Q is a silyl protecting group; and
where M is Br or I,
with Bu 3 SnH or tris-(trimethyl silyl)-silane ((TMS) 3 SiH) and a free radical initiator so as to thereby produce the compound.
Furthermore, the process can produce a compound having the structure
by treating a compound having the structure
with Bu 3 SnH and AlBN so as to thereby produce the compound.
This invention also provides a process for synthesizing a compound having the structure
comprising
a) reacting a compound having the structure
where Q is a silyl protecting group, with a compound having the structure
at a temperature of from about 140° C. to 230° C. to produce a compound having the structure
b) reacting the compound of step a) with MeONa to produce
c) treating both products of step b) with ClCO 2 Me to produce
d) treating both products, of step c) with NaBH 4 to produce
e) treating the products of step d) with LiOH to produce
f) treating the product of step e) with O 3 followed by Bn 2 NH*TFA to produce
g) treating the product of step f) with NaBH 4 to produce
h) treating the product of step g) with MeC(OEt) 3 to produce
i) treating the product of step h) LiOH and I 2 and to produce
j) treating the product of step i) with allylSnBu 3 to produce
k) treating the product of step j) with LHMDS, TMSCl and PhSeCl, and then with PhSeBr and MeCN to produce
l) treating the product of step k) with O 3 , CH 2 Cl 2 and 1-hexene to produce
m) treating the product of step l) with Bu 3 SnH and AlBN to produce
n) treating the product of step m) with TsOH to produce
o) treating the product of step n) with mCPBA or a dimethyldioxirane to produce
p) treating the product of step o) with an acid to produce the compound.
The process can also synthesize a compound having the structure
comprising
a) reacting a compound having the structure
with a compound having the structure
at a temperature of from about 160° C. to 180° C. to produce a compound having the structure
b) reacting the compound of step a) with MeONa and MeOH to produce
c) treating both products of step b) with ClCO 2 Me in THF to produce
d) treating both products of step c) with NaBH 4 and MeOH to produce
e) treating the products of step d) with aqueous LiOH to produce
f) treating the product of step e) first with O 3 and PPh 3 , and then with Bn 2 NH*TFA in benzene to produce
g) treating the product of step f) with NaBH 4 and CH 2 Cl 2 in MeOH to produce
h) treating the product of step g) with MeC(OEt) 3 and PivOH to produce
i) treating the product of step h) first with aqueous LiOH and MeOH, and then with I 2 and NaHCO 3 in THF to produce
j) treating the product of step i) with allylSnBu 3 , AlBN and PhH to produce
k) treating the product of step j) first with LHMDS, TMSCI and PhSeCl, and then with PhSeBr and MeCN to produce
l) treating the product of step k) first with O 3 , CH 2 Cl 2 and 1-hexene, and then with PhH, NEt 3 under reflux conditions to produce
m) treating the product of step l) with Bu 3 SnH and AlBN, and PhH to produce
n) treating the product of step m) with aqueous TsOH and PhH under reflux conditions to produce
o) treating the product of step n) with mCPBA and CH 2 Cl 2 to produce
p) treating the product of step o) with aqueous TsOH and CH 2 Cl 2 to produce the compound.
The abbreviations used are defined below:
TFA=trifluoroacetic acid THF=tetrahydrofuran Bn 2 NH.TFA=dibenzylammonium trifluoroacetate LHMDS=lithium hexamethyldisilazide TBS=tert-butyldimethylsilyl PivOH=pivalic acid AIBN=azobis-(isobutyronitrile) PhH=benzene MeCN=acetonitrile MeOH=methanol mCPBA=meta-chloroperbenzoic acid TsOH=para-toluenesulfonic acid
The invention further contemplates the use of prodrugs which are converted in vivo to the therapeutic compounds of the invention (see, e.g., R. B. Silverman, 1992, “The Organic Chemistry of Drug Design and Drug Action”, Academic Press, Chapter 8, the entire contents of which are hereby incorporated by reference). Such prodrugs can be used to alter the biodistribution (e.g., to allow compounds which would not typically enter the reactive site of the protease) or the pharmacokinetics of the therapeutic compound.
Certain embodiments of the disclosed compounds can contain a basic functional group, such as amino or alkylamino, and are thus capable of forming pharmaceutically acceptable salts with pharmaceutically acceptable acids, or contain an acidic functional group and are thus capable of forming pharmaceutically acceptable salts with bases. The term “pharmaceutically acceptable salts” in this respect, refers to the relatively non-toxic, inorganic and organic acid or base addition salts of compounds of the present invention. These salts can be prepared in situ during the final isolation and purification of the compounds of the invention, or by separately reacting a purified compound of the invention in its free base or free acid form with a suitable organic or inorganic acid or base, and isolating the salt thus formed. Representative salts include the hydrobromide, hydrochloride, sulfate, bisulfate, phosphate, nitrate, acetate, valerate, oleate, palmitate, stearate, laurate, benzoate, lactate, phosphate, tosylate, citrate, maleate, fumarate, succinate, tartrate, napthylate, mesylate, glucoheptonate, lactobionate, and laurylsulphonate salts and the like. (See, e.g., Berge et al. (1977) “Pharmaceutical Salts”, J. Pharm. Sci. 66:1–19).
It will be noted that the structure of some of the compounds of this invention includes asymmetric carbon atoms and thus occur as racemates and racemic mixtures, single enantiomers, diastereomeric mixtures and individual diastereomers. All such isomeric forms of these compounds are expressly included in this invention. Each stereogenic carbon may be of the R or S configuration. It is to be understood accordingly that the isomers arising from such asymmetry (e.g., all enantiomers and diastereomers) are included within the scope of this invention, unless indicated otherwise. Such isomers can be obtained in substantially pure form by classical separation techniques and/or by stereochemically controlled synthesis.
Compounds discussed above, such a merrilactone A, promote the maintenance and growth of neurons both in vivo and in vitro and promote neurite outgrowth in fetal rat cortical neurons. Based on their chemical and structural similarities to merrilactone A, such activity of the disclosed compounds is not expected. Furthermore, the activity of the disclosed compounds both in vivo and in vitro can be determined by using published test procedures.
EXAMPLES AND DISCUSSION
Example 1
The challenge of creating the densely oxygenated, highly compact architecture of merrilactone A in the laboratory added to the attractiveness of the project. One of the provocative features of the target system is the presence of an oxetane linkage bridging the β-faces of C7 and C1. We envisioned the possibility that such an oxetane might arise by Payne-like rearrangement of α-epoxide 2. It was further conjectured that isomerization of exo-olefin 3 followed by epoxidation would lead to 2. A critical step en route to 3 might be a free radical cyclization 6 of a substrate of type 4, enabling formation of a new quaternary center in a densely substituted environment. It was further anticipated that suitable two-fold oxidation of 5 might provide the required complementary functionality of 4. This line of reasoning invited a proposal that overall “allyl-lactonization” could be used to convert 6 to 5. Recognition of the γ,δ-unsaturated acid character of 6 called to mind the possibility of reaching this intermediate by Claisen rearrangement via 7. Preparation of 7 was to be achieved through a ring cleavage-reclosure sequence from 8. The latter structure, in turn, was suggestive of a Diels-Alder based construction. However, the prospects of a direct cycloaddition between 9 and 10 to reach 8 were not promising. Even uncongested butenolides are not particularly powerful dienophiles. The presence of the two methyl groups, creating a tetrasubstituted “dienophilic” double bond, was likely to preclude such a cycloaddition. Hence, we sought to compensate for the expected steric impediment through recourse to a more reactive dienophile substructure (cf. 12). The development of a scheme which, in effect, circumvents the inertness of 10 was a key challenge to our prospectus.
The reaction of 2,3-dimethylmaleic anhydride (12) 7 and 11 8 occurred under the conditions shown, to afford 13 in 74% yield. We next turned to regioselective reduction of the C14 carbonyl group (future merrilactone A numbering). Attempted reductions with conventional borohydride reagents led to complex mixtures. This lack of selectivity necessitated a somewhat awkward, but high yielding, circumvention. It was established that ring opening of 13 with sodium methoxide proceeded smoothly. Treatment of the resulting salts (14 and 15) with ClCO 2 Me in THF afforded mixed anhydrides 16 and 17. Remarkably, exposure of this mixture to the action of NaBH 4 and methanol 9 led to clean reduction of 17 while leaving 16 unchanged. (The inertness of the C12 carbonyl in 16 may be due to its axial orientation.) Subsequent addition of lithium hydroxide to the mixture afforded compounds 18 and 20, easily separable by a simple extraction. Treatment of 18 with LiBHEt 3 11 also afforded 20. The regioconvergence of this scheme obviated any need for chromatographic separation of intermediates and afforded 20 in 78% overall yield from 13.
The stage was now set for the ring cleavage-reclosure sequence (cf. 8→7 in retrosynthesis plan). Ozonolysis of 20 followed by reductive workup, as shown, led to a dialdehyde, which on aldol condensation using Corey's conditions 12 afforded the cyclodehydrated product 21 in high yield. Following reduction 13 of the aldehyde function, allylic alcohol 22 was in hand. The next stage called for Claisen rearrangement to reach 23. The most advantageous way to achieve this result proved to be via the Johnson orthoester protocol. 14 The mixture of esters (23/24˜1.8:1) thus produced was hydrolyzed, and the resultant acids subjected to iodolactonization. Two crystalline and chromatographically separable iodolactones, 25 and 26, were obtained in 35 and 59% yields, respectively. Chain extension of the required “anti-backbone” isomer 26 was accomplished (75% yield) by the elegant C-allylation method of Keck. 15
As noted above, (cf. 5→4 in the retrosynthesis) oxidation at two sites would be required to complete the setting for the proposed key cyclization step (cf. 4→3). An efficient sequence to deal with potentially awkward functional group management issues in advancing beyond 27 was developed. Thus, selenenylation at C10 was accomplished via an intermediate silyl ketene acetal. With this subgoal achieved, bromoselenenylation of the terminal vinyl group of 27 was conducted according to methodology introduced some years ago by Rauscher. 16 Concurrent oxidative deselenation afforded the desired 29. The setting for testing the key free radical cyclization was at hand. Our initial concerns that the steric congestion at the sp 2 center at C9 might lead to the competitive reduction of the vinylic radical, fortunately, proved groundless. In the event, treatment of 29 under the standard conditions 6a afforded a 90% yield of 30.
Isomerization of the exo methylene group in 30 envisioned at the planning stage was accomplished concurrently with liberation of the C7 β-alcohol. While hydroxyl groups have often been used to direct epoxidation with peracids in a syn sense, 17 in the case at hand the congested nature of the β-face of the C1–C2 double bond is such that epoxidation occurs primarily (3.5:1) from its α-face (see compound 2). 18 In the final step of the synthesis, merrilactone A is produced by an acid-induced homo-Payne rearrangement (see 2→1). The spectroscopic properties of 31, 2, and 1 were in complete accord with the published data. 5b Further confirmation came from the identity of the NMR spectra of synthetic (±)−1 with those of natural merrilactone A.
In summary, a total synthesis of merrilactone A has been accomplished. The first generation route described above provides, for the first time, ample material for extensive preclinical evaluations of merrilactone A. The chemistry developed to date (20 steps, 10.7% overall yield) is amenable to scale-up to multigram levels. Moreover, the use of dimethylmaleic anhydride (12) as a dienophile leading to the incorporation of two angular methyl groups has broad potential implications which warrant follow-up.
Experimental Details for Example 1
All reactions were carried out under an argon atmosphere. Tetrahydrofuran, diethyl ether, and dichloromethane were purified by passing through solvent columns. 10 Other solvents were obtained commercially and were used as received. 1-(t-butyldimethylsilyloxy)-1,3-butadiene was prepared according to a literature procedure. All other reagents were reagent grade and purified where necessary. Reactions were monitored by thin layer chromatography (TLC) using EM Science 60F silica gel plates. Flash column chromatography was performed over Scientific Adsorbents Inc. silica gel (32–63 μm). Melting points were measured on a Thomas Hoover capillary melting point apparatus and are uncorrected. 1 H NMR and 13 C NMR spectra were recorded on Bruker-Spectrospin spectrometers. The chemical shifts are reported as δ values (ppm) relative to TMS. Infrared spectra were recorded on a Perkin-Elmer Paragon 1000 FT-IR Spectrophotometer (NaCl plates, film). Low-Resolution mass spectral analyses were performed on a Jeol LC/MS system using chemical ionization.
Diels-Alder Adduct 13. A flask containing a mixture of 2,3-dimethylmaleic anhydride (2.520 g, 20.0 mmol), 1-(t-butyldimethylsilyloxy)-1,3-butadiene (5.53 g, 30.0 mmol), symm-collidine (150 mg), Methylene Blue (5 mg), and mesitylene (6.2 mL) was purged with argon several times and stirred under reflux in an oil bath at 165° C. for 2.5 days. The solvents were removed by Kugelrohr distillation at 100° C., and the residue was purified by flash chromatography (hexanes/EtOAc 19:1) to afford 4.604 g (74% yield) of the product which crystallized upon standing. 1 H NMR (CDCl 3 , 400 MHz): δ −0.03 (s, 3H), 0.01 (s, 3H), 0.79 (s, 9H), 1.16 (s, 3H), 1.31 (s, 3H), 2.00 (dd, J=21, J=4, 1H), 2.99 (d, J=21, 1H), 4.13 (d, J=5.7, 1H), 5.96 (m, 2H); 13 C NMR (CDCl 3 , 100 MHz): −5.6, −4.4, 14.7, 17.7, 25.3, 25.6, 30.0, 44.2, 53.9, 70.2, 126.9, 130.1, 175.4, 176.7; IR (NaCl, cm −1 ): 1784 s, 1852 m (anhydride C═O); MS Found: 311.1 (M+1), Calc. 310.16; Mp 62–63° C.
Lactone 20. Part A. A stirring mixture of Diels-Alder Adduct 13 (1.240 g, 4.00 mmol) and dry methanol (10 mL) was treated at RT with 25% methanolic solution of MeONa (0.92 mL, 4.02 mmol). After 15 minutes, the mixture was rotary evaporated, and the residue was coevaporated twice with benzene to dryness. The resulting viscous oil was dissolved in THF (10 mL), the solution was cooled in an ice bath and treated with ClCO 2 Me (0.400 mL, 5.18 mmol). After 20 minutes, the mixture was cooled to −78° C., and solid NaBH 4 (400 mg, 10.57 mmol) was added, followed by dropwise addition of dry MeOH (1.60 mL). The mixture was allowed to warm up to −35° C., quenched with saturated aqueous ammonium chloride (6 mL), warmed to RT, diluted with water, and extracted twice with Et 2 O. The aqueous phase was acidified to pH 3–4 with 1 M HCl and extracted twice with Et 2 O. The combined ethereal extract was evaporated, the residue dissolved in THF (12 mL), and stirred vigorously with aqueous LiOH (4 mL, 5%) for 1.5 hours. The mixture was diluted with water and extracted 3 times with hexanes. The hexane extract (containing almost pure lactone 20) was washed twice with 1 M NaOH, then brine, dried with Na 2 SO 4 , and set aside.
Part B. The combined alkaline aqueous phase from the previous step was acidified with 1 M HCl and extracted 3 times with Et 2 O. The ethereal solution was dried over MgSO 4 , rotary evaporated, and the residue was coevaporated with benzene. The resulting crude half-ester 18 (758 mg, 2.21 mmol) was cooled in an ice bath and treated with LiBHEt 3 (1M in THF, 12 mL). After stirring overnight at RT, the mixture was cooled again in an ice bath, quenched with 1 M NaOH (8 mL), and then carefully treated with 10% H 2 O 2 (18 mL) added in several portions to avoid excessive heating. After stirring for 0.5 hour, the solution was acidified with 1 M HCl to pH 5–6 and extracted with Et 2 O twice. The viscous residue on the bottom of the flask was shaken vigorously with 1 M HCl and Et 2 O until completely dissolved. The resulting two-phase mixture was combined with the aqueous phase, acidified to pH 5–6 again, and extracted with ether twice. The combined ethereal extract was washed with brine once, dried over MgSO 4 , rotary evaporated, redissolved in 10 mL of CH 2 Cl 2 , and treated with TFA (0.04 mL). After 3 days, this mixture was combined with the previously obtained hexane solution of lactone 20, evaporated, and subjected to flash chromatography (hexanes/EtOAc 19:1) to afford 925 mg (78% yield) of the product as colorless oil which crystallized upon standing. 1 H NMR (CDCl 3 , 500 MHz): δ 0.05 (s, 3H), 0.08 (s, 3H), 0.86 (s, 9H), 1.06 (s, 3H), 1.09 (s, 3H), 2.00 (ddd, J=19.3, J=1.9, J=1.0, 1H), 2.14 (ddd, J=19.3, J=2.1, J=1.6, 1H), 3.73 (d, J=7.6, 1H), 3.97 (d, J=4.7, 1H), 4.32 (d, J=7.6, 1H), 5.76–5.83 (m, 2H); 13 C NMR (CDCl 3 , 100 MHz): −5.4, −4.1, 16.2, 17.7, 25.6, 26.2, 30.7, 39.2, 50.1, 70.0, 75.4, 126.4, 126.7, 179.6; IR (NaCl, cm −1 ): 1777s (C═O); MS Found: 297.1 (M+1), Calc. 296.18; Mp 44–44.5° C.
Unsaturated aldehyde 21. A solution of lactone 20 (592 mg, 2 mmol) in a mixture of dry CH 2 Cl 2 (20 mL) and dry MeOH (20 mL) was ozonated at −78° C. until blue color appeared, then purged with oxygen until colorless, treated with PPh 3 (630 mg, 2.4 mmol, added in 6 mL of CH 2 Cl 2 ), and allowed to warm up to RT. The solvents were removed by rotary evaporation, the residue was coevaporated with benzene and dissolved in benzene (40 mL). Dibenzylammonium trifluoroacetate (124 mg, 0.4 mmol) was added, and the resulting solution was stirred at 63° C. for 9 hours. The solvent was evaporated, and the residue was chromatographed (hexanes/ethyl acetate 9:1) to afford 580 mg (94% yield) of the product as colorless oil which crystallized upon standing. 1 H NMR (CDCl 3 , 400 MHz): δ 0.12 (s, 3H), 0.15 (s, 3H), 0.90 (s, 9H), 1.25 (s, 3H), 1.33 (s, 3H), 4.04 (d, J=9.2, 1H), 4.26 (d, J=9.2, 1H), 4.61 (d, J=2.2, 1H), 6.62 (d, J=2.2, 1H), 9.82 (s, 1H); 13 C NMR (CDCl 3 , 100 MHz): −5.1, −4.7, 16.3, 17.5, 18.0, 25.6, 53.2, 57.4, 75.8, 82.9, 132.9, 149.3, 149.6, 176.1, 189.8; IR (NaCl, cm −1 ): 1688 s (aldehyde C═O), 1778 s (lactone C═O); MS Found: 311.1 (M+1), Calc. 310.16; Mp 57–57.5° C.
Allylic alcohol 22. Solid NaBH 4 (130 mg, 3.44 mmol) was added to a solution of aldehyde 21 (536 mg, 1.73 mmol) in CH 2 Cl 2 (28 mL) stirring at −78° C., followed by slow addition of methanol (12 mL). The mixture was allowed to warm slowly to RT and then quenched by careful addition of saturated aqueous NH 4 Cl (5 mL), then diluted with water, and extracted 3 times with CH 2 Cl 2 . The organic extract was washed once with brine, dried over Na 2 SO 4 and rotary evaporated. The resulting colorless oil contained 1% of CH 2 Cl 2 by 1 H NMR, but otherwise was completely pure (593 mg, quant. yield). The oil crystallized after prolonged standing. 1 H NMR (CDCl 3 , D 2 O, 500 MHz): δ 0.07 (s, 3H), 0.09 (s, 3H), 0.87 (s, 9H), 1.16 (s, 3H), 1.18 (s, 3H), 4.03 (d, J=8.7, 1H), 4.15 (d, J=14.0, 1H), 4.21 (d, J=8.7, 1H), 4.28 (d, J=14.0, 1H), 4.30 (d, J=0.8, 1H), 5.59 (d, J=0.8, 1H); 13 C NMR (CDCl 3 , 100 MHz): −5.1, −4.6, 16.3, 17.4, 18.0, 25.7, 54.6, 58.7, 59.5, 78.9, 83.1, 126.2, 150.6, 177.3; IR (NaCl, cm −1 ): 1757 s (C═O), 3436 br (O—H); MS Found: 313.1 (M+1), Calc. 312.18; Mp 71.5–72.5° C.
Claisen Esters 23 and 24. A mixture of allylic alcohol 22 (593 mg, 1.87 mmol), pivalic acid (75 mg, 0.74 mmol), freshly distilled triethyl orthoacetate (5.5 mL, 30 mmol), and mesitylene (5.5 mL) was stirred in an oil bath at 135–140° C. in a flask equipped with a short-path distillation head under a slow flow of argon, adding 75 mg of pivalic acid every 2 hours and monitoring the progress of the reaction by 1 H NMR. After 12 hrs, 2 mL of triethyl orthoacetate was added and the heating was continued overnight. NMR analysis indicated ca. 95% conversion. The mixture was cooled to RT, the solvents were removed by Kugelrohr distillation at 100° C., and the residue was purified by flash chromatography (hexanes/EtOAc 14:1) to afford 658 mg (92% yield) of the product as a mixture of diastereomers (23/24=1.8:1). 1 H NMR (CDCl 3 , 400 MHz): δ −0.03 (s, 1.65H), 0.08 (app s, 4.65H), 0.11 (s, 3H), 0.86 (s, 4.95H), 0.88 (s, 9H), 1.18 (s, 3H), 1.19 (s, 3H), 1.23–1.30 (m, 7.95H), 2.46 (dd, J=15.8, J=7.4, 1H), 2.53 (m, 1.1H), 2.58 (dd, J=15.8, J 6.5, 1H), 3.05 (m, 1H), 3.24 (m, 0.55H), 3.88 (d, J=8.7, 1H), 3.90 (d, J=4.1, 1H), 3.94 (d, J=8.2, 0.55H), 4.13–4.19 (m, 5.2H), 4.85 (d, J=3, 0.55H), 4.91 (d, J=3, 0.55H), 5.00 (d, J=2.2, 1H), 5.03 (d, J=2.2, 1H); IR (NaCl, cm −1 ): 1736s (ester C═O), 1777 s (lactone C═O); MS Found: 383.2 (M+1), Calc. 382.22.
Iodolactones 25 and 26. Part A: Hydrolysis. The diastereomeric mixture of esters 23 and 24 (569 mg, 1.49 mmol) was stirred with a solution of LiOH (200 mg) in a mixture of MeOH (6 mL) and water (2 mL) at RT for 12 hrs, diluted with water, acidified with 1 M HCl to pH 2–3, and extracted 3 times with CH 2 Cl 2 . The organic extract was washed with brine, dried over Na 2 SO 4 , and rotary evaporated. The residue (ca. 0.55 g) was used directly in the next step. 1 H NMR (CDCl 3 , 400 MHz): δ 0.01 (s, 1.65H), 0.08 (s, 3H), 0.09 (s, 1.65H), 0.11 (s, 3H), 0.87 (s, 4.95H), 0.89 (s, 9H), 1.18 (s, 3H), 1.20 (s, 3H), 1.23 (s, 1.65H), 1.25 (s, 1.65H), 2.53 (dd, J=16.2, J=7.3, 1H), 2.61 (m, obscured by 2.64dd, 1.1H), 2.64 (dd, J=16.2, J=6.6, 1H), 3.06 (m, 1H), 3.23 (m, 0.55H), 3.88 (d, J=4.0, 1H), 3.89 (d, J=8.6, 1H), 3.95 (d, J=8.2, 0.55H), 4.15 (d, J=8.2, 0.55H), 4.16 (d, obscured by 4.19d, 0.55H), 4.19 (d, J=8.6, 1H), 4.90 (d, J=2.9, 0.55H), 4.95 (d, J=2.9, 0.55H), 5.04 (d, J=2.2, 1H), 5.06 (d, J=2.2, 1H), COOH not observed; IR (NaCl, cm −1 ): 1711s (acid C═O), 1774s, br (lactone C═O), 3000–3500br (COO—H); MS Found: 355.1 (M+1), Calc. 354.19.
Part B: Iodolactonization. To a solution of the mixture of carboxylic acids 23a and 23b (0.55 g, see above) in 3 mL of THF, was added 7.5 mL of saturated aqueous NaHCO 3 . The mixture was cooled in an ice bath, treated with a solution of I 2 (1.143 g, 4.5 mmol) in 12 mL of THF, protected from light, and stirred at RT for 12 hrs. Excess I 2 was quenched by addition of aqueous Na 2 SO 3 , the mixture was diluted with water and extracted 3 times with CH 2 Cl 2 . The organic extract was washed with brine, dried over Na 2 SO 4 , and rotary evaporated. The mixture of products crystallized spontaneously. The crude product was taken up in CH 2 Cl 2 and preadsorbed on silica gel. Column chromatography (hexanes/EtOAc 7:1, then 3:1) gave incomplete separation. The mixed fractions were chromatographed again. Combined yield of the desired iodolactone 26 was 421 mg (59% based on the ester mixture). Additionally, 250 mg of the epimeric iodolactone 25 (35% yield) was obtained. 26 (major iodolactone): 1 H NMR (CDCl 3 , 400 MHz): δ 0.08 (app s, 6H), 0.89 (s, 9H), 1.17 (s, 3H), 1.24 (s, 3H), 2.45 (dd, J=19.3, J=2.4, 1H), 2.79 (dd, J=11.5, J=2.4, 1H), 3.33 (d, J=11.1, 1H), 3.36 (dd, partly obscured by 3.33d, J=19.3, J=11.5, 1H), 3.57 (d, J=11.1, 1H), 3.82 (s, 1H), 3.89 (d, J=8.4, 1H), 4.31 (d, J=8.4, 1H); 13 C NMR (CDCl 3 , 100 MHz): −5.3, −4.9, 7.8, 15.8, 16.2, 17.7, 25.6, 37.3, 55.9, 57.1, 61.2, 72.4, 87.9, 95.5, 174.1, 176.3; IR (NaCl, cm −1 ): 1777s (C═O); MS Found: 481.0 (M+1), Calc. 480.08; Mp 213–214° C. 25 (minor iodolactone): 1 H NMR (CDCl 3 , 400 MHz): δ 0.06 (s, 3H), 0.10 (s, 3H), 0.91 (s, 9H), 1.20 (s, 3H), 1.23 (s, 3H), 2.78–2.89 (m, 2H), 3.06 (m, 1H), 3.25 (d, J=11.1, 1H), 3.73 (d, J=11.1, 1H), 3.85 (d, J=9.4, 1H), 4.00 (d, J=7.2, 1H), 4.27 (d, J=9.4, 1H); 13 C NMR (CDCl 3 , 100 MHz): −5.0, −4.5, 14.5, 15.7, 17.2, 17.8, 25.7, 30.9, 50.0, 55.9, 61.3, 73.7, 78.3, 93.4, 175.4, 176.0; IR (NaCl, cm −1 ): 1774s (C═O); MS Found: 481.0 (M+1), Calc. 480.08; Mp 216–217° C.
Keck Product 27. Iodolactone 26 (421 mg, 0.876 mmol), allyltributyltin (1.36 mL, 4.39 mmol), AIBN (14 mg, 0.085 mmol), and benzene (4.4 mL) were added into a flask equipped with a reflux condenser and a magnetic stirring bar, the mixture was degassed using the freeze-pump-thaw technique (3–4 cycles) and immersed into an oil bath kept at 85° C. After 3 hours, another 14 mg of AIBN was added, and the heating was continued for an additional 1.5 hours. The mixture was cooled, the solvent was rotary evaporated, and the residue was diluted with 1 mL of CH 2 Cl 2 (to prevent crystallization) and chromatographed (hexanes/EtOAc 7:1) to afford the crystalline product contaminated with Bu 3 SnBr. The impurities were removed by washing the crystals with hexanes, evaporating the washings, and washing the crystalline residue with hexanes again, and so on until evaporation gave mostly oil. The pure product thus obtained weighed 258 mg (75% yield). 1 H NMR (CDCl 3 , 500 MHz): δ 0.06 (s, 3H), 0.07 (s, 3H), 0.88 (s, 9H), 1.17 (s, 3H), 1.23 (s, 3H), 1.56 (m, 1H), 1.98 (m, 1H), 2.05 (m, 1H), 2.17 (m, 1H), 2.54 (dd, J=8.8, J=1.5, 1H), 2.71 (d, J=10.9, 1H), 3.00 (dd, J=18.8, J=10.9, 1H), 3.78 (s, 1H), 3.87 (d, J=8.6, 1H), 4.21 (d, J=8.6, 1H), 5.05 (d, J=10.2, 1H), 5.10 (dd, J=17.2, J=1.2, 1H), 5.77 (d, J=10.3, 1H), 5.80 (m, 1H); 13 C NMR (CDCl 3 , 100 MHz): −5.2, −4.8, 16.2, 16.4, 17.8, 25.6, 27.7, 33.9, 36.5, 54.0, 58.0, 60.3, 72.5, 89.0, 98.3, 116.1, 136.5, 174.6, 176.6; IR (NaCl, cm −1 ): 1779s (C═O); MS Found: 395.2 (M+1), Calc. 394.22; Mp 154–155° C.
Cyclization Precursor 29. To a solution of 27 (258 mg, 0.654 mmol) in 12 mL of THF stirring at −78° C. was added LHMDS (1 M in THF, 0.75 mL). After 0.5 hour, TMSCl (100 μL, 0.788 mmol) was added. The mixture was stirred for 0.5 hour at −78° C., then for 0.5 hour at RT, cooled to −78° C. and treated with PhSeCl (142 mg, 0.741 mmol) in 9 mL of THF. The mixture was allowed to warm to RT over 1.5 hours, diluted with water, and extracted with Et 2 O 3 times. The ethereal extract was dried over MgSO 4 , rotary evaporated, the residue was diluted with CH 2 Cl 2 , and evaporated again. The crude selenide was dissolved in 7 mL of dry MeCN and treated with a solution of PhSeBr until brownish color persisted (ca. 6 mL of solution prepared from 119 mg of (PhSe) 2 , 0.38 mL of 2M Br 2 in CHCl 3 , and 6.6 mL of MeCN) at RT. After 0.5 hour, the mixture was evaporated at 25° C. by stirring under vacuum, the residue redissolved in 20 ml of CH 2 Cl 2 , and ozonated at −78° C. until blue color persisted. The cold mixture was treated with 3 mL of 1-hexene and then added in several portions to a boiling solution of 2 mL of NEt 3 in 80 mL of benzene. After the addition was complete, the mixture was refluxed for 0.5 hour, evaporated to dryness, and the residue was chromatographed (hexanes/EtOAc 4:1) to afford 237 mg (77% yield) of the white crystalline product. 1 H NMR (CDCl 3 , 400 MHz): δ 0.17(s, 3H), 0.19 (s, 3H), 0.90 (s, 9H), 0.91 (s, 3H), 1.20 (s, 3H), 2.18–2.26 (m, 1H), 2.32–2.49 (m, 3H), 3.93 (d, J=10.2, 1H), 4.36 (s, 1H), 4.68 (d, J=10.2, 1H), 5.42 (d, J=2.0, 1H), 5.57 (dd, J=1.0, J=0.8, 1H), 5.93 (s, 1H); 13 C NMR (CDCl 3 , 100 MHz): −5.2, −5.0, 16.2, 18.4, 25.8, 32.4, 35.5, 49.7, 59.7, 71.7, 73.9, 94.7, 114.3, 117.4, 132.1, 171.4, 171.9, 175.6; IR (NaCl, cm −1 ): 1765s (C═O); MS Found: 471.0 (M+1), Calc. 470.11; Mp 145–146.5° C.
Exo Olefin 30. A solution of 29 (237 mg, 0.492 mmol), Bu 3 SnH (270 μL, 0.985 mmol), and AIBN (8 mg, 0.049 mmol) in 50 mL of benzene was degassed using the freeze-pump-thaw technique (3 cycles) and heated under reflux in an oil bath at 85° C. After 2.5 hrs, 8 mg of AIBN was added and the heating was continued for 1.5 hrs. The mixture was evaporated, and the residue was chromatographed (hexanes/EtOAc 7:1) to afford 185 mg of the white crystalline product still containing tributyltin impurities. The latter were removed by washing the crystals with hexanes (3×3 mL), evaporating the washings, and washing the crystalline residue with hexanes again, and so on until evaporation gave mostly oil. The product thus obtained was pure by 1 H NMR and weighed 177 mg (90% yield). 1 H NMR (CDCl 3 , 400 MHz): δ 0.01(s, 3H), 0.06 (s, 3H), 0.86 (s, 9H), 1.22 (s, 3H), 1.24 (s, 3H), 1.76 (m, 1H), 2.14 (m, 1H), 2.61 (m, 2H), 2.79 (d, J=19.2, 1H), 3.03 (d, J=19.2, 1H), 3.89 (d, J=8.4, 1H), 4.01 (s, 1H), 4.43 (d, J=8.4, 1H), 4.95 (app s, 1H), 5.25 (dd, J=1.9, J=1.7, 1H); 13 C NMR (CDCl 3 , 100 MHz): −4.4, −3.4, 16.7, 17.7, 17.9, 25.8, 33.8, 37.6, 43.6, 56.8, 62.5, 66.3, 72.4, 89.2, 106.2, 112.2, 152.9, 174.5, 177.0; IR (NaCl, cm −1 ): 1778 s (C═O); MS Found: 393.1 (M+1), Calc. 392.20; Mp 175–175.5° C.
Alcohol 31. A mixture of 30 (177 mg, 0.451 mmol), TsOH.H 2 O (343 mg, 1.80 mmol), and benzene (17 mL) was heated under reflux for 3 hours in an oil bath at 90° C., then cooled, diluted with Et 2 O, and washed with aqueous NaHCO 3 . The aqueous wash was extracted with CH 2 Cl 2 3 times, the combined organic phase was dried over Na 2 SO 4 , rotary evaporated, and chromatographed (CH 2 Cl 2 /EtOAc 5:1) to afford 123 mg (98%) of the product. 1 H NMR (CDCl 3 , 300 MHz): δ 1.19 (s, 3H), 1.23 (s, 3H), 1.82 (d, J=1.5, 3H), 1.82 (m, 2H), 2.66 (d, J=19.1, 1H), 2.85 (d, J=19.1, 1H), 3.75 (d, J=6.0, 1H), 3.95 (d, J=8.7, 1H), 4.16 (d, J=6.0, 1H), 4.22 (d, J=8.7, 1H), 5.37 (m, J= 32 1.5, 1H), 13 C NMR (CDCl 3 , 75 MHz): 15.0, 15.7, 16.7, 39.9, 41.0, 55.5, 62.5, 69.8, 73.8, 86.3, 104.6, 124.6, 141.5, 175.4, 179.0; 1 H NMR (CD 3 OD, 400 MHz): 1.15 (s, 3H), 1.19 (d, J=0.8, 3H), 1.79 (ddd, J=2.4, J=2.1, J=1.5, 3H), 2.35 (ddq, J=18.4, J=2.4, J=2.4, 1H), 2.55 (ddq, J=18.4, J=2.1, J=2.1, 1H), 2.77 (d, J=19.3, 1H), 2.87 (d, J=19.3, 1H), 3.97 (d, J=8.6, 1H), 4.08 (s, 1H), 4.16 (d, J=8.6, J=0.8, 1H), 5.33 (ddq, J=2.4, J=2.1, J=1.5, 1H); 67 13 C NMR (CD 3 OD, 100 MHz): 15.1, 16.1, 16.9, 40.6, 41.9, 57.0, 64.0, 71.5, 74.4, 87.1, 106.5, 125.1, 143.8, 177.9, 180.2; IR (NaCl, cm −1 ): 1770 s (C═O), 3462 br (O—H); MS Found: 279.1 (M+1), Calc. 278.12; Mp 189–190° C. (softens at 175° C).
Our 1 H and 13 C NMR data for spectra recorded in CD 3 OD match those reported by Fukuyama et al. 5b for CDCl 3 (probably due to a typographical error).
Epoxides 2 and 2a. The procedure of Fukuyama et al. 5b was essentially followed. A solution of alcohol 30 (123 mg, 0.442 mmol) and mCPBA (180 mg, 1.04 mmol) in 12 ml of CH 2 Cl 2 was left for 2 days at RT. The mixture was treated with saturated aqueous Na 2 SO 3 and aqueous NaHCO 3 , and extracted 3 times with CH 2 Cl 2 . The extract was washed with brine, dried over Na 2 SO 4 , and rotary evaporated. The crude product (133 mg, quant.) consisted of a 3.5:1 mixture of epoxides 2 and 2a. The mixture was used directly in the next step, since column chromatography (CHCl 3 /MeOH 5b or CH 2 Cl 2 /AcOEt) did not result in efficient separation of the epimers. The pure major epoxide 2 could be obtained by two recrystallizations from EtOAc/hexanes. Major epoxide 2: 1 H NMR (CD 3 OD, 400 MHz): δ 1.11 (s, 3H), 1.16 (s, 3H), 1.54 (s, 3H), 2.07 (d, J=16.2, 1H), 2.25 (dd, J=16.2, J=1.6, 1H), 2.58 (d, J=19.1, 1H), 3.00 (d, J=19.1, 1H), 3.66 (d, J=1.6, 1H), 3.93 (d, J=8.5, 1H), 4.12 (s, 1H), 4.47 (d, J=8.5, 1H); 13 C NMR (CD 3 OD, 100 MHz): 16.1, 16.6, 17.9, 37.3, 38.6, 57.3, 64.8, 67.4, 69.4, 71.7, 75.8, 83.9, 108.3, 177.4, 180.2; IR (NaCl, cm −1 ): 1772 s (C═O), 3410 br (O—H); MS Found: 295.0 (M+1), Calc. 294.11; Mp 249.5–250° C.
(±)-Merrilactone A (1). The procedure of Fukuyama et al. 5b was essentially followed. The mixture of epoxides 2 and 2a (133 mg) was stirred with TsOH.H 2 O (80 mg, 0.42 mmol) in 25 mL of CH 2 Cl 2 for 1 day at RT. The TsOH.H 2 O was filtered off and washed 3 times with CH 2 Cl 2 . The crude product was adsorbed on silica gel (ca. 0.5 g) and chromatographed (CH 2 Cl 2 /AcOEt 4:1, then 2:1, then 1:1) to give 14 mg (11% from alcohol 30) of somewhat impure minor epoxide 2a followed by (±)-merrilactone A (92 mg, 71% from alcohol 30). Minor epoxide 2a: 1 H NMR (CD 3 OD, 300 MHz): δ 1.10 (s, 3H), 1.13 (d, J=0.7, 3H), 1.49 (s, 3H), 1.93 (dd, J=16.2, J=2.2, 1H), 2.39 (d, J=16.2, 1H), 2.82 (d, j=19.0, 1H), 3.28 (d, J=19.0, 1H), 3.40 (d, J=2.2, 1H), 3.74 (d, J=9.0, 1H), 4.14 (s, 1H), 5.20 (d, J=9.0, 1H); 13 C NMR (CD 3 OD, 75 MHz): 16.0, 17.0, 17.8, 37.4, 41.7, 64.2, 65.5, 68.0, 73.4, 88.0, 107.4, 176.6, 180.2; IR (NaCl, cm −1 ): 1772 s (C═O), 3450 br (O—H); MS Found: 295.0 (M+1), Calc. 294.11; Merrilactone A: 1 H NMR (CD 3 OD, 400 MHz): δ 1.08 (s, 3H), 1.23 (s, 3H), 1.48 (s, 3H), 2.28 (dd, J=15.4, J=1.5, 1H), 2.68 (d, J=19.4, 1H), 2.70 (d, J=5.2, 1H), 2.73 (d, J=5.2, 1H), 2.90 (d, J=19.4, 1H), 3.94 (dd, J=5.2, J=1.5, 1H), 4.01 (d, J=10.1, 1H), 4.59 (d, J=10.1, 1H), 4.73 (s, 1H); 13 C NMR (CD 3 OD, 75 MHz): 16.0, 17.4, 17.4, 32.2, 43.9, 58.5, 61.2, 66.0, 75.5, 79.9, 90.3, 96.2, 107.3, 177.7, 179.3; IR (NaCl, cm −1 ): 1761 s (C═O), 3450 br (O—H); MS Found: 295.0 (M+1), Calc. 294.11; Mp 233.5–234.5° C. (from EtOAc/CHCl 3 ).
Example 2
The schemes above have been adapted to synthesizing nitrogen containing Merrilactone analogues having the general structure:
wherein Z is >N—X, where X is straight or branched substituted or unsubstituted alkyl, alkenyl or alkynyl, or cycloalkyl, aryl, heterocycloalkyl, heteroaryl, aralkyl, amino, alkyl amino, or dialkyl amino.
The basic modification which resulted in such analogues was simply the replacing of the starting material
with a nitrogen containing starting material such as
and alkylating, e.g. methylating, the resulting Diels-Alder adduct.
REFERENCES
(1) Hefti, F. Annu. Rev. Pharmacol. Toxicol. 1997, 37, 239.
(2) (a) Siegel, G. J.; Chauhan, N. B. Brain Res. Rev. 2000, 33, 199; (b) Gash, D. M.; Zhang, Z.; Ovadia, A.; Cass, W. A.; Yi, A.; Simmerman, L.; Russel, D.; Martin, D.; Lapchak, P. A.; Collins, F.; Hoffer, B. J.; Gerhardt, G. A. Nature, 1996, 380, 252.
(3) Backman, C.; Rose, G. M.; Hoffer, B. J.; Henry, M. A.; Bartus, R. T.; Friden, P.; Granholm, A. C. J. Neurosci. 1996, 16, 5437.
(4) For a discussion of small molecule mimetics and for references to neurotrophic natural products, see: Ref.1, pp. 255–257.
(5) (a) Huang, J.-m.; Yokoyama, R.; Yang, C.-s.; Fukuyama, Y. Tetrahedron Lett. 2000, 41, 6111 (b) Huang, J.-m.; Yang, C.-s.; Tanaka, M.; Fukuyama, Y. Tetrahedron 2001, 57, 4691.
(6) (a) Marinovic, N. N.; Ramanathan, H. Tetrahedron Lett. 1983, 24, 1871; (b) Jasperse, C. P.; Curran, D. P.; Fevig, T. L. Chem. Rev. 1991, 91, 1237.
(7) DMMA itself is capable of reacting only with the most reactive dienes: (a) Dauben, W. G.; Kessel, C. R.; Takemura, K. H. J. Am. Chem. Soc. 1980, 102, 6893 and references cited therein; (b) Rae, I. D.; Serelis, A. K.; Aust. J. Chem. 1990, 43, 1941; (c) von Ziegler, K.; Flaig, W.; and Velling, G. Liebigs Ann. 1950, 567, 204.
(8) Defoin, A.; Pires, J.; Streith, J. Helv. Chim. Acta 1991, 74, 1665.
(9) (a) Soai, K.; Yokoyama, S.; Mochida, K. Synthesis 1987, 647; (b) Alexandre, F.-R.; Legoupy, S.; Huet, F. Tetrahedron 2000, 56, 3921.
(10) Pangborn, A. B.; Giardello, M. A.; Grubbs, R. H.; Rosen, R. K.; Timmers, F. J. Organometallics 1996, 15, 1518.
(11) Jaeschke, G.; Seebach, D. J. Org. Chem. 1998, 63, 1190.
(12) Corey, E. J.; Danheiser, R. L.; Chandrasekaran, S.; Siret, P.; Keck, G. E.; Gras, J. L. J. Am. Chem. Soc. 1978, 100, 8031.
(13) Ward, D. E.; Rhee, C. K. Can. J. Chem. 1989, 67, 1210.
(14) (a) Johnson, W. S.; Wertheman, L.; Bartlett, W. R.; Lee, T.-T.; Faulkner, D. J.; Petersen, M. R. J. Am. Chem. Soc. 1970, 92, 741; (b) Ziegler, F. E. Acc. Chem. Res. 1977, 10, 227.
(15) Keck, G. E.; Yates, J. B. J. Am. Chem. Soc. 1982, 104, 5829.
(16) (a) Rauscher, S. Tetrahedron Lett. 1977, 44, 3909.
(17) Henbest, H. B.; Wilson, R. A. L. Chem. Ind. (London) 1956, 659.
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This invention provides a total synthesis of Merrillactone and Merrilactone analogues for use as neurotrophic agents in the treatment of neurodegenerative diseases. The invention also provides intermediates for use in the synthesis of Merrilactone and its analogues.
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PRIORITY INFORMATION
This application claims priority from German application 10 2004 038 754.0 filed Aug. 9, 2004.
BACKGROUND OF THE INVENTION
The invention relates in general to decoders and in particular to a decoder for executing a Viterbi algorithm.
A Viterbi algorithm makes it possible to correct transmission errors in communications systems. The application of a Viterbi algorithm is also known from many other search problems, for example in the field of pattern recognition. The Viterbi algorithm has a disadvantage that the computation is very complex, thereby requiring a relatively large amount of memory resources. As a consequence, a system clock frequency of a decoder for executing a Viterbi algorithm is typically correspondingly high. The system clock frequency at which the individual operations of the Viterbi algorithm are to be executed is generally several times higher than the data rate when the algorithm is employed in communications systems. This requirement is of note particularly in systems having very high data rates, such as digital video broadcasting (“DVB”) systems, because the requisite clock frequencies necessitate the use of relatively expensive technology.
The principle of a Viterbi decoder is known, for example, from G. David Forney, Jr., “ The Viterbi Algorithm ,” Proc. IEEE, Vol. 61, No. 3, March 1973, pp. 268-278. Modules used in such a decoder for calculating distances or total distances and for calculating accumulations and comparisons, as well as a generic structure of a logical module for a Viterbi decoder, are employed in decoders according to European Published Patent Application EP 0 769 853 A1. Possibilities for parallelization are known from H. Burckhardt and L. C. Barbosa, “ Contributions to the Application of the Viterbi Algorithm ,” IEEE Trans. on IT, Vol. 31, No. 5, September 1985, pp. 626-634.
Prior art Viterbi decoders and Viterbi algorithms typically require a relatively high system clock frequency.
One embodiment of a prior art Viterbi decoder 10 having a degree of parallelization p is illustrated in FIG. 8 . Via a receiver bus 12 , K×N bits of received data r(n, k) are provided to a total-distance module 14 . In the module 14 , total distances are calculated and correspondingly 2 K ×(N+1d(K)) bits are provided on a bus 16 to a computing device 18 having accumulate-and-compare modules 20 . The total distances are stored in a temporary memory 22 . Via a bidirectional distance bus 24 , 2×(N+1d(K)+1)×2 p+1 bits are correspondingly transmitted from the computing device 18 to a distance memory 26 that stores (N+1d(K)+1)×2 L−1 bits. Here L is the length of generator polynomials, of which a set containing a number K is to be considered in the calculation. The received data r(n, k) on the bus 12 are resolved to N bits. The degree of parallelization is p. From the distance memory 26 , a corresponding number of 2×(N+1d(K)+1)×2 p+1 bits are transmitted on the distance bus 24 back to the computing device 18 .
The computing device 18 is also connected to a path memory 28 via a bidirectional path bus 30 where 2×T×2 p+1 bits are transmitted from the path memory 28 or a second temporary memory 32 of the computing device 18 to and from the path memory 28 via the path bus 30 . In the path memory 28 , T×2 L− 1 bits are stored. After corresponding calculations, in particular accumulations and comparisons, have been executed in the accumulate-and-compare modules 20 , a search is executed in the computing device 18 and a data bit string c(n, k) determined to be the most desirable is furnished on a line 34 at the output of the Viterbi decoder 10 .
In such a Viterbi decoder 10 , a lower system clock frequency can be attained with a plurality of parallel modules, depending on the degree of parallelization (0<p<L−2). In the case where the system clock frequency is equal to the data rate (p=L−2), all 2 L−1 accumulate-and-compare modules 20 are implemented in parallel. The bus then becomes the limiting factor. For available embodiments, it may be that no acceptable compromise can be found between the system clock frequency and the requisite bus widths of the path bus 30 and the distance bus 24 .
FIG. 9 illustrates the ratio between the system clock frequency and bus width as functions of the degree of parallelization p for the case of such a Viterbi decoder for DVB systems. Typical parameters are L=7, K=2 and T=64 for data rates up to 50 Mbit/s. If there is no parallelization (p=0) and the bus width is relatively small, a system clock frequency of 1600 MHz is used. If the system clock frequency is to be equal to the data rate (i.e., the degree of parallelization is p=5) a bandwidth of 9000 bits is needed for the bus width. In practice this is not acceptable in light of the realization and the costs arising therefrom. Given an acceptable system clock frequency of up to 100 MHz (p=4), the requisite bus width of 4500 bits is still relatively high for a commercially favorable approach.
What is needed is a Viterbi decoder for executing a Viterbi algorithm that allows the system clock frequency to equal the data rate at relatively high bit rates.
SUMMARY OF THE INVENTION
A Viterbi decoder includes a computing device that receives sets of data values and calculates distances from the received data values and accumulates and compares the distances according to a Viterbi algorithm and decides data values. Also included is a path memory for storing decided-upon data values. A bus connects the computing device and the path memory. The computing device generates control signals dependent on the decisions that are associated with paths. The bus conveys the control signals to the path memory. The computing device and/or the path memory shifts data strings with the control signals associated with the paths in the path memory according to conditions of the Viterbi algorithm. The path memory provides at least one output value.
The computing device evaluates the requisite distances, for example all distances required for each set of received values (e.g., in one module), and accumulates and compares the associated distances according to the Viterbi algorithm, where, for example the relatively smallest distances may be selected and stored in a distance memory.
The computing device and/or the path memory may delay the data strings in a second part of the path memory using simple shift registers to compensate for the time required for a search among the selected accumulated distances.
The computing device and/or the path memory may provide from the path memory, for example, from a shift register in the path memory, the output value that corresponds to the path found by the search having the relatively smallest distance.
The computing device may subtract a found distance from all accumulated distances in the next decoder cycle.
The path memory may be structured in a row-wise manner to accept row-wise paths from the data strings that have led, upon decision, to a state and that are to be newly shifted in each decoder cycle, for example, to accept paths m(p, t), p=0, 1, . . . , P−1, where P is the number of paths, t=0, 1, . . . , T−1+D, where T is the decoder depth and D is the delay.
The path memory may have two parts and executes the shift according to the Viterbi algorithm in the first part, with a specified length T, and a simple shift using shift registers with a further length D in the second part.
The computing device and/or the path memory may write, in each decoder cycle, the initial value in each path ({m(p, 0), p=0, 1, . . . , P−1}) according to a fixed pattern that depends on a path number.
The computing device and/or the path memory may control the data shift with respect to paths m(p, t) in the first part of the path memory using control signals at the input of the path memory, for example, according to
m ( p, t )= m (2 p+s ( p ), t− 1), with p =0, 1 , . . . , P/ 2−1 and
m ( P/ 2 +p, t )= m (2 p+s ( P/ 2 +p ), t− 1), with t= 1, 2 , . . . , T− 1,
where s(p)ε(0, 1, . . . , S−1), for p=0, 1, . . . , P−1, and S is the number of possible data values.
The computing device and/or the path memory may execute a simple shift in a second part of the path memory, for example, according to
m ( p, t )= m ( p, t− 1), with p= 0, 1 , . . . , P− 1 , t=T, . . . , T+D− 1,
and/or to determine as the output value the selected path (q) having the relatively smallest distance, for example, according to output=m(q, T+D−1).
The decoder may have three modules for evaluating, accumulating and comparing the distances, generating control signals, and executing the search. The decoder may also include a temporary memory for time compensation, a distance memory, and the path memory. A bidirectional bus may be arranged between the distance memory and the computing device for reading the accumulated distance from the next-to-last decoder cycle and storing newly computed accumulated distances. A unidirectional bus may be arranged between the computing device and the path memory for transmitting control signals for the shift in the memory and transmitting an address of the path having the relatively smallest accumulated distance.
The decoder may have a system clock frequency equal to the decoder cycle frequency or the data rate. As such, the number of accumulate-and-compare modules of the computing device are equal to the number of states, for example, paths. The bus width of the bus to the distance memory may be sized for reading and storing the distances for all paths at the same time, with the bus to the path memory carrying all the control signals at the same time.
The decoder may have a system frequency as a multiple X of a data rate or a decoder cycle frequency. As such, the number of accumulate-and-compare modules in the computing device are P/X, with P being the number of paths or states, the bus to the distance memory reading and storing P/X distances, and the bus to the path memory carrying P/X control signals, for example, at the same time.
The decoder may process data as binary data for encoding (S=2) and may process data values, for example, bit strings, encoded with a convolutional encoder of a length (L bits) and an encoding rate (1/K). The reception range is resolved to N bits on a range of whole numbers from 0 to 2N−2, the number of possible states or paths is 2L−1, and the ratio between the system frequency and the data rate is a power of two (X=2x, x=0, 1, . . . , L−2). Further, the bus width to the distance memory may be of a size for reading and storing a total of 2(N+1d(K)+2)2x+1 bits at the same time, and the bus width to the path memory may be 2x+1 bits for control signals and L−1 bits for the address of the path having the relatively smallest accumulated distance.
The decoder of the invention makes it possible to fabricate commercially favorable IC (integrated circuit) solutions. The proposed decoder architecture includes the computing devices adapted for the Viterbi algorithm and a relatively efficient approach to a memory structure that can replace its contents in accordance with the Viterbi algorithm within, for example, a single system clock cycle.
These and other objects, features and advantages of the present invention will become more apparent in light of the following detailed description of preferred embodiments thereof, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustration of a memory portion of a Viterbi decoder;
FIG. 2 is a block diagram of an accumulate-and-compare module within a Viterbi decoder;
FIG. 3 is a block diagram of various components of a Viterbi decoder having the memory portion of FIG. 1 ;
FIG. 4 is a graph illustrating the relationship of the system clock frequency and bus width as functions of the degree of parallelization for the Viterbi decoder of FIGS. 1-3 ;
FIG. 5 is a block diagram of a prior art distance-calculating module;
FIG. 6 is a block diagram of a prior art module for accumulating and comparing distances;
FIG. 7 is a block diagram of a prior art Viterbi decoder;
FIG. 8 is a block diagram of various components of a prior art Viterbi decoder;
FIG. 9 is a graph illustrating the relationship of the system clock frequency and bus width as functions of the degree of parallelization of the prior art Viterbi decoder of FIG. 8 ;
FIG. 10 is a diagram illustrating the principle of convolutional encoding; and
FIG. 11 is a state diagram of a convolutional encoder for the convolutional encoding principle illustrated in FIG. 10 .
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , a two-part structure of a memory device 40 as a part of a Viterbi decoder may be used in conjunction with a Viterbi algorithm at relatively high data rates. A relatively simple construction of the memory 40 is possible using simple technology due to the structure of a path memory as the memory 40 is adapted according to the Viterbi algorithm. Here the dependence between the system clock frequency and the bus width is separated for every degree of parallelization.
A Viterbi algorithm is executed in a Viterbi decoder in a known manner. In a communications system, for example, the Viterbi decoder is situated in a receiver-side device and is part of relatively extensive signal processing comprising, for example, demodulation, equalization, etc.
A Viterbi decoder 42 having the memory 40 of FIG. 1 is illustrated in FIG. 3 . In comparison to the prior art Viterbi decoder 10 of FIG. 8 , the Viterbi decoder 42 of FIG. 3 differs in particular in how a computing device 44 , which comprises accumulate-and-compare modules 46 , 48 for accumulating and comparing distances, is connected to the memory device 40 described of FIG. 1 . The connection comprises a unidirectional control bus 50 for transmitting, for example, 1×2 p+1 bits from the computing device 44 to the memory device 40 .
The memory device 40 includes a path memory 52 having a memory capacity of T×2 L−1 bits, and a demultiplexer 54 . The computing device 44 includes an output on a line 56 from which the address of the state having the determined relatively smallest or “minimal” distance q is provided to the demultiplexer 54 . The address comprises L−1 bits. From the demultiplexer 54 or the memory device 40 , the corresponding data bit string c(n, k) is conveyed on a line 118 at an output of the Viterbi decoder 42 .
A received value r(n, k) is associated with each encoded bit c(n, k) of the output data on the line 118 . From the received values r(n, k), the Viterbi algorithm reconstructs, with as few errors as possible, a data bit string {b(n)} sent by a transmitting device. The following prerequisites govern the usage of the Viterbi algorithm.
The received value range extends between two nominal values that correspond to the two possible values {W 0 and W 1 } of an encoded bit (0 or 1). In the extreme case referred to as “hard decision,” the received value range includes only the two nominal values. The efficiency of the decoder improves if the received value range is more highly resolved, a situation referred to as “soft decision.”
As a second prerequisite, a distance metric is defined in terms of the distance between received values and nominal values according to equation 1:
d 0 ( r )=distance{ r, W 0 } and d 1 ( r )=distance{ r, W 1 }, (1)
where d 0 and d 1 describe deviation values or distances and the assumption is made that a smaller distance from a nominal value W indicates a higher probability for this value. The maximal distance d 0 (W 1 )=d 1 (W 0 )=d max defines a symmetrical received value range. The metric may be further defined such that the sum of two distances always remains constant for each received value r(n, k), so that d 0 (r)+d 1 (r)=d max .
A third prerequisite is assumed with respect to a received value range. The received value range and the metric applied are to guarantee the existence of a neutral value W n such that d 0 (W n )=d 1 (W n )=d max /2. This neutral value is needed to replace missing received values r(n, k) that correspond to encoded bits c(n, k) omitted as a result of puncturing.
A fourth prerequisite commonly relates to a structure for the application of the Viterbi algorithm. For each of the 2 L−1 possible states, this structure includes a distance accumulator {A q (n), q=0, . . . , 2 L−1 } and a path memory 52 with {M q (n)={m q (n, 0), . . . , m q (n, T−1)}, q=0, . . . , 2 L−1 −1} of length T bits in which are stored all decided-upon bits b up to time n that have led to the state. Parameter T defines a decoding depth, which directly determines the efficiency of the Viterbi decoder 42 .
The Viterbi algorithm includes a plurality of steps for each new input of K received values {r(n, 0), . . . , r(n, K−1)}.
In a first step, a total distance is calculated. Because a set of K bits corresponds to one bit from the data bit string, a total distance for the entire set of bits is used according to equation 2:
d c ( 0 ) , c ( 0 ) , … , c ( K - 1 ) { r ( n , 0 ) r ( n , 1 ) , … , r ( n , K - 1 ) } = ∑ k = 0 K - 1 d c ( K ) ( r ( n , k ) ) . ( 2 )
With K bits {c( 0 ), c( 1 ), . . . , c(K−1)}, the number of distinct total distances that are calculated for a set of K received values is 2 K .
In a second step, two competing values for each state are calculated and compared for the distance accumulator. This is also referred to as an accumulate and compare operation as given by equation 3:
A new / 0 = A old / b = 0 + d c / b = 0 A new / 1 = A old / b = 1 + d c / b = 1 , s = 0 A new / 0 < A new / 1 1 A new / 0 ≥ A new / 1 , ( 3 )
where, according to a conventional state diagram, which is illustrated in FIG. 11 , the values A old/b from the distance accumulators arise from two possible prior states and the values d c/b as total distances correspond to the K encoded bits.
In a third step, the following values are associated and shifted according to the comparison result s, specifically the distance accumulator A new =A new/s , the path memory M new : m new (n, 0)=b; m new (n, t)=m old/s (n, t−1), t=1, . . . , T, and the candidate bit for output b new =m old/s (n, T−1)(4), the candidate bit b following a fixed specified pattern according to the state diagram, in which the first half of the states are assigned a 0 and the remainder of the states are assigned a 1.
In a fourth step, the state having the minimal distance accumulator q determines the newly decided-upon bit b at the output according to equation 4:
A min = A q ( n ) = min x = 0 , … , 2 L - 1 - 1 { Ax ( n ) } ⇒ b ( n ) = b new / q . ( 4 )
This bit is typically from the sent data bit string b(n−T). The delay of T is due to the decoding process.
In a fifth step, the values in the distance accumulators thus remain limited, the minimum A q (n) of all the newly obtained values in the distance accumulators being subtracted for this purpose according to A new (n)=A new (n)−A q (n).
In a sixth step, these values are employed as old values in the next pass or employed as values that are to be used in the next cycle, so that according to equation 5:
A old ( n+ 1)= A new ( n ) and M old ( n+ 1)= M new ( n ). (5)
By way of illustration, a frequently applied method is represented for an exemplary convolutional code. If the received values are resolved to N bits, the reception range will include values {0, 1, . . . , 2 N −2}, with W 0 =0, W 1 =2 N −2 and W n =2 N−1 −1. For this purpose, a simple metric is adapted as per equation 6:
d 0 ( r )= r and d 1 ( r )=2 N −2− r for rε{ 0, . . . , 2 N −2}
d max =2 N −2 and 0 ≦d 0 ( r ), d 1 ( r )≦2 N −2. (6)
The value range of the total distances, that is, a total of 2 K values according to equation (2), is then limited to 1d(K)+N and the value range of the distance accumulators is one bit larger.
The Viterbi decoder 42 of FIG. 3 and the prior art Viterbi decoder 10 of FIG. 8 each include some components that are the same, for example, the receiver bus 12 , the distance-calculating module 14 , the distance bus 24 , and the distance memory 26 . The distances or total distances may be determined, for example, in accordance with at least equation (2). The total distance module 14 is used to calculate the distances. According to FIG. 5 , a known distance-calculating module 14 comprises two inputs for the input of received data values r(n, 0) and r(n, 1) on lines 58 , 60 , which have been subjected to appropriate preliminary processing. Each of these data values r(n, 0), r(n, 1) is fed to a corresponding first and third adder 62 , 64 , respectively. The other one of these two data values r(n, 1) or r(n, 0) is fed to the first and third adders 62 , 64 , respectively. Also, data values d 00 and d 10 are output on lines 66 , 68 from the adders 62 , 64 , respectively. Further, received data values r(n, 0), r(n, 1) are each fed to an associated subtraction element 70 , 72 that subtracts 2 N −2. The subtraction results on lines 74 , 76 are each fed to a second and a fourth adder 78 , 80 , respectively. The subtraction results on the lines 74 , 76 are also cross-fed to these adders 78 , 80 . The results from these adders 78 , 80 are output on lines 82 , 84 as further data values d 11 and d 01 respectively.
Steps 2 and 3 of the Viterbi algorithm represent the actual base operation for the Viterbi decoder 42 and are the accumulate and compare operations. These steps are executed in one or, according to the invention, a plurality of parallel accumulate-and-compare modules 46 , 48 ( FIG. 3 ) for accumulating and comparing the distances.
FIG. 7 illustrates a generic structure of a known Viterbi decoder 86 for implementing equation (5). The decoder 86 exhibits symmetry that makes the various kinds of parallelization possible. For every number of states, it is possible to identify a smallest processing step in which two states are to be handled in one step. The unlike sequences of input and output states, however, prohibit overwriting of old values as soon as new ones are calculated.
“In-place” calculation is consequently not possible, so that a temporary memory is used which holds the newly calculated values A new , M new until the correct moment for overwriting. In terms of realization, the size of this temporary memory for all states lies between values of ¼ and 1.
Given a degree of parallelization p, the structure of the Viterbi decoder 86 requires 2×2 p accumulate-and-compare modules in a parallel implementation, and the entire six-step procedure is executed 2 L−3−p times for each output bit. The ratio of system clock frequency and data rate can be thus determined. If L=7, for example, there are two extrema. With 64 accumulate-and-compare modules, p=5, and the system clock frequency is equal to the data rate. With just two accumulate-and-compare modules, p=0, and the system clock frequency is a factor of 32 higher than the data rate.
The known generic structure of the Viterbi decoder according to the foregoing preferred exemplary embodiment can be generalized without substantial structural differences. If the original data string, instead of binary elements or bits, contains symbols from a polyvalent alphabet having N s symbols, a polyvalent arithmetic being applied in the convolutional encoder and in the calculation of distances, there are N s L−1 possible states and a plurality N s of paths leading to each state upon a transition in the state diagram. This requires a comparison of N s distances in the accumulate-and-compare module. Bits are also replaced with symbols in the Viterbi decoder 42 of the present invention. The structure of the decoder of FIGS. 5-7 and procedural steps 1 - 6 of the Viterbi decoder remain largely unchanged.
FIG. 1 illustrates a memory device 40 having a two-part construction. The first part is a controlled memory portion 88 under the control of additional control signals s. The second part comprises a shift register 90 .
The structure of the memory device 40 introduces the additional control signals {s(k), k=0, . . . , 2 L−1 } in the path memory 52 , organized in matrix fashion, for the individual data elements {m(k, t), k=0, . . . , 2 L−1 , t=0, . . . , T−1}, which, according to the state diagram and according to the comparison result, make possible all requisite shifts between the individual paths directly in the memory. In this way, the corresponding path bus of the prior art is replaced by the substantially narrower control bus 50 as a control bus for transmitting 2 L−1 bits.
In the first part 88 of the memory 40 , a shift of each bit between the individual paths by a demultiplexer controlled by the control signals s(k) is possible. Only the first bits are specified in all paths, zeroes being specified in the first half and ones in the second half. Before all other bits there is a demultiplexer according to the transition rules of equation (5). The upper transition is selected if s=0 and the lower transition if s=1.
The second part 90 of the memory device 40 comprises simple shift registers which serve to compensate for the processing delays. The length of the shift register 90 may match the number of delay cycles in the accumulate-and-compare modules and in the minimum search.
This memory structure makes it possible to use a simplified accumulate-and-compare module 46 according to FIG. 2 . Via two inputs, corresponding values A old/b=0 and A old/b=1 are applied on the lines 92 , 94 to this module 46 . The inputs on the lines 92 , 94 are each conveyed to an input of a corresponding adder 96 , 98 . A distance value d c/b=0 on a line 100 is applied to the first adder 96 for addition to the corresponding first input value. A corresponding distance value d c/b=1 on a line 102 is applied to the second adder 98 for addition to the second input value on the line 94 . The output values of the two adders 96 , 98 are fed to a comparator 104 . A control signal s is provided at an output of the comparator 104 , which is fed to an output of the accumulate-and-compare module 46 and is also fed to a module 106 for selection of the smaller of the distances. Also, the added values on the lines 108 , 110 of the two adders 96 , 98 are fed to the module 106 for selection of the smaller distance. The calculation of the new value, that is, the selection of the found minimal distance A new , takes place in the module 106 for selection of the smaller distance. Thus the accumulate-and-compare module 46 has two inputs for distances and two outputs, one for the found minimal distance A new on a line 112 and the other for control signal s on a line 114 . Here s=0 if A old/b=0 <A old/b=1 , and s=1 otherwise.
The structure of the memory device 40 of FIG. 1 also makes possible a simplified realization of the entire Viterbi decoder 42 , as illustrated in FIG. 3 .
The arrangement and manner of functioning of the individual components of the decoder 42 of FIG. 3 is somewhat similar to the prior art decoder 10 of FIG. 8 . The bidirectional path bus 30 of FIG. 8 is replaced with a unidirectional control bus 50 in FIG. 3 from the computing device 44 having the accumulate-and-compare modules 46 , 48 for the transmission of 1×2 p+1 bits to the memory 40 .
As discussed above, the memory 40 comprises the path memory 52 and the demultiplexer 54 . The path memory 52 stores T×2 L−1 bits. Further, the address line 56 leads to the memory 40 from the computing device 44 , in particular from an output of a minimum-search module 116 . The address line 56 serves to transmit an address of the state having the minimal distance q, with a data volume of L−1 bits, to feed the address to the demultiplexer 54 . From the memory 40 , or under control of the demultiplexer 54 , the ultimately determined data bit string c(n, k) is provided on a line 118 to the output of the Viterbi decoder 42 .
The wide path bus 30 according to the prior art decoder 10 of FIG. 8 is in this way replaced by the narrow control bus 50 ( FIG. 3 ). The relatively large temporary memory 22 , 32 for paths in the computing device 10 according to the prior art is replaced by relatively smaller temporary memories 120 , 122 . To this end there are other L−1 bits to be transmitted as the address q of the selected path. The demultiplexer 54 selects, for the reconstructed output bit c(n, k), the last bit in the path that corresponds to the minimal distance. A delay of the system clock frequency in the accumulate-and-compare module 46 , 48 is obligatory so that the old distances in the distance memory can be overwritten with the newly calculated distances at the proper time. The minimum search involves an additional delay of D system clock cycles, so that the shift registers at the end of each path in the path memory 52 are formed as D+1 system clock cycles long in order for the corresponding output bit to be correctly associated with the minimum found. These delays also require a slight expansion, by one bit, of the value range for distance accumulators.
The Viterbi decoder 42 offers a relaxed dependence between the system clock frequency and the bus widths, as illustrated in FIG. 4 for various degrees of parallelization p. For ease of comparison with FIG. 9 , the same parameters have been used in FIG. 4 as in FIG. 9 .
The Viterbi decoder 42 offers a relatively small bus width of 900 bits, which can be realized economically, even when the system clock frequency is equal to the data rate, which corresponds to a degree of parallelization p=5. In the DVB example, the system clock frequency is then 50 MHz. Given a system clock frequency of 100 MHz (i.e., a degree of parallelization p=4) the requisite bus width drops to 450 bits, which is a factor of 10 narrower than the requisite bus width according to standard memory structures.
Applied at the input of the Viterbi decoder 42 are data or data values r(n, k) on the line 12 , which have been transmitted via a usually wireless interface of a communications system. The actual data to be sent, which on the receiver side for example are to be reconstructed using the Viterbi algorithm, are processed by error-protection encoding on the transmitter side. What follows is an explanation of the transmitter-side convolutional encoding of a bit string to be transmitted.
A data bit string { . . . , b(n), b(n+1), . . . } is to be transmitted. For the employment of the Viterbi algorithm on the receiver side, this data bit string is encoded in the following way on the transmitter side:
In a first step, the data of the data bit string are pushed into a shift buffer. At each step, the shift buffer of length L bits {B( 0 ), B( 1 ), . . . , B(L−1)} is shifted to the right {B(m)=B(m−1), m=2, 3, . . . , L−1} and filled with a new input bit {B( 0 )=b(n)}. The length L defines a parameter of the encoding, the “constraint length.”
In a second step, K output bits {c(n, k), k=0, 1, . . . , K−1} are calculated according to the buffer state at the output. The calculation is uniquely determined with a set of K generator polynomials of length L {G(k, m), k=0, 1, . . . , K−1, m=0, 1, . . . , L−1} with binary coefficients 0 or 1, according to equation 7:
c ( n , k ) = ∑ m = 0 L - 1 G ( k , m ) · B ( m ) = ∑ m = 0 L - 1 G ( k , m ) · b ( n - m ) , ( 7 )
the additions in the sum being understood in the sense of modulo 2 addition (EXOR). The ratio between the number of useful bits at the input and the number of bits for transmission at the output is defined as a second parameter, namely the “code rate” R. In this case, R=1/K.
Third, to obtain different code rates R, the encoding described above is followed by the application of “puncturing” as a post-processing operation. In this process, from P successive sets of K bits, certain bits are dropped in accordance with a previously specified binary P-matrix {P(a, b), a=0, 1, . . . , K−1, b=0, 1, . . . , P−1}; these bits are marked with P(a, b)=0. With the number of ones in the matrix P 1 , the code rate can be determined as R=P/P 1 lying between 1/K and 1, at most all the PK matrix coefficients being 1 and at least one 1 appearing in each P-column.
FIG. 10 illustrates a prior art example in which the code word of a convolutional code can be infinitely long. A description of the encoding with a state diagram is helpful for analysis of the Viterbi algorithm. The state of the encoder is uniquely determined with the last L−1 bits of the buffer Z B(1), . . . , B(L−1) . In the binary case there are 2 L−1 distinct states, and from each of them there are two possible transitions into a next state in dependence on the new bit at the input b=b(n). Upon each transition, K encoded bits c={c( 0 ), . . . , c(K−1)} are generated at the output. The generator polynomials are always selected such that all K bits in the two competing bit sets are distinct.
FIG. 11 is a state diagram of the convolutional encoder for the example of FIG. 10 . From the state diagram it follows that only certain transitions are possible, for example from the states {Z 00 , Z 01 } only to the states {Z 00 , Z 10 } and from {Z 10 , Z 10 } to the states {Z 01 , Z 11 }. This analysis can be generalized. Let all states be numbered with {Z k , k=0, . . . , 2 L−1 }. The transition rule is then as follows:
Z K with b=0, the code being=c {Z 2K , Z 2K+1 } k=0, . . . , 2 L−2 Z 2 L−2 +k with b=1, the code being= c ,
where c denotes the inverted code word.
Next, the encoded data {p(m)} are transmitted using a modulation, for example quadrature amplitude modulation (“QAM”) or phase shift keying (“PSK”), over a channel, for example, a channel of a wireless interface of a communications system. As a result of the transmission, the data becomes distorted and noise and other interference signals are superimposed on the data. The original data are reconstructed with the Viterbi algorithm.
Although the present invention has been shown and described with respect to several preferred embodiments thereof, various changes, omissions and additions to the form and detail thereof, may be made therein, without departing from the spirit and scope of the invention.
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A Viterbi decoder includes a computing device, a memory and a bus. The computing device receives sets of data values and calculates distances for the received sets of data values, accumulates and compares the calculated distances according to a Viterbi algorithm, decides data values and generates control signals dependent on a plurality of decisions associated with a plurality of paths. The memory stores the decided data values and provides at least one output value. The bus connects the computing device and the memory and is configured to convey the control signals to the path memory. The computing device or the memory shifts data strings in the memory according to conditions of the Viterbi algorithm with the control signals associated with the plurality of paths.
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BACKGROUND OF THE INVENTION
This invention relates to improvements in a system for cleaning weaving machines, and at the same time, conditioning the weft yarns to improve both the quality of the fabric and the production of the weaving machines. The invention relates to equipment which is strategically located in an area of the weaving machine where a significant part of lint, fly, dust, oil, etc. are generated from the operation of the weaving machine.
Lint, fly and dust (hereinafter referred to as lint) are minute textile fibers, size and other particles which have become separated from the warp yarn or from the weft yarn at a number of different locations, especially where the warp yarns pass through the eyes of the drop wires, the eyes of the heddles, and between the blades of the reed. Lint is also generated from handling of the weft yarn. Such lint tends to collect on the surfaces of the weaving machine and is often incorporated into the fabric inadvertently when a large chunk of such lint falls off the surface of the weaving machine into the warp shed, or is entwined about individual warp or weft yarns and passes into the fabric past the beat-up point, resulting in defective fabric.
Lint is also objectionable because thick layers of the lint forming on the weaving machine surfaces may clog the weaving machine by falling into the weaving machine mechanisms and also collect oil used to lubricate the weaving machine. Furthermore, such large accumulations of this highly flammable material constitutes a fire hazard.
The general cleaning approach in most mills today is to permit the lint to accumulate on the surfaces of the weaving machine and periodically to manually blow such lint off of the weaving machine surfaces onto the floor where it is manually swept up by brooms. This removes a large amount of the lint; however, much of the lint is suspended in the air and lands back on the weaving machines, accumulates on the walls or ceilings, or into the fabric. With the high speed weaving machines used in today's textile plants, much production is lost due to the cleaning of the machines, therefore, it has become necessary to provide means for cleaning the weaving machines continuously to remove the bulk of the lint from the surfaces of the weaving machine while such machines are in operation.
Many attempts have been made to provide for a cleaning mechanism on weaving machines. One such attempt is shown in U.S. Pat. No. 3,627,201. This patent teaches a system which requires that each weaving machine be provided with a downwardly opening hood which fits snugly around the weaving machine and which has an annular rim around the downwardly directed opening thereof. The hood is supported by a mechanism which moves the hood upwardly and away from the operative position. The atmosphere within the hood is said to be maintained at a temperature of 15° to 50° C. by a source of air at that temperature which is supplied through the floor under the weaving machine. An exhaust conduit is also provided for leading the air injected into the hood outwardly after it has circulated around the weaving machine.
There are many problems connected with the device in U.S. Pat. No. 3,627,201. The main problem is that the mechanism is very cumbersome and it is very difficult for the weavers to have access to the weaving machines when broken warp yarns or the like must be repaired. Furthermore, the system disclosed in this patent does little or no cleaning of the surfaces of the weaving machine.
Another attempt was made in U.S. Pat. No. 3,378,998. In this patent, an attempt is made to provide an enclosure for the yarn manipulating mechanism of a weaving machine. A hood is provided for enclosing the upper portion of the weaving machine. This hood has an opening for receiving air. An air input means is connected to the opening in the hood. A central chamber is attached to the hood which encloses the working instrumentalities of the weaving machine at points where the lint is normally discharged and collects. A base enclosure is connected to the central chamber for receiving accumulated lint from the central chamber. A suction and collecting unit is provided for the base enclosure for creating a negative pressure within the hood. The flow of air through the enclosure is said to pass through the machinery and to maintain it substantially free from lint and fly.
The enclosure of U.S. Pat. No. 3,378,998 makes it very difficult for the weaver to get at the weaving mechanism to repair broken warp ends or broken weft ends, as was pointed out above, with regard to the device in U.S. Pat. No. 3,627,201. It should also be pointed out, however, that the air flow provided by both of these patents is generalized and is not concentrated upon the surfaces where the lint is most likely to accumulate. The general flow of air through these all encompassing housings does not remove the lint from the machine surfaces unless the flow is so strong as to cause false stops of the warp motion. While the device in U.S. Pat. No. 3,378,998 might be adequate for conditioning the yarn, it is not adequate for cleaning the surfaces of the weaving machine, and is so burdensome upon the weavers as to preclude its commercial usage.
An early attempt to clean a weaving machine was suggested in U.S. Pat. No. 1,850,502. In this patent, a pan-like device is located below the warp threads between the harnesses and the whip roll for collecting dust, fly and lint by a downdraft of air induced by a suction device, which is connected to the bottom of the pan or receptacle. While this device may collect some fly or lint from the warp yarns there is no suggestion that this device could clean adjacent surfaces of the weaving machine or condition the warp yarn by drawing the ambient atmosphere over and through the warp yarns.
A more recent attempt, which is similar to that of U.S. Pat. No. 1,850,502 is found in U.S. Pat. No. 2,984,263. In the system shown in this patent, a collection system is mounted directly on the weaving machine under the stop motion where it is said that the major fly and lint accumulation takes place. The system of this patent primarily utilizes a directed high velocity stream of air to cause a low pressure area in its surrounding environment, which draws the lint and fly to it and then transmits the lint and fly to a desired collection point. The use of such an air stream is said to be much more efficient than the use of a vacuum, and thus enables the device to collect large portions of lint and fly without the use of large, powerful or expensive equipment. While the device shown in this patent may be an efficient collector of lint which falls onto the surfaces of its baffles, there is nothing in this patent to indicate that the ambient atmosphere of the weave room is drawn across the surfaces of the warp yarn to condition such yarn prior to weaving. Furthermore, no provision is made for cleaning the surfaces of the heddles or harnesses or weft insertion device where large amounts of fly and lint are also generated.
In U.S. Pat. No. 3,451,435 a nozzle body with the shape of a prism is positioned across the warp directly above the reed and adjacent to the heddles of the weaving machine so that air currents containing dust are fanned by the oscillating reed into the inlet of a suction nozzle. While this device may be adequate to remove lightweight dust, fly or lint set into motion already by the reed, it is not adequate for conditioning the warp yarn or the weft yarn, nor does this mechanism suggest or teach any way in which the stop motion can be cleaned and the warp yarn conditioned at the same time.
Another more elaborate attempt to provide a cleaning mechanism for a weaving machine is found in U.S. Pat. No. 3,311,135. In this system, the patentees suggest the provision of one enclosure for the sley and reed and another enclosure for the warp stop motion, and still a third enclosure for the harness mechanism. The patentees suggest that the air within the various enclosures is conditioned and that such housings or enclosures, prevent the escape of lint or fly into the weave room at large. While the enclosures shown and suggested in this patent will enable the maintenance of the desired atmospheric conditions within the chambers and will provide some cleaning of adjacent weaving machine surfaces, it still suffers from the adverse drawback of being very difficult for the weaver to operate the weaving machines with this mechanism in place.
Still another attempt to provide a cleaning mechanism is found in U.S. Pat. No. 3,678,965. In this patent, lint and fly is said to be effectively and efficiently removed by suction box 34 located in the path of the warp yarns between the warp stop motion and the harnesses, with a first suction opening directed towards the warp stop motion, and a second suction opening directed towards the harnesses. Suction means is connected to the suction box for drawing the atmosphere across the warp stop motion and across the harnesses. However, this device is in a position which will necessarily interfere with the weaving operations by the weavers. For example, one merely has to observe FIG. 1 to determine how difficult it would be for the weaver to repair broken warp yarns which requires him to thread-up a new yarn through the stop motion, the hood and the warp heddles. Thus, such handicaps to the weaver makes it very unlikely that this device can function successfully on a commercial basis.
SUMMARY OF THE INVENTION
It is a primary object of this invention to provide an improved system for removing lint, size, oil, fly or other contaminating substances from selected surfaces of the weaving machine, while at the same time drawing air from the ambient atmosphere across the weft to condition the weft yarns.
Still another object of the invention is to provide means for drawing air from the ambient atmosphere across the weft loading station and the weft yarn to condition the weft yarn and to provide an air flow across the adjacent weaving machine surfaces.
It is a still further object of the invention to provide means for conditioning the weft yarn and for cleaning the surfaces of the weaving machine at the weft loading and picking station of the weaving machine.
These and other objects and advantages of the invention will appear from a description taken hereinafter in connection with the accompanying drawings, illustrating a preferred embodiment of the form of the invention to accomplish these objectives.
The present invention generally provides at least one vacuum chamber locatable adjacent the weft loading and picking station of a weaving machine for conditioning the weft yarn at same and for cleaning adjacent surfaces of the weaving machine thereat. Preferably, a first vacuum chamber is provided, having a configuration to fit snugly into an opening beneath the weft loading and picking station with at least one and preferably two further vacuum chambers secured to the first chamber and extending outwardly therefrom adjacent an underside of the static. The further vacuum chamber or chambers are provided with a longitudinal slot that extends along the picking station through which oil, lint, fly and the like is removed from the immediate environs where a partial vacuum is created within the chamber, with ambient air being drawn across the weft yarn for conditioning same.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood when considering the following detailed description in conjunction with the accompanying drawings wherein:
FIG. 1 is a perspective view of the loading and picking station of a weaving machine showing the rectangular vacuum chamber for conditioning the weft yarn and for cleaning the surfaces of the adjacent picking and loading mechanism;
FIG. 2 is a perspective view of the picking and loading station of a weaving machine showing the tubular vacuum chamber for conditioning the weft yarn and for cleaning the adjacent surfaces of the weaving machine;
FIG. 3 is a perspective view of a vacuum chamber device for cleaning the picking station and for conditioning the weft yarn;
FIG. 4 is a perspective view similar to that of FIG. 3 but showing the other side of the vacuum chamber device;
FIG. 5 is an enlarged end view of the vacuum chamber device for cleaning the loading station and for conditioning the weft yarn taken along line 5--5 of FIG. 2 with some parts broken away for clarity;
FIG. 6 is a top plan view of the warp stop motion and the harnesses on a weaving machine;
FIG. 7 is a rear view of a weaving machine taken along line 7--7 of FIG. 8 with some parts shown in phantom for clarity;
FIG. 8 is a side sectional view of the weaving machine taken along line 8--8 of FIG. 6 and enlarged for clarity; and
FIG. 9 is a rear cross-sectional view of the vacuum chamber at the warp stop motion taken along line 9--9 of FIG. 8.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1-5 of the drawings, FIGS. 1 and 2 show the loading and picking station of a weaving machine such as those manufactured by Sulzer of Winterthur, Switzerland. Picking station 20 comprises weft yarn guides 23 and 23' for presenting the weft yarn 22 to a gripper shuttle 24. Gripper shuttle 24 fits within a slot 28 formed by upper and lower shuttle guide rails 26.
A closed rectangular vacuum chamber 30 is disposed beneath the picking station and comprises two tubular (i.e. hollow, elongated) vacuum chambers 32 and 34 which extend horizontally from the rectangular vacuum chamber 30. Tubular vacuum chambers 32 and 34 are pneumatically sealed at their ends 33 and 35, respectively. Tubular vacuum chambers 32 and 34 are provided with elongated slots 38 and 40, respectively. Slots 38 and 40 are located so as to draw air from the ambient atmosphere of the weave room whenever a partial vacuum is created within tubular vacuum chambers 32 and 34 or rectangular vacuum chamber 30. Thus, as shown more clearly in FIG. 5, slots 38 and 40 are disposed so as to draw air from the ambient atmosphere across different surfaces of the upper and lower guide rails and the projectile, as well as across the weft yarn itself.
Rectangular vacuum chamber 30 also acts as a baffle in that it fits snugly within the available space on the weaving machine beneath the loading station and prevents air from the ambient atmosphere from being drawn along the longitudinal axes of tubular vacuum chambers 32 and 34. This assures that air drawn into said tubular chambers will pass over the weft yarn and the surfaces of said loading station.
The ambient atmosphere in the weave room is one in which the relative humidity is raised to a level which is conducive to proper weaving conditions. Inasmuch as the vacuum chambers of the invention have a partial vacuum created within the vacuum chambers, this causes air from the ambient atmosphere to rush across the weft yarn and the adjacent surfaces of the weaving machine, thereby removing accumulated lint, fly, oil or dust as well as drawing the humidified air across the weft yarn to thereby condition the yarn by increasing the water content thereof at precisely the point at which such yarn is under its greatest strain or stress, i.e. during the weft insertion stage of the weaving process.
The vacuum within the tubular vacuum chamber and rectangular vacuum chamber 30 is created by a suitable pump or vacuum source within the weave room through exhaust pipe 36. Exhaust pipe 36 also directs any lint, fly, size, oil or the like which may be cleaned from the adjacent weaving machine surfaces to a waste recovery station (not shown). This waste recovery station may be provided for each individual weaving machine in the case of an individual drive or individual suction device, or to a central collection station where a central system is used within the weave room.
Referring now to FIGS. 6, 7, 8 and 9, wherein the vacuum chambers for cleaning the warp stop motion and the harnesses and for conditioning the warp yarn are shown in detail. As best seen in FIG. 8, the warp yarns 46 are drawn from a beam (not shown) through a series of drop wires 43 at warp stop motion 42. As is common in such warp stop motions, each warp end is provided with its own drop wire in either a mechanical or electrical warp stop motion. Surrounding the lower portion of the drop wires is a vacuum chamber 50, having four walls, disposed to draw air from the ambient atmosphere of the weave room across the drop wires 43 and the warp yarns 46 for removing all lint, fly, dust, size, oil or the like from the surfaces of the drop wires and for conditioning the warp yarn by concentrating the air from the ambient atmosphere onto such yarn just prior to its being subjected to its greatest stress during the weaving process, i.e. the formation of the warp sheds and the beat-up process. The concentration of the air drawn from the ambient atmosphere on the warp yarn increases the moisture content of the warp yarn over that naturally absorbed by its passage through the unconcentrated ambient atmosphere. This permits a lower relative humidity to be utilized in the ambient atmosphere for a given moisture content in the warp yarn. Vacuum chamber 50 extends the length of the warp stop motion and has walls which partially surround the drop wires. At one end of the vacuum chamber 50 is an exhaust pipe or duct 52. Exhaust duct 52 extends down the side of the weaving machine and extends to a central duct 56 which is connected to a central collection point either on the weaving machine itself or to a central collection system for the entire weave room.
Disposed beneath the harnesses 44 is a generally rectangular vacuum chamber 53. Vacuum chamber 53 is connected to central exhaust duct 56 through exhaust duct 54, as best seen in FIGS. 7 and 9. Where the weaving machines are very wide, vacuum chambers 53 and 50 may be compartmentalized as shown in FIG. 7. That is, different sections of the vacuum chambers may be separately exhausted so as to provide more uniform movement of air from the ambient atmosphere across the warp yarns and the adjacent surfaces of the weaving machine for cleaning the same.
Disposed within vacuum chamber 53 are two baffles 60 and 62. The surfaces of baffles 60 and 62 lie in planes that extend at an angle to each other and intersect beneath the harnesses. Baffle 60 extends beyond the intersection point, whereas baffle 62 terminates short of baffle 60 so as to provide an exhaust slot or port for exhausting the dust, lint, fly, oil or other foreign material which may be removed from the surfaces of the heddles and harnesses by passage of air from the ambient atmosphere across the surfaces when a partial vacuum is created within the vacuum chamber.
Clearances 64 and 66 are also provided between the upper portions of baffles 60 and 62 and the adjacent surfaces of the walls of the vacuum chamber. The use of baffles 60 and 62 permit a greater velocity movement of air currents across the surfaces of the weaving machine and through the warp yarn for a given energy consumption in the vacuum creating mechanism.
As will be seen in FIG. 8, the positions of baffles 60 and 62 may be adjustable so as to vary the size of slot 68 and clearances 64 and 66. By varying the size of slot 68 and clearances 64 and 66, the velocity of the air drawn from the ambient atmosphere may be varied for a given vacuum within the vacuum chamber.
As illustrated herein, the hollow, elongated vacuum chambers adjacent to the picking station may have a round cross-section, a rectangular cross-section, or other cross-section, as desired, and as space permits. For example, chambers 30, 32, 34, 50, and 53 may be so varied, as desired. It will also be understood that the means for creating a partial vacuum within the vacuum chambers may be provided for each individual weaving machine with its own individual vacuum pump and motor, or the vacuum creating mechanism may be provided at a central station within the weaving room with suitable connections to each of the weaving machines. The use of a central collection point makes recovery of the waste material more efficient.
In any event, whether the pneumatic source is provided for individually on the weaving machines or by a central location, means are contemplated for turning the vacuum producing means off for individual weaving machines. Means are provided for closing a suitable damper in the exhaust system when the weaving machine ceases operation; for example, in exhaust duct 56, when a central collection system is utilized.
While there is shown and described a preferred embodiment of the invention using specific terms, it is to be understood that the invention is not limited thereto but may be otherwise variously embodied and practiced within the scope of the appended claims.
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In a weaving machine having a warp supply, a harness motion, a reed and filling insertion mechanism, vacuum chambers are provided adjacent to the weft insertion station for drawing air from the ambient atmosphere of the weave room across the weft yarn to concentrate the ambient air from the atmosphere onto such yarn and to condition the same, and also to move the air drawn from the ambient atmosphere across the adjacent surfaces of the weaving machine for removing fly, lint, dust, oil or the like from such surfaces, and for preventing such material from becoming incorporated into the fabric.
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BACKGROUND OF THE INVENTION
The present invention relates to aryl substituted alkylsilanes and a preparation method thereof. More particularly, the present invention relates to aryl substituted alkylsilanes and a preparation method thereof by reacting substituted benzenes with aryl substituted alkylsilanes in the presence of Lewis acid catalysts.
Since Friedel and Crafts first reported the alkylation reaction of benzene with alkyl halide in the presence of aluminum chloride catalyst in 1877, the Friedel-Crafts type alkylation reaction has been widely used as a synthetic procedure in organic synthesis(R. M. Roberts and A. A. Khalaf, Friedel-Crafts Alkylation Chemistry, Marcel Dekker, Inc., NY, 1984).
Chernyshev and Dolgaya reported the Friedel-Crafts type alkylation of (chloroalkyl)trichlorosilanes to substituted benzenes to produce (trichlorosilyl)-alkylbenzenes [E. A. Chernyshev and M. E. Dolgaya, Zhur. Obschchei Khim, 25, 2469(1955)]. ##STR2##
They reacted (dichloromethyl)silane or (dichloroethyl) silane with benzene, chlorobenzene, or toluene to produce two phenyl groups substituted alkylchlorosilanes [E. A. Chernyshev, M. E. Dolgaya, and A. D. Petrov, Zhur. Obschchei Khim, 28, 613 (1958)]. They also reacted (chloropropyl)silane with benzene, chlorobenzene, toluene, biphenyl, or biphenyl ether to produce phenyl groups substituted propylchlorosilanes [E. A. Chernyshev, M. E. Dolgaya, and Yu. P. Egorov, Zhur. Obschchei Khim, 28, 2829(1958)]. ##STR3##
Recently, we reported the Friedel-Crafts type alkylation of substituted benzenes with allyldichlorosilanes (Jung, I. N.; Yoo, B. R.; Lee, B. W.; Yeon, S. H., U.S. Pat. No. 5,527,938) and vinylchlorosilanes (Korea Patent Application No. 95-48114). ##STR4##
(Chloroalkyl)silanes can be easily prepared by the photochlorination of alkylsilanes on a large scale. In this process, polychlorinated alkylsilanes are inevitably produced as byproducts, because the chlorinated organic moieties are more susceptible toward the chlorination [R. H. Krieble and J. R. Elliott, J. Am. Chem. Soc., 67, 1810 (1945)]. However, polychlorinated alkylsilanes do not find any applications in industry and are disposed. Thus, it is very important to develop a method to convert the polychlorinated byproducts from chlorination reactions of alkylchlrosilanes to useful organosilane compounds. We found that the chloro groups of polychlorinated alkylsilanes can be converted to the corresponding polyaryl substituted alkylsilanes by the Friedel-Crafts type alkylation with particularly more than two halogen atoms substituted benzenes in the presence of Lewis acid catalysts. This method can be applied to the alkylsilane compounds having not only one or two chlorine atoms but also three chlorines.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide aryl substituted alkylsilanes represented by the formula (I). ##STR5## (wherein m, p, and q are 0 or 1, respectively; n and y are 0, 1, or 2, respectively; X 1 , X 2 , X 3 , X 4 , and X 5 which are same or different represent hydrogen, fluoro, chloro; R represents C 1 -C 12 alkyl group; provided that if n is 0, m is 0 and if n is 1 or 2, at least two of X 1 , X 2 , X 3 , X 4 , and X 5 represent chloro or fluoro group).
Another object of the present invention is to provide a method for preparing aryl substituted alkylsilanes which comprises reacting substituted benzenes of the formula (II) with (polychloroalkyl)silane of the formula (III) in the presence of Lewis acid catalysts such as aluminum chloride: ##STR6## (wherein, m, p, q, n, y, X 1 , X 2 , X 3 , X 4 , and X 5 have the same definition as in the formula (I))
The manner in which the foregoing and other objects of this invention are accomplished will be apparent from the accompanying specification and claims considered together with the working examples.
DETAILED DESCRIPTION OF THE INVENTION
The preparation of aryl substituted alkylsilanes containing more than two halogen groups on the aromatic ring according to the present invention can be run in standard laboratory glassware or commercial equipments, under inert atmosphere, with units for external heating and cooling, stirring, and for incremental addition of the start silanes. The reaction can be carried out in neat or in most of nonaromatic or nonprotic solvents such as hexane or dichloromethane. In a typical preparation, substituted benzenes and polychlorinated alkylsilane represented by the formula III are placed in the reactor under inert atmosphere. Substituted benzenes and (polychloroalkyl)silanes are used in the molar ratio of 1 to 20:1. Aluminum chloride or Aluminum is the best catalyst and can be used alone or in junction with other Lewis acid such as chlorides of zinc, boron, iron, tin, titanium and antimony. The (polychloroalkyl)silane is then slowly added to the reactants in the reactor with stirring at the reaction temperatures between 0° C. and 200° C. The amount of Lewis acid used is 1-100 mole %, preferably 5-50 mole % of polychlorinated alkylsilanes. After completion of addition, the solution may be kept stirring for a certain period of time to complete the alkylation and then the products may be fractionally distilled at atmosphere or under vacuum.
The invention will be further illustrated by the following examples, but not limited to the examples given.
EXAMPLE 1
Alkylation of 1,4-dichlorobenzene with (Dichloromethyl)Methyldichlorosilane
To a 250 ml, three-necked, frame dried, round bottom flask equipped with a magnetic stirrer, a reflux condenser, and a dropping funnel, aluminum chloride 1.28 g (9.60 mmol) and 1,4-dichlorobenzene 62.89 g (428 mmol) were placed under dry nitrogen atmospheric pressure. After (dichloromethyl) methyldichlorosilane 14.12 g (72.31 mmol) was added to the solution, the reaction mixture was heated for 7 hours at 150° C. The aluminum chloride catalyst was quenched with POCl 3 1.47 g (9.59 mmol) and then stirred for another 1 hour to complete the deactivation. Freshly distilled hexane (100 ml) was added to the reaction mixture and insoluble solids in hexane were filtered from the organic soultion. After hexane was distilled, the reaction products were vacuum distilled at 0.2 torr to give 14.14 g of [bis(2,5-dichlorophenyl)methyl] methyldichlorosilane (bp; 154° C./0.2 torr, yield; 47%).
1 H-NMR(CDCl 3 , ppm) 0.86 (s, 3H, SiCH 3 ), 5.05 (s, 1H, CH), 7.20-7.58 (m, 6H, ArH)
13 C-NMR(CDCl 3 , ppm) 5.3 (CH 3 ), 39.5 (CH), 128.6, 130.8, 131.2, 132.9, 133.4, 136.7 (ArC)
EXAMPLE 2
Alkylation of Fluorobenzene with (Dichloromethyl)Methyldichlorosilane
In a 100 ml, three-necked, frame dried, round bottom flask, aluminum chloride 1.679 (12.5 mmol), fluorobenzene 37.93 ml (404 mmol), and (dichloromethyl)methyldichlorosilane 7.08 ml (50.5 mmol) were reacted for 2 hours as in EXAMPLE 1. The aluminum chloride catalyst was quenched with POCl 3 1.15 ml (12.5 mmol) and then stirred for another 1 hour to complete the deactivation. Freshly distilled hexane (50 ml) was added to the reaction mixture and insoluble solids in hexane were filtered from the organic solution. After hexane and fluorobenzene were distilled, the reaction products were vacuum distilled to give 10.49 g of [bis(fluorophenyl)methyl]methyldichlorosilane as a mixture of isomers (bp; 103° C./0.2 torr, yield; 65%).
1 H-NMR(CDCl 3 , ppm) 0.79-0.89 (3H, SiCH 3 ) , 4.01-4.78 (1H, CH), 6.97-7.58 (8H, ArH)
EXAMPLE 3
Alkylation of Benzene with (Trichloromethyl) Methyldichlorosilane
In the same apparatus and procedures as EXAMPLE 1 above, 50.4 ml (564 mmol) of benzene and 2.92 g (21.9 mmol) of aluminum chloride were alkylated with 10.0 g (43.0 mmol) of (trichloromethyl)methyldichlorosilane under dry nitrogen atmospheric pressure for 5 hours at room temperature. The aluminum chloride catalyst was quenched with PoCl 3 and then stirred for another 1 hour to complete the deactivation. Freshly distilled hexane (100 ml) was added to the reaction mixture and insoluble solids in hexane were filtered from the organic soultion. After hexane and benzene were distilled, recrystallization from chloroform yielded 3.58 g of (triphenylmethyl)methyldichlorosilane (mp: 170-172° C., yield; 23%).
1 H-NMR(CDCl 3 , ppm) 0.88 (s, 3H, SiCH 3 ), 7.19-7.33 (m, 15H, ArH)
13C-NMR(CDCl 3 , ppm) 7.9 (CH 3 ), 57.5 (C--Si), 126.8, 128.3, 130.4, 142.9(ArC)
EXAMPLE 4
Alkylation of Benzene with (Trichloromethyl) Trichlorosilane
In the same apparatus and procedures as EXAMPLE 2 above, 22.88 ml (256 mmol) of benzene and 0.80 g (6.0 mmol) of aluminum chloride were alkylated with 9.04 g (17.2 mmol) of (trichloromethyl)trichlorosilane under dry nitrogen atmospheric pressure for 1 hr at 50° C. The aluminum chloride catalyst was quenched with POCl 3 and then stirred for another 1 hour to complete the deactivation. Freshly distilled hexane(50 ml) was added to the reaction mixture and insoluble solids in hexane were filtered from the organic soultion. After hexane and benzene were distilled, recrystallization from chloroform yielded 1.23 g of (triphenylmethyl)trichlorosilane (mp; 195-7: E, yield; 19%).
1 H-NMR(CDCl 3 , ppm) 7.17-7.32 (m, 15H, ArH)
EXAMPLE 5
Alkylation of 1,4-dichlorobenzene with (2,2-dichloroethyl)Trichlorosilane
In the same apparatus and procedures as EXAMPLE 2 above, 14.70 g (100 mmol) of 1,4-dichlorobenzene and 0.027 g (1.0 mmol) of aluminum foil were alkylated with 4.98 g (21.4 mmol) of (2,2-dichloroethyl)trichlorosilane for 1 hour at 80° C. Freshly distilled hexane (50 ml) was added to the reaction mixture and insoluble solids in hexane were filtered from the organic soultion. After hexane and benzene were distilled, the reaction products were vacuum distilled to give 3.33 g of [2,2-bis(2,5-dichlorophenyl)ethyl]trichlorosilane (bp; 161-163° C./1 torr, yield; 59%).
1 H-NMR(CDCl 3 , ppm) 2.17 (d, J=7.8 Hz, 2H, CH 2 ), 5.26 (t, J=7.8 Hz, 1H, CH), 7.19-7.36 (m, 6H, ArH)
EXAMPLE 6
Alkylation of Benzene with (3,3-dichloropropyl)Trichlorosilane
In the same apparatus and procedures as EXAMPLE 2 above, 36.0 ml (405 mmol) of benzene and 0.53 g (4.0 mmol) of aluminum chloride were alkylated with 10.08 g (41.0 mmol) of (3,3-dichloropropyl)trichlorosilane. The aluminum chloride catalyst was quenched with POCl 3 and then stirred for another 1 hour to complete the deactivation. Freshly distilled hexane (50 ml) was added to the reaction mixture and insoluble solids in hexane were filtered from the organic soultion. After hexane and benzene were distilled, the reaction products were vacuum distilled to give 6.76 g of (3,3-diphenylpropyl)trichlorosilane (bp; 124-125° C./0.5 torr, yield; 50%).
1 H-NMR(CDCl 3 , ppm) 1.4 (t, J=8.0, 2H, CH 2 Si), 2.36 (q, J=8.0 Hz, 2H, CH 2 ), 3.97 (t, J=8.0 Hz, 1H, CH), 7.05-7.38 (m, 10H, ArH).
EXAMPLE 7
Alkylation of Fluorobenzene with (3,3-dichloropropyl)Trichlorosilane
In the same apparatus and procedures as EXAMPLE 2 above, 18.8 ml (200 mmol) of fluorobenzene and 0.035 g (1.3 mmol) of aluminum foil were alkylated with 6.42 g (26.1 mmol) of (3,3-dichloropropyl)trichlorosilane for 2 hours at 70° C. Freshly distilled hexane(50 ml) was added to the reaction mixture and insoluble solids in hexane were filtered from the organic soultion. After hexane and fluorobenzene were distilled, the reaction products were vacuum distilled to give 4.50 g of [3,3-bis(fluorophenyl)propyl]trichlorosilanes as a mixture of isomers (bp; 121-122° C./0.5 torr, yield; 47%).
1 H-NMR(CDCl 3 , ppm) 1.32-1.45 (2H, CH 2 Si), 2.22-2.34 (2H, CH 2 CH 2 Si), 3.89-3.95, 4.25-4.32, 4.57-4.63 (1H, CH), 6.90-7.31 (8H, ArH)
EXAMPLE 8
Alkylation of Benzene with (1,2-dichloroethyl) Trichlorosilane
In the same apparatus and procedures as EXAMPLE 2 above, 25.2 ml (282 mmol) of benzene and 0.80 g (6.0 m) of aluminum chloride were alkylated with 6.60 g (28.2 mmol) of (1,2-dichloroethyl)trichlorosilane for 20 min at 70° C. The aluminum chloride catalyst was quenched with POCl 3 and then stirred for another 1 hour to complete the deactivation. Freshly distilled hexane(50 ml) was added to the reaction mixture and insoluble solids in hexane were filtered from the organic soultion. After hexane and benzene were distilled, the reaction products were vacuum distilled to give 4.82 g of (2,2-diphenylethyl)trichlorosilane (bp; 117° C./0.5 torr, yield; 54%).
1 H-NMR(CDCl 3 , ppm) 2.33 (d, J=7.7 Hz, 2H, CH 2 ), 4.44 (t, J=7.7 Hz, 1H, CH), 7.22-7.34 (m, 10H, ArH)
EXAMPLE 9
Alkylation of 1,4-dichlorobenzene with (1,2-dichloroethyl)Trichlorosilane
In the same apparatus and procedures as EXAMPLE 2 above, 17.35 g (118 mmol) of 1,4-dichlorobenzene and 0.47 g (3.5 mmol) of aluminum chloride were alkylated with 5.45 g (23.5 mmol) of (1,2-dichloroethyl)trichlorosilane for 20 min at 120° C. The aluminum chloride catalyst was quenched with POCl 3 and then stirred for another 1 hour to complete the deactivation. Freshly distilled hexane (50 ml) was added to the reaction mixture and insoluble solids in hexane were filtered from the organic soultion. After hexane was distilled, the reaction products were vacuum distilled to give 4.56 g of [2,2-bis(2,5-dichlorophenyl)ethyl]trichlorosilane (bp; 161-163° C./0.5 torr, yield; 43%).
1 H-NMR(CDCl 3 , ppm) 2.17 (d, J=7.8 Hz, 2H, CH 2 ), 5.26 (t, J=7.8 Hz, 1H, CH), 7.19-7.36 (m, 6H, ArH)
EXAMPLE 10
Alkylation of 1,3-dichlorobenzene with (1,2-dichloroethyl)Trichlorosilane
In the same apparatus and procedures as EXAMPLE 1 above, 49.1 ml (430 mmol) of 1,3-dichlorobenzene and 2.30 g (17.2 mmol) of aluminum chloride were alkylated with 19.40 g (83.5 mmol) of (1,2-dichloroethyl)trichlorosilane for 30 min at 120° C. The aluminum chloride catalyst was quenched with POCl 3 and then stirred for another 1 hour to complete the deactivation. Freshly distilled hexane (100 ml) was added to the reaction mixture and insoluble solids in hexane were filtered from the organic soultion. After hexane was distilled, the reaction products were vacuum distilled to give 14.6 g of [2,2-bis(2,4-dichlorophenyl)ethyl]trichlorosilane (bp; 175-180° C./0.5 torr, yield; 39%).
1 H-NMR(CDCl 3 , ppm) 2.17 (d, J=7.6 Hz, 2H, CH 2 ), 5.26 (t, J=7.6 Hz, 1H, CH), 7.13-7.42 (m, 6H, ArH)
EXAMPLE 11
Alkylation of 1,2,4-trichlorobenzene with (1,2-dichloroethyl)Trichlorosilane
In the same apparatus and procedures as EXAMPLE 2 above, 21.5 ml (172 mmol) of 1,2,4-trichlorobenzene and 0.92 g (6.9 mmol) of aluminum chloride were alkylated with 8.17 g (35.2 mmol) of (1,2-dichloroethyl)trichlorosilane for 10 min at at 120° C. The aluminum chloride catalyst was quenched with POCl 3 and then stirred for another 1 hour to complete the deactivation. Freshly distilled hexane (50 ml) was added to the reaction mixture and insoluble solids in hexane were filtered from the organic soultion. After hexane was distilled, the reaction products were vacuum distilled to give 10.70 g of [2,2-bis(trichlorophenyl)ethyl]trichlorosilane as a mixture of isomers (bp; 192-194° C./0.5 torr, yield; 58%).
1 H-NMR(CDCl 3 , ppm) 2.14 (d, J=7.8 Hz, 2H, CH 2 ), 5.16 (t, J=7.6 Hz, 1H, CH), 7.27, 7.53 (S, 4H, ArH)
EXAMPLE 12
Alkylation of 1,2,3,4-tetrachlorobenzene with (1,2-dichloroethyl)Trichlorosilane
In the same apparatus and procedures as EXAMPLE 1 above, 43.18 g (200 mmol) of 1,2,3,4-tetrachlorobenzene and 1.07 g (8.0 mmol) of aluminum chloride were alkylated with 9.30 g (40.0 mmol) of (1,2-dichloroethyl)trichlorosilane for 10 min at 130° C. The aluminum chloride catalyst was quenched with POCl 3 and then stirred for another 30 min to complete the deactivation. Freshly distilled hexane(100 ml) was added to the reaction mixture and insoluble solids in hexane were filtered from the organic soultion. After hexane was distilled, the reaction products were vacuum distilled to give 10.41 g of [2,2-bis(2,3,4,5-tetrachlorophenyl) ethyl]trichlorosilane (bp; 218-222° C./0.5 torr, yield; 44%).
1 H-NMR(CDCl 3 , ppm) 2.11 (d, J=7.7 Hz, 2H, CH 2 ), 5.12 (t, J=7.7 Hz, 1H, CH), 7.28 (S, 2H, ArH)
EXAMPLE 13
Alkylation of Benzene with (2,3-dichloropropyl)Trichlorosilane
In the same apparatus and procedures as EXAMPLE 2 above, 17.8 ml (200 mmol) of benzene and 0.27 g (2.0 mmol) of aluminum chloride were alkylated with 4.51 g (18.3 mmol) of (2,3dichloropropyl)trichlorosilane for 10 min at 70° C. The aluminum chloride catalyst was quenched with POCl 3 and then stirred for another 30 min to complete the deactivation. Freshly distilled hexane (50 ml) was added to the reaction mixture and insoluble solids in hexane were filtered from the organic soultion. After hexane and benzene were distilled, the reaction products were vacuum distilled to give 2.91 g of (3,3-diphenylpropyl)trichlorosilane (bp; 124-125° C./0.5 torr, yield; 48%).
1 H-NMR(CDCl 3 , ppm) 1.40 (t, J=8.0, 2H, CH 2 si), 2.36 (q, J=8.0 Hz, 2H, CH 2 ), 3.97 (t, J=8.0 Hz, 1H, CH), 7.05-7.38 (m, 10H, ArH)
EXAMPLE 14
Alkylation of Fluorobenzene with (2,3-dichloropropyl)Trichlorosilane
In the same apparatus and procedures as EXAMPLE 2 above, 18.8 ml (200 mmol) of fluorobenzene and 0.31 g (2.3 mmol) of aluminum chloride were alkylated with 5.61 g (22.8 mmol) of (2,3-dichloropropyl)trichlorosilane for 10 min at 70° C. The aluminum chloride catalyst was quenched with POCl 3 and then stirred for another 1 hour to complete the deactivation. Freshly distilled hexane (50 ml) was added to the reaction mixture and insoluble solids in hexane were filtered from the organic soultion. After hexane and fluorobenzene were distilled, the reaction products were vacuum distilled to give 3.39 g of [3,3-bis(fluorophenyl)propyl]trichlorosilane (bp; 121-122° C./0.5 torr, yield; 41%) as a mixutre of isomers.
1 H-NMR(CDCl 31 ppm) 1.32-1.45 (m, 2H, CH 2 Si), 2.22-2.34 (m, 2H, CH 2 CH 2 Si), 3.89-3.95, 4.25-4.32, 4.57-4.63 (m, 1H, CH), 6.90-7.31 (m, 8H, ArH)
EXAMPLE 15
Alkylation of Benzene with (2,3-dichlorobutyl)Trichlorosilane
In the same apparatus and procedures as EXAMPLE 2 above, benzene 24.1 ml (270 mmol) and 0.72 g (5.4 mmol) of aluminum chloride were alkylated with 7.17 g (27.5 mmol) of (2,3-dichlorobutyl)trichlorosilane for 10 min at 70° C. The aluminum chloride catalyst was quenched with POCl 3 and then stirred for another 1 hour to complete the deactivation. Freshly distilled hexane (50 ml) was added to the reaction mixture and insoluble solids in hexane were filtered from the organic soultion. After hexane and benzene were distilled, the reaction products were vacuum distilled to give 2.31 g of (3,3-diphenylbutyl)trichlorosilane (bp; 122-124° C./0.5 torr, yield; 24%).
1 H-NMR(CDCl 3 , ppm) 1.20 (t, J=8.0 Hz, 2H, CH 2 Si), 1.70 (s, 3H, CH 3 ), 2.38 (t, J=8.0 Hz, 2H, CH 2 CH 2 Si), 6.95-7.37 (m, 10H, ArH)
EXAMPLE 16
Alkylation of 1,3-dichlorobenzene with (2,3-dichlorobutyl)Trichlorosilane
In the same apparatus and procedures as EXAMPLE 2 above, 26.3 ml (230 mmol) of 2,3-dichlorobenzene and 1.23 g (9.2 mmol) of aluminum chloride were alkylated with 11.91 g (45.7 mmol) of (2,3-dichlorobutyl)trichlorosilane for 20 min at 90° C. The aluminum chloride catalyst was quenched with POCl 3 and then stirred for another 30 min to complete the deactivation. Freshly distilled hexane (50 ml) was added to the reaction mixture and insoluble solids in hexane were filtered from the organic soultion. After hexane and benzene were distilled, the reaction products were vacuum distilled to give 5.06 g of [3,3-bis(2,4-dichlorophenyl)butyl]trichlorosilane (bp; 186-190° C./0.5 torr, yield; 23%).
1 H-NMR(CDCl 3 , ppm) 1.12 (t, J=7.8 Hz, 2H, CH 2 Si), 1.50 (s, 3H, CH 3 ), 2.44 (t, J=7.8 Hz, 2H, CH 2 CH 2 Si), 7.13-7.55 (m, 6H, ArH)
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Aryl substituted alkylsilanes represented by the formula I and a preparation method thereof by reacting substituted benzenes represented by the formula II with aryl substituted alkylsilanes represented by the formula III in the presence of Lewis acid catalysts such as aluminum chloride: ##STR1## wherein m, p, and q are 0 or 1, respectively; n and y are 0, 1, or 2, respectively; X 1 , X 2 , X 3 , X 4 , and X 5 which are same or different represent hydrogen, fluoro, chloro; R represents C 1 -C 12 alkyl group; provided that if n is 0, m is 0 and if n is 1 or 2, at least two of X 1 , X 2 , X 3 , X 4 , and X 5 represent chloro or fluoro group.
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TECHNICAL FIELD
Embodiments of the present invention relate to design, fabrication and operation of rocket-propelled aerospace vehicles in the form of so-called “guided missiles.” More specifically, embodiments of the present invention relate to guided missiles having a component, such as a rocket motor case containing a propellant grain, with an initial, non-circular transverse cross-sectional shape, which deforms to a second, different transverse cross-sectional shape responsive to internal pressure generated upon ignition of a propellant grain disposed within the case. Other embodiments relate to a missile launch assembly comprising a partitioned, circular launch tube and a missile having at least a portion of a non-circular transverse cross-section disposed in a segment thereof.
BACKGROUND
Submarine-launched ballistic missiles have been in place for decades. In conventional submarine launch platforms, such as Trident submarines as deployed by the United States Navy, one missile per launch tube was the initial deployment. The missiles are conventionally ejected from the launch tubes using steam. This one-missile-per-tube approach severely restricts the number of missiles that may be carried.
It has been proposed to partition launch tubes, which are conventionally of circular cross-sectional shape, to enable two or even three missiles to be carried per tube. While increasing the number of missile payloads per submarine, partitioning a launch tube severely constrains the diameter of circular cross-section missiles that may be placed in the tube and, consequently, limits the propellant loading (volume) for such a missile, adversely affecting the range of the missile.
In the case of a partitioned missile launch tube, loading with circular cross-section missiles results in significant unused cross-sectional volume in a given launch tube.
Air-to-air missiles having a propulsion section of non-circular and, specifically, elliptical, transverse cross-section have been proposed. See, for example, U.S. Pat. No. 5,677,508. However, such missiles, as described, remain in their initial, elliptical shape during flight.
Consequently, it would be desirable to develop a missile configuration that would enable more efficient use of existing space in a missile launch tube in terms of accommodating greater propellant loading.
BRIEF SUMMARY
In one embodiment, the present invention comprises a missile component in the form of a rocket motor case containing a propellant grain and having at least a portion of initial, non-circular transverse cross-sectional shape, which may be flexed into a second, different transverse cross-section responsive to application of internal pressure from ignition of a propellant grain therein. Such flexure may occur during a launch event, including without limitation after escape from a missile launch tube. In one embodiment, the initial, non-circular cross-section may comprise a substantially elliptical cross-section and the second, different transverse cross-sectional shape may comprise a substantially circular cross-section.
In yet another embodiment, the present invention comprises a multi-stage missile including at least a first stage and a second stage of a first, non-circular transverse cross-section, at least one of the stages being flexible, in response to application of internal pressure from ignition of a propellant grain therein, from the first, non-circular transverse cross-section to a second, different transverse cross-section.
In another embodiment, the present invention comprises a missile launch assembly including at least one missile having at least a component of non-circular transverse cross-section disposed within a segment of a partitioned circular launch tube. The non-circular transverse cross-section may be selected to maximize volume of the launch tube segment occupied by the missile and, specifically, a rocket motor case thereof. One suitable transverse cross-sectional configuration is a substantially elliptical cross-section.
In a further embodiment, the present invention comprises a method of launching a missile including igniting a rocket motor of a first, non-circular transverse cross-section missile component, internally pressurizing the missile component substantially concurrently with motor ignition and flexing the component into a second, different transverse cross-sectional shape. The method may, optionally, be effected in conjunction with ejection of the missile from a launch tube such as, without limitation, a partitioned launch tube of a missile-carrying submarine.
As used herein, the term “missile” includes, without limitation, a missile having a non-circular cross-section throughout substantially an entire length of a fuselage as well as a missile having non-circular cross-section throughout only a portion, or component, thereof. One non-limiting example of a non-circular component of a missile is a rocket motor case.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is an illustration of an ellipse and its associated axes;
FIG. 1A is a schematic, transverse cross-sectional view of a missile launch tube partitioned into three equal segments and depicting the respective, available cross-sectional areas for a missile of circular cross-section and a missile of elliptical cross-section;
FIG. 1B is a schematic, transverse cross-sectional view of a missile launch tube partitioned diametrically into two equal segments and depicting the respective, available cross-sectional areas for a missile of circular cross-section and a missile of elliptical cross-section;
FIGS. 2A through 2C are schematic, quarter-sectional representations of various propellant configurations before and after pressurization of a rocket motor case in which the propellant is disposed, according to embodiments of the invention;
FIGS. 3A and 3B are schematic side and aft end elevations of a rocket motor case of an embodiment of the present invention prior to internal pressurization from propellant ignition;
FIGS. 4A and 4B are schematic side and aft end elevations of the rocket motor case of the embodiment of FIGS. 3A and 3B after internal pressurization and ejection from a launch tube;
FIGS. 5A and 5B are schematic side and aft end elevations of an embodiment of the invention comprising a multi-stage missile having first and second stages prior to internal pressurization from propellant ignition; and
FIGS. 6A and 6B are schematic side and aft end elevations of the multi-stage missile of FIGS. 5A and 5B after internal pressurization of the first stage and ejection from a launch tube.
DETAILED DESCRIPTION OF THE INVENTION
As noted above, propellant loading within a circular rocket motor case of a missile capable of fitting within a partitioned, circular rocket motor launch tube is severely constrained, and substantial unused cross-sectional area, greater than one-half of the total cross-sectional area, remains within the launch tube. As a result, a circular rocket motor case sized for disposition in a segment of a partitioned launch tube imposes significant limitations in terms of obtainable propellant grain volume. Therefore, it would be desirable to employ a rocket motor case of a non-circular cross-section that would reduce the unused cross-sectional area of the launch tube. Stated another way, it would be desirable to employ a rocket motor case of a cross-sectional configuration that would maximize the volume of a launch tube segment occupied by the rocket motor case and enclosed propellant grain. Cross-sectional configurations that are asymmetrical about a central axis provide such a capability.
One suitable asymmetric cross-sectional shape comprises an ellipse, which is of an arcuate shape having two perpendicular axes of unequal length. Thus, using a rocket motor case of substantially elliptical cross-section and sized to fit within a segment of a partitioned launch tube greatly enhances available cross-sectional area usable for propellant loading within the rocket motor case, in comparison to a rocket motor case of circular cross-section sized to fit within the same sized segment. As used herein, the term “substantially elliptical” includes and encompasses transverse cross-sections that are approximately, but not precisely, elliptical. Similarly, the term “substantially circular” includes and encompasses transverse cross-sections that are approximately, but not precisely, circular.
For example, with reference to FIG. 1A , it can easily be seen that missiles 10 with circular rocket motor cases 12 disposed in three-segment circular launch tube 14 partitioned at 120° intervals, leave an unacceptably high transverse unoccupied cross-sectional area 16 within launch tube segments 18 a and 18 b , and thus volume, within each partitioned launch tube segment 16 . On the other hand, a missile 20 having an elliptical cross-section rocket motor case 22 consumes a much greater transverse cross-sectional area within a launch tube segment 18 c of equal size to those within which circular rocket motor cases 12 may be disposed, leaving a significantly reduced unoccupied area 24 . In the instance of an elliptical cross-section rocket motor case 22 having a 1.4 to 1 b/a (see FIG. 1 ) elliptical axis ratio, which is suited for deployment within a three-segment partitioned launch tube 14 as depicted in FIG. 1A , about 25% more propellant may be accommodated within an elliptical rocket motor case in comparison to that within a circular rocket motor case fitting into the same size launch tube segment 18 a , 18 b , 18 c.
FIG. 1B depicts a diametrically partitioned, two-segment, circular launch tube 14 in which a missile 10 having a circular rocket motor case 12 is depicted disposed in one segment 18 a at the top of the drawing figure, and a missile 20 having an elliptical rocket motor case 22 is disposed in the other segment 18 b at the bottom thereof. In this launch tube partitioning arrangement, an elliptical rocket motor case having a 1.6 to 1 elliptical axis ratio may be deployed, wherein the achievable increased propellant loading is, remarkably, about 45% over that of a circular rocket motor case 12 fitting within the same shaped segment, the unoccupied cross-sectional area 16 within segment 18 a vastly exceeding unoccupied area 24 within segment 18 b . Of course, the appropriate elliptical ratio selected for as most suitable for a given missile system is dependent on parameters (case material properties, center bore size, etc.) other than, and in addition to, the number of partitions in a launch tube.
Stated in terms of relative attainable range for missiles fitting within the same-sized segment of a launch tube, a 32.5 inch diameter 44 foot missile using a Class 1.1 propellant and deployable in a partitioned, three-segment Trident missile D-5 launch tube, would offer a range of only about 1800 to 2000 nautical miles (nm) when a 1400 lb. throw weight including a 1000 lb. warhead is deployed. An elliptical missile of the same length and deployable in a like-sized launch tube segment, having a 1.4 to 1 ellipse ratio and having about 25% greater propellant loading capacity, with the same propellant and the same throw weight and warhead, is predicted to offer a range of about 2300 nm to 2500 nm.
In the instance of a diametrically partitioned D-5 launch tube, the largest usable circular cross-section missile, of 36 inch diameter and of 44 foot length, loaded with Class 1.1 propellant and having a throw weight of 1400 lb., would offer a range of only about 2300 nm to 2500 nm. An elliptical missile of the same length, deployable in a like-sized launch tube segment and having a 1.6 to 1 ellipse ratio and having about 45% greater propellant loading capacity, with the same propellant and the same throw weight and warhead, is predicted to offer a range of about 4300 nm to 4600 nm.
Rocket Motor Case
It is contemplated that a rocket motor case suitable for implementation of an embodiment of the present invention may comprise a housing fabricated from an isotropic metallic or non-isotropic, non-metallic material exhibiting a sufficiently high strain and low Young's modulus properties to enable flexure without failure from a first transverse cross-section to a second, different transverse cross-section. In one non-limiting example, a rocket motor case may be fabricated to deform from an initial, elliptical transverse cross-sectional shape to a circular transverse cross-sectional shape. Characterized another way, the rocket motor case must exhibit sufficient elasticity and tensile strength to flex from the first to the second, different transverse cross-section without failure. In practice, such flexure may be initiated at a relatively low internal pressure within the rocket motor case, on the order of 200 psi, as generated by the ignited propellant. This is within acceptable limits for maintaining propellant-to-case bonding.
By way of non-limiting example, the housing may comprise a steel or a material comprising aluminum such as an aluminum alloy (including without limitation lithium-aluminum) and, in some embodiments, may be fabricated from a composite material. Case wall thickness may be, for example, 0.25 inch, to withstand a 1000 psi internal motor pressure during ignition, launch and flight. Suitable composite materials may include KEVLAR® fiber, glass fiber or carbon fiber disposed within an epoxy resin matrix or a polyurethane resin matrix. Further, it is contemplated that fiber placement may be effected on a mandrel, as is known to those of ordinary skill in the art, using a filament winding process effected by a multi-axis apparatus, as known to those of ordinary skill in the art. One example of a suitable apparatus is a commercially available multi-axis machine; suitable apparatuses for filament winding include the 5K Series, available from Entec Composite Machines, Inc. of Salt Lake City, Utah, and the Titan, available from McClean Anderson of Schofield, Wis.
The fore and aft ends of the rocket motor case must likewise be sufficiently flexible to accommodate flexure of the housing from a first to a second, different transverse cross-section without failure. In the case of deformation of a rocket motor case from an elliptical shape to a circular shape, it is contemplated that ellipsoidal domes, which remain ellipsoidal when the rocket motor case is pressurized, can accommodate anticipated stresses without strain to failure during such housing flexure. It is also contemplated that circular domes with a dome diameter the same as the minor axis of an elliptical case, which remain circular when the rocket motor case is pressurized, may be suitable for some applications. The ellipsoidal or circular domes retain their respective shapes through use of dome materials of sufficient strength and stiffness such that the internal pressure loads do not circularize these structures.
It is also contemplated that a dome may be fabricated from a composite material to enable a dome to deflect from an initial ellipse to a circular shape when the case is pressurized. The fiber layup results in a ply angle change when the rocket motor is pressurized. The ply angle change, along with the dome contour, enables the dome to deform at case pressurization. The dome contour has a bulge along the minor ellipse axis when unpressurized, and the contour along the major axis has a bulge when the case is pressurized. This provides a constant dome arc length at each azimuth of the case.
To accommodate stresses during circularization of the housing, which subjects the housing and the domes to both bending and tensile stresses, if a composite rocket motor case is employed, the fibers of at least some adjacent layers are permitted to shift, as the initial layup angles will change with flexure of the case. Therefore, spacers may be placed between selected layers of fibers and portions of layers at flexure stress points, and a high strain capability resin matrix system may be employed.
Propellant
As implied above, it is contemplated that a solid fuel, Class 1.1 propellant will be employed within the rocket motor case. In one basic form, the propellant may comprise an oxidizer, a fuel and an elastomeric binder binding the oxidizer and fuel into a solid propellant grain. One suitable propellant is a Nitride Ester Poly Ether (NEPE) propellant, of a type currently employed in ballistic missiles by the United States Navy. Another potentially suitable propellant is a Hydroxy-terminated Poly Butadiene (HTPB) propellant. Yet another potentially suitable propellant is Hydroxy-terminated Poly Ether, (HTPE).
Propellant strain under stress of burning and of housing (rocket motor case) flexure is of concern, and a capability of withstanding at least 90% strain without propellant fragmentation is desirable. It is contemplated that a slotted bore propellant may be employed, with attendant relatively high strains that are offset by a much higher propellant loading capability due to the initially small cross-sectional area of the bore. A slotted bore comprises a plurality of relatively thin slots extending radially from a center bore of the propellant grain at the aft end thereof. The number and size of the slots may be employed to control internal pressurization of the rocket motor case as a function of time or, stated another way, the pressure versus time curve. Use of slots cast into the propellant grain provides an initial, high thrust capability with a lower thrust thereafter.
Notably, the use of a slotted bore propellant grain provides maximum propellant loading in conjunction with uniform pressurized grain geometry. Stated another way, when the rocket motor case deforms, so does the propellant grain bonded to it, so the initial configuration must be capable of providing a uniform grain and bore geometry after circularization. Use of a slotted bore grain may, however, require the use of NEPE, which exhibits a 150% strain capability to failure, due to the high degree of flexure of the propellant grain as the bore opens responsive to circularization of the case. HTPE is limited to 70% strain to failure and HTPB is limited to 30% strain to failure and, so, may not be suitable for some initial bore configurations, such as a slotted bore.
The propellant grain is formed by a casting process within a rocket motor case by disposing a mold mandrel centrally within the case for defining a center bore with, optionally, longitudinally extending, radial slots within the propellant grain when formed, pouring the propellant into the rocket motor case, permitting the propellant to cure into the propellant grain, and pulling the mold mandrel. Suitable transverse configurations for the propellant center bore, as formable by the mold mandrel, include a 1.6 ratio ellipse, a 3.0 ratio ellipse and a “dog bone” shape with a narrow neck, or mid-section and enlarged ends. The dog bone shape is a center bore configuration designed to maximize propellant loading and minimize propellant strain.
FIG. 2A depicts a quarter-section of an elliptical rocket motor case 22 with a propellant grain 30 disposed therein and bonded thereto. Reference numeral 22 i indicates the initial, elliptical motor case profile, while reference numeral 22 p indicates the circular rocket motor case profile after internal pressurization of the rocket motor case 22 . Propellant grain 30 includes a longitudinal bore 32 having an initial elliptical transverse cross-section E 1.6 (1.6:1), which deforms to a substantially circular cross-section C responsive to internal pressure-induced deformation of propellant 30 bonded to rocket motor case 22 .
FIG. 2B depicts a quarter-section of another elliptical rocket motor case 22 ′ with a propellant grain 30 disposed therein and bonded thereto. Reference numeral 22 i ′ indicates the initial, elliptical motor case profile, while reference numeral 22 p ′ indicates the circular rocket motor case profile after internal pressurization of the rocket motor case 22 ′. Propellant grain 30 includes a longitudinal bore 32 having an initial elliptical transverse cross-section E 3.0 (3.0:1), which deforms to a substantially circular cross-section C responsive to internal pressure-induced deformation of propellant grain 30 bonded to rocket motor case 22 ′.
FIG. 2C depicts a quarter-section of an elliptical rocket motor case 22 ″ with a propellant grain 30 disposed therein and bonded thereto. Reference numeral 22 i ″ indicates the initial, elliptical motor case profile, while reference numeral 22 p ″ indicates the circular rocket motor case profile after internal pressurization of the rocket motor case 22 ″. Propellant grain 30 includes a longitudinal bore 32 having a transverse, elongated cross-section S, which may be characterized as a “dog bone” configuration due to its narrow neck or midsection and the enlarged ends thereof. The dog bone transverse cross-section S of bore 32 deforms to a substantially circular cross-section C responsive to internal pressure-induced deformation of propellant 30 bonded to rocket motor case 22 ″.
As is conventional, a liner is disposed between the rocker motor case interior and the propellant grain. However, due to the flexure of the rocket motor case from one cross-sectional shape to another (for example, elliptical to circular shape), bond stresses between the rocket motor case and the end domes and the propellant may be accommodated by disposing a liner flap linearly on the side of the case and on the domes, between the case and propellant and between the domes and propellant to minimize strain between domes or casing and propellant. Use of a liner flap provides a conventional means for decoupling the solid propellant grain from the side of the rocket motor case and from the domes, during deformation of the rocket motor case from one transverse cross-sectional shape to another, different shape. This provides stress relief for the propellant grain. The need for a liner flap at a given location is rocket motor configuration-dependent and is not required in all instances.
Ports
It is further contemplated that the rocket motor ports may be formed initially in an oval, an elliptical or other suitable non-circular shape, which will also circularize during launch. As another approach, circular ports may also be employed.
As is conventional, an igniter for the propellant may be disposed in a longitudinally forward port in the rocket motor case assembly in the forward dome and a nozzle is associated with an aft port in the assembly, in the aft dome. The nozzle port is larger than the ignition port. In another arrangement, which is also conventional, the igniter may be disposed at the same longitudinal end of the rocket motor case, and attached to the nozzle.
Operation
Referring to FIGS. 3A and 3B and 4 A and 4 B, when a rocket motor 20 having an elliptical case 22 and fore and aft domed ends 42 , 44 is disposed within a launch tube, the rocket motor 20 , when viewed from the side ( FIG. 3A ) has a low profile. When viewed from the end, aft end 44 with nozzle 46 protruding therefrom, the elliptical shape is clearly apparent. Nozzle 46 may be gimbaled, as is known in the art. When igniter 48 of rocket motor 20 (as noted previously, igniter 48 may be positioned proximate either end of a rocket motor 20 ) is initiated after the missile in which rocket motor 20 is completely ejected (as by a steam pulse) from a launch tube, elliptical case 22 of rocket motor 20 quickly deforms into a circular shape, as depicted in FIGS. 4A and 4B . The ignition transient may be extremely short, on the order of 15 milliseconds (ms). As is also apparent from FIG. 4A , fore and aft domed ends 42 , 44 may deform to accommodate the change in cross-sectional configuration of the rocket motor case 22 and, thus, contain the internal pressure generated from ignition and burning of propellant grain 30 to propel the missile with which rocket motor 20 is associated. As is also readily apparent from FIGS. 3A and 3B and as described previously with regard to FIGS. 2A through 2C , upon deformation of rocket motor case 22 under internal pressurization from propellant grain burn, bore 32 of propellant grain 30 opens from a collapsed configuration, such as an ellipse ( FIGS. 2A and 2B ) or a slot ( FIG. 2C ) into a circular shape. The propellant grain geometry and composition is designed to provide a desired internal motor pressure for a given propellant burn rate. Thus, nonuniform burning and potential fragmentation of propellant grain 30 or burn-through to rocket motor case 22 is prevented.
Multi-Stage Assembly
In some embodiments, the missile may comprise a multi-stage assembly. For example, two or more stages may be employed. In one multi-stage embodiment, the first and second stages may be formed in a non-circular, for example, elliptical, shape, but only the first stage is configured to circularize upon internal pressurization, for example, after exiting a launch tube. In another embodiment, both the first and second stages are configured to circularize upon internal pressurization responsive to ignition of their respective propellant grains.
As shown in FIGS. 5A and 5B , multi-stage missile 50 includes first and second stages 52 and 54 , and payload 56 , which may comprise, without limitation, a warhead and control electronics, as is conventional. The rocket motors for first and second stages 52 , 54 may be configured as previously described herein. As disposed in a launch tube, missile 50 exhibits an elliptical cross-sectional configuration ( FIG. 5A ). After ejection from a launch tube in a conventional manner and subsequent ignition of the rocket motor of first stage 52 , the rocket motor case of first stage 52 deforms into a circular cross-section ( FIGS. 6A and 6B ), while second stage 54 retains its initial elliptical shape. Mechanical connection between first and second stages 52 , 54 is effected through interstage section 58 during deformation of first stage 52 . A raceway (not shown), as is conventional, extends through interstage section 58 and provides a location for electrical wiring and conduits, which provide electrical connections to, and control for, the first stage 52 . After completion of the burn of first stage 52 , it is detached from second stage 54 in a conventional manner, and the propellant of second stage 54 ignited, upon which second stage 54 also deforms into a circular cross-sectional shape.
OTHER APPLICATIONS
Embodiments of the invention have been described herein with respect to use in conjunction with a partitioned launch tube carried, for example, by a submarine. However, it is contemplated that the present invention may have utility for any application wherein cross-sectional space for deployment of ordnance comprising a rocket motor is limited, or enhanced propellant grain volume is required or desired. Thus, land vehicles, as well as aerospace vehicles, may carry missiles having rocket motors configured in accordance with embodiments of the present invention.
While the invention is susceptible to various modifications and alternative forms, specific embodiments of which have been shown by way of non-limiting example in the drawings and have been described in detail herein, it should be understood that the invention is not limited to the particular forms disclosed. Rather, the invention includes all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the following appended claims and their legal equivalents.
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A missile component such as a rocket motor case, of an initial transverse cross-sectional shape flexible into another, different cross-section responsive to application of internal pressure from ignition of a propellant grain within the component. A missile launch assembly including at least one missile of a non-circular cross-section disposed within a segment of a partitioned circular launch tube. A multi-stage missile comprising at least a first stage and a second stage having rocket motor cases of non-circular transverse cross-section, the rocket motor case of at least one of the stages being deformable into another, different cross-section. A method of launching a missile including igniting a rocket motor of a missile component having a first cross-section, internally pressurizing the missile component substantially concurrently with motor ignition and flexing the component rocket motor into a second, different cross-sectional shape.
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CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This application is a Divisional of U.S. patent application Ser. No. 12/341,745, filed Dec. 22, 2008, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/042,371, filed Jan. 25, 2005, which claims priority to German Application No. 102004008569.2, filed Feb. 19, 2004, the complete disclosure of which are all incorporated herein by reference in their entirety.
FIELD
[0002] The present disclosure relates to an intrinsically-safe battery power supply for electrical equipment in underground mining or in other areas exposed to the danger of explosion or firedamp ignition, with at least one chargeable storage battery cell disposed in a battery housing.
BACKGROUND
[0003] In underground mining and in other areas exposed to the danger of explosion or firedamp ignition, there is a need for the supply, independently of a power supply network, of sufficient intrinsically-safe voltage to electrical equipment. In underground mining, for example, a chargeable battery power supply that uses Nickel Cadmium storage battery cells (NiCad accumulators) is utilized for support shield controllers, remote controllers, measuring equipment in poorly-accessible areas and other electrical equipment. The NiCad storage batteries have a low charge capacity and poor recharging characteristics since, due to the so-called “memory effect”, reduced charging capacity results if the NiCad storage battery was not completely discharged before being recharged. Due to the low charging capacity of NiCad accumulators, a great number of spare storage batteries is required in underground mining that have to be taken underground and temporarily stored there. Recharging of the NiCad storage batteries takes place exclusively on the surface, wherein the transportation of charged and discharged storage batteries (accumulators) also represents a logistical problem.
[0004] In underground mining, power supply sources may only be used if they are certified for use in areas that are exposed to the danger of explosion and correspond with the ignition protection legislation (e.g. ATEX, IEC, Eex etc.) that is applicable in the place of utilization. Here, each approval examination is associated with substantial cost. Hence for reasons of cost, it is hardly possible to have repeatedly modified storage battery cells re-certified for use in areas that are exposed to the danger of explosion.
[0005] For this reason, intrinsically-safe battery power supplies are often used in underground mining that do not technologically correspond to the latest state of the art and whose basic structure is disclosed in DE 30 15 751 C2 from 1980. The battery power supplies comprise NiCad storage battery cells that are disposed in a battery housing and electronics, that are not intrinsically-safe, cast in silicon rubber and embedded in an electronics housing, wherein the two housings are inserted together in a master housing. Alternatively, the storage battery cells can be cast together with a necessary protection circuit to comply with the ignition protection class that is applicable to gain certification. Repair of such battery power supplies, especially the replacement of storage batteries within such battery power supplies, is not possible without unacceptable cost.
[0006] Outside the field of underground mining, especially in the field of the communications and entertainment industries, lithium storage battery cells (lithium accumulators) are increasingly replacing the lead-containing batteries and NiCad storage battery cells that have previously been used. Fundamental efforts are therefore being made to be able to use lithium storage battery cells in other areas of technology, as can be seen, for example, in U.S. Pat. No. 5,376,475 that relates to chargeable, aqueous lithium hydrogen ion batteries. There are, however, substantial safety problems associated with the use of lithium storage battery cells regarding possible explosion of the storage battery cells, as can be seen in U.S. Pat. No. 5,376,475. Up to now, lithium storage battery cells have therefore not been used in underground mining and other areas that are exposed to the danger of explosion.
SUMMARY
[0007] One embodiment of the disclosure relates to an intrinsically safe battery power supply for electrical equipment in underground mining, and includes a battery housing having a first end with a first opening and a second end having a pressure-resistant second opening. The battery housing defines a first space. At least one storage battery cell is provided in the first space, and a lid is coupled to the battery housing near the first end providing access to the storage battery cell through the first opening. An envelope housing is coupled near the second end of the battery housing and has a charging socket and a consumption socket and defines a second space. A circuit board having intrinsically-safe circuits is provided in the second space, the circuit board electrically coupled to the storage battery cell through the pressure resistant second opening in the battery housing, and electrically coupled to the charging socket and the consumption socket on the envelope housing.
[0008] Another embodiment of the disclosure relates to a method of making an intrinsically safe battery power supply for electrical equipment in underground mining, where the method includes forming a battery housing having a first end with a first opening and a second end having a pressure-resistant second opening, the battery housing defining a first space therein; installing at least one storage battery cell disposed in the first space; coupling a lid to the battery housing proximate the first end to provide access to the storage battery cell through the first opening; coupling an envelope housing proximate the second end of the battery housing, the envelope housing having a charging socket and a consumption socket, and defining a second space therein; and installing a circuit board having intrinsically-safe circuits in the second space, the circuit board electrically coupled to the storage battery cell through the pressure resistant second opening in the battery housing, and electrically coupled to the charging socket and the consumption socket on the envelope housing.
[0009] Another embodiment of the disclosure relates to an intrinsically safe battery power supply for electrical equipment in underground mining, and includes a battery housing having a first end with a first opening and a second end having a pressure-resistant second opening, the battery housing defining a first space therein. At least one storage battery cell is provided in the first space and a first circuit board and a second circuit board are provided in the first space and coupled to the storage battery cell. A lid is coupled to the battery housing near the first end providing access to the storage battery cell through the first opening. An envelope housing is coupled near the second end of the battery housing, the envelope housing having a charging socket and a consumption socket, and defining a second space therein. A third circuit board having a protection circuit is provided in the second space, the third circuit board electrically coupled to the first circuit board through the pressure resistant second opening in the battery housing, and electrically coupled to the charging socket on the envelope housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a schematic illustration of a battery power supply for underground mining.
[0011] FIG. 2 is a schematic illustration of another battery power supply for underground mining.
DETAILED DESCRIPTION
[0012] According to one aspect, an intrinsically-safe battery power supply is provided for electrical equipment that can be used in underground mining and other areas that are exposed to the danger of explosion. The battery power supply can comprise storage battery cells that correspond with the latest technical state of development and for which a certification examination for the respective ignition protection class can be provided at minimum or no additional cost.
[0013] In one embodiment, at least one storage battery cell comprises a chargeable lithium storage battery cell (lithium accumulator) and a battery housing is configured to receive all lithium storage battery cells and to be explosion-proof and pressure resistant. According to the same or other aspect, an intrinsically-safe battery power supply comprises a battery housing that is configured to be pressure-resistant in such a way that all lithium storage battery cells disposed therein do not present a danger of explosion to their environment. Advantageously, only the pressure-resistant battery housing will be subjected to certification for the respective ignition protection class and the specified internal resistance against pressure need only be equivalent to an internal pressure that could possible be generated by an explosion of a lithium storage battery cell. Therefore, exchanging the actual lithium storage battery cells that are disposed in the certified, pressure-resistant battery housing does not cause the certification of the battery power supply to be invalidated. Due to the pressure-resistant configuration of the battery housing, it will now be possible to use lithium storage battery cells in underground mining. These are not susceptible to a noticeable “memory effect”, they have a substantially longer service life and with a substantially higher charging capacity, they also allow a significantly longer operating phase underground.
[0014] In one embodiment, the battery housing is pressure-resistant and gas-tight. The battery housing can be configured to be resistant to electrolyte. The aforementioned measures ensure that different storage battery technologies can be used for the lithium storage batteries without requiring renewed certification for the ignition protection class. This is especially advantageous in that smaller alterations to the cell structure, to the actual composition of the lithium storage battery cell and to the housing of the lithium storage battery cell do not require renewed ignition protection certification. New storage battery technology can therefore be integrated immediately into the intrinsically-safe battery power supply described herein.
[0015] The lithium storage battery cells can basically function in accordance with any possible storage battery or accumulator technology. In one embodiment, these can be lithium ion storage battery cells, lithium polymer storage battery cells or lithium storage battery cells with a fluid electrolyte. By way of example, reference is made to U.S. Pat. No. 5,376,475, herein incorporated by reference.
[0016] In order to guarantee electrically faultless functioning of lithium storage battery cells that are installed in pressure-resistant battery housings, independent of the technological structure of the lithium storage battery cells, an intrinsically-safe circuit can be disposed together with the lithium storage battery cells in the battery housing to limit overcurrent and/or overvoltage. By use of this circuit, the current and the voltage that is present at the contact terminals or contacts of the pressure-resistant battery housing can always be limited at the storage battery side to specified maximum electrical parameters, independent of the type of storage battery used.
[0017] In another embodiment, a charging circuit is also disposed in the battery housing in addition to the storage batteries. This allows the lithium storage battery cells to be charged via a charging plug that is connected to the underground, intrinsically-safe power supply network. In one embodiment, however, the battery housing is housed in a master housing or is provided with an enveloping or additional housing so that the intrinsically-safe battery power supply can be substantially constructed in accordance with a modular principle in that lithium storage battery cells, encapsulated so as to be explosion-proof, are disposed in the pressure-resistant battery housing and can be combined with all necessary or desired circuits in enveloping or master housings. In addition, with this embodiment the battery housing can comprise a lightweight, pressure-resistant material such as a light metal, in particular an aluminum sheet, while the master housing is formed from a suitable plastic.
[0018] The battery power supply can include a charging circuit, in particular an intrinsically-safe charging circuit being disposed within the master housing and outside of the battery housing. Here, it is advantageous if the charging circuit comprises control electronics to control the charging current and charging voltage for the lithium storage battery cells. With regard to the embodiment with the master housing, it is especially advantageous if a charging socket is attached to the master housing in which a charging plug that can be supplied with current from the underground power supply network can be inserted. The charging and current consumption sockets and/or operating switch and/or on/off switch can be attached to the master housing. With this embodiment, an external protection circuit can be disposed within the master housing and outside of the battery housing. The charging circuit and the protection circuit can then expediently be electrically incorporated between electrical contact points or connection lines on the pressure-resistant battery housing for the lithium storage battery cells and the charging and current consumption sockets.
[0019] In one embodiment, the lithium storage battery cells in the pressure-resistant battery housing together supply an internal operating voltage that is greater than the external, intrinsically safe operating voltage that can be applied to the electrical equipment. In order to obtain a sufficiently high voltage potential, several lithium storage battery cells can be disposed in series. In order to carry out charging with the intrinsically-safe underground power supply network in spite of the higher internal voltage potential without causing an excess voltage at the end consumer, the charging circuit and/or the current limiting circuit can be provided with direct current transformers to transform the voltage potentials to the corresponding higher internal operating voltage or lower external operating voltage. DC/DC transformers can be used for this transformation.
[0020] By way of example, FIG. 1 shows a battery power supply for underground mining, indicated by reference number 10 . In the illustrated exemplary embodiment, the battery power supply comprises a pressure resistant battery housing 1 and an enveloping or additional housing 2 . The battery housing 1 comprises a battery box 3 , in the receiving space 4 of which is disposed a lithium ion storage battery cell 5 , which can comprise several lithium ion storage battery cells connected in series. The battery box 3 is closed, for example by use of several bolted connections 7 indicated in the drawing, in a pressure resistant manner by a battery box lid 6 , through which the lithium ion storage battery cells can be installed in the receiving space 4 . The strengths of the surrounding walls of the battery box 3 and the lid 6 and the bolted connections 7 are configured in such a way that the battery housing 1 remains closed in a pressure proof and gas-tight manner even if an explosion with a specified maximum explosion pressure occurs in the interior space 4 . Here, the resistance to pressure of the battery housing 1 is adapted to the maximum burst pressure that is to be expected in the case of lithium storage battery cells 5 . The material of the battery housing 3 and the lid 6 , and the seals disposed between the two, is selected so that the battery housing 1 is gas-tight and resistant to those electrolytes that are used by chargeable lithium storage battery cells 5 for the movement and conduction of ions in order to provide an energy supply with the lithium storage battery cell or cells 5 for intrinsically safe equipment in underground mining.
[0021] In the illustrated exemplary embodiment, the enveloping housing 2 is bolted on a front side of the battery box 3 , opposite the lid 6 , by means of a bolted connection 8 . The battery box 3 and the lid 6 can be formed of a light metal, such as aluminum and the additional housing 2 can be formed of a suitable plastic. The embodiment example only serves to schematically explain the structure of the battery power supply, since in one embodiment (not shown) the battery box 3 and its lid 6 comprise a light metal such as aluminum, while the enveloping housing 2 comprises a suitable plastic and completely encloses the battery box and the lid 6 , so that the battery power supply 10 does not have any metallic surfaces. In the illustrated embodiment, on the other hand, if comprising an aluminum plate, the surface 3 ′ of the battery box 3 and the surface 6 ′ of the lid 6 could be provided with a plastic coating to achieve the same effect, though this is not required.
[0022] A multi-function circuit is shown schematically with a circuit board 9 in the enveloping housing 2 . All circuits on the circuit board 9 are preferably intrinsically safe. The circuit 9 is connected with the corresponding contact points on the lithium storage battery cell 5 via electrical connections 11 , 12 or connection lines and at least one sensor line 13 for a temperature sensor. The lines 11 , 12 , 13 penetrate an opening 14 in the base of the battery box 3 , wherein the opening 14 is configured as a pressure-resistant opening 15 and is closed in a suitable manner by means of installed parts adhesives and or stability supports. On the circuit board 9 there is both an intrinsically-safe charging circuit and an intrinsically-safe protection circuit disposed. The protection circuit is switched electrically between the lines 11 , 12 , 13 and a schematically-illustrated current consumption socket 16 that is certified for use in underground mining, to which a consumer can be connected. A charging socket 17 is also disposed in the enveloping housing 2 in addition to the current consumption socket 16 . The circuit board 9 contains a charging circuit that is integrated between the charging socket 17 and the connection lines 11 , 12 for the lithium storage battery cell 5 , so that the lithium storage battery cell of the intrinsically-safe battery power supply 10 can be recharged underground via a charging plug, not illustrated, that is connected to the underground power supply network. In particular, in FIG. 1 , charging circuit and overcurrent circuit, integrated in circuit 9 , are both electrically incorporated between electrical contact points 11 , 12 on the battery housing 3 for the lithium storage battery cells 5 and the charging and current consumption sockets 16 , 17 .
[0023] In one embodiment, the lithium storage battery cells 5 have a voltage potential at both connection terminals 11 , 12 that is greater than the voltage potential required for operation of controllers, extraction controllers, measuring equipment and other, portable, electrical equipment without the possibility of connection to the underground energy supply network. Both the charging and the protection circuit on the circuit board 9 then have direct current transformers (DC/DC transformers) to transform the internal operating voltage of the storage battery cells 5 to the external operating voltage required at the current consumption socket 16 or to transform the operating voltage at the charging socket 17 to the required higher operating voltage.
[0024] While not shown in FIG. 1 , an additional circuit to limit overcurrent and/or overvoltage can be disposed in the interior space 4 of the battery housing 1 in an alternate embodiment, via which the maximum value of the voltage supplied by the lithium storage battery cells 5 can be limited. In addition, the charging circuit can comprise control electronics to control the charging current and voltage for the lithium storage battery cells.
[0025] FIG. 2 shows an alternate battery power supply for underground mining indicated by reference number 100 . Except as indicated below, the battery power supply illustrated in FIG. 2 is generally similar to that illustrated in FIG. 1 and thus like reference numerals are used to identify like components. The battery supply of FIG. 2 comprises a pressure resistant battery housing 102 and an enveloping or additional housing 104 which can be formed the same or similar to battery housing 1 and additional housing 2 , respectively. The battery housing 102 comprises a battery box 3 , in the receiving space 4 of which is disposed a lithium ion storage battery cell 5 , which can comprise several lithium ion storage battery cells connected in series.
[0026] The battery box 3 , which can be formed from a material that is suitably resistant to electrolyte, is closed, for example by use of several bolted connections 7 , in a pressure resistant manner by a battery box lid 6 ′, through which the lithium ion storage battery cells can be installed in a receiving space 4 . The strength of the surrounding walls of the battery box 3 and the lid 6 and the bolted connection 7 are configured in such a way that the battery housing 102 remains closed in a pressure proof and gas-tight manner even if an explosion with a specified maximum explosion pressure occurs in the interior space 4 . Here, the resistance to pressure of the battery housing 102 is adapted to the maximum first pressure that is expected in the case of lithium storage battery cells 5 . The material of the battery housing and the lid 6 , and the seals disposed between the two, is selected so that the battery housing 102 is gas-tight and resistant to those electrolytes that are used by chargeable lithium storage battery cells 5 for the movement and conduction of ions in order to provide an energy supply with the lithium storage battery cell or cells 5 for intrinsically safe equipment in underground mining.
[0027] In the illustrated exemplary embodiment of FIG. 2 , the enveloping housing 104 is bolted on a front side of the battery box 3 , opposite the lid 6 , by means of a bolted connection 8 . Like the embodiment of FIG. 1 , the embodiment of FIG. 2 only serves to schematically explain the structure of the battery supply. If desired, surface 3 ′ of the battery box 3 and surface 6 ′ of the lid 6 could be provided with a plastic coating. The enveloping housing 102 can be formed from a suitable plastic. Also if desired, the battery box 3 and its lid 6 can comprise a light metal such as aluminum. Alternatively, though not shown, the enveloping housing 2 can completely enclose the battery box 3 and the lid 6 .
[0028] One or more circuits can be provided in the illustrated battery power supply 100 , and all such circuits can be intrinsically safe. In FIG. 2 , circuit board 9 is a protection circuit disposed within the additional housing 104 . In addition to the circuit board 9 , circuit or circuit board 106 can be a charging circuit and circuit or circuit board 108 can be an overcurrent circuit. In this arrangement, the intrinsically-safe circuits 106 , 108 are each disposed in the battery housing 3 together with the storage battery cells 5 . The overcurrent circuit 108 is particularly disposed in the battery housing 3 , specifically in the receiving space 4 , together with the storage battery cells 5 between the storage battery cells 5 and a consumption socket 16 . The charging circuit 106 is particularly disposed in the battery housing 3 , specifically in the receiving space 4 , together with the storage battery cells 5 between the storage battery cells 5 and a charging socket 17 , and more specifically between the storage battery cells 5 and the protection circuit 9 . The circuit 108 can limit overcurrent and/or overvoltage on the consumption socket 16 , whereas the charging circuit 106 can comprise control electronics to control the charging current and voltage for the storage battery cells 5 disposed in the battery housing 3 .
[0029] Accordingly, the charging circuit 106 of FIG. 2 differs from the circuit 9 of FIG. 1 , which can include a charging circuit, in that the charging circuit 106 is disposed within the battery housing 3 in the receiving space 4 , whereas the circuit 9 of FIG. 1 is disposed within the additional housing 2 and outside the battery housing 3 .
[0030] Numerous modifications will be apparent to the person skilled in the art which modifications should fall within the scope of protection of the appended claims. The illustrated embodiments are purely schematic and should not limit the scope of protection of the appended claims.
[0031] The exemplary embodiment has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the exemplary embodiment be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
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An intrinsically safe battery power supply for electrical equipment in underground mining includes a battery housing having a first end with a first opening and a second end having a pressure-resistant second opening. The battery housing defines a first space. At least one storage battery cell is provided in the first space, and a lid is coupled to the battery housing near the first end providing access to the storage battery cell through the first opening. An envelope housing is coupled near the second end of the battery housing and has a charging socket and a consumption socket and defines a second space. A circuit board having intrinsically-safe circuits is provided in the second space, the circuit board electrically coupled to the storage battery cell through the pressure resistant second opening in the battery housing, and electrically coupled to the charging socket and the consumption socket on the envelope housing.
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CROSS REFERENCE TO RELATED APPLICATION AND PRIORITY CLAIM
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 60/599,337 filed on Aug. 6, 2004.
TECHNICAL FIELD
[0002] The present invention relates to endlessing of polyurethane timing belts.
[0000] Industry Definitions:
[0000]
SPLICE: Methods for joining the ends of belting together without using a mechanical fastener.
ENDLESS: A belt made without a joint or splice.
FINGER SPLICE: Belt ends cut into mating fingers.
BACKGROUND
[0006] Timing belts are commonly used in industrial applications around the world. Timing belts are mostly used to radially synchronize two or more shafts or to position a single point on the belt between two pulleys. Timing belts have protrusions from their bottom surface called teeth. The distance between teeth is regular (referred to as pitch), and the belts are generally manufactured in various pitches for different applications. A timing belt pulley has the profile of the teeth machined around its circumference. It is the meshing of the teeth on the belt's inner surface with the corresponding teeth in a pulley that enables a timing belt to deliver a precise measured movement in a predetermined time span.
[0007] Timing belts are constructed primarily of two types of material: rubber and polyurethane. The compounds used in making rubber timing belts can vary from manufacturer to manufacturer. These belts are usually molded and cured in an autoclave and are produced endless. The size of the mold is the determining factor of how long and wide the rubber timing belt can be supplied to the end user. The second type of timing belt is made of polyurethane. Polyurethane timing belts [PTB] are extruded both endless and extruded flat and open-ended. They have internal tension members of steel or Kevlar to minimize the elongation or stretch of the timing belt, ensuring the proper function. The present invention deals with the open ended PTB, or an endless belt that has been cut to allow a splice.
[0008] Timing belts are made in a variety of pitches. A single pitch is the distance between one point of the tooth and the same point on the next tooth. Timing belts are made in metric pitches and standard pitches. The distance between the teeth is precise to a tolerance of +/−0.001 inches.
[0009] When a timing belt needs replacing due to wear or age, it can be installed endless or spliced. If the timing belt is installed endless, some disassembly of the equipment is necessary to install the belt. Disassembly of a machine can be very time-consuming, but can be averted by splicing the timing belt on the machine. If the PTB is installed using a splice, a press consisting of two heated platens with an internal bladder to develop pressure on the PTB has been utilized. In a majority of cases, the press units are too large to fit in the equipment, leaving disassembly as the only option.
BRIEF SUMMARY
[0010] The Timing Belt Rail Assembly [TBRA] allows a PTB to be spliced on a majority of applications without disassembly of the equipment. This is achieved by its small size; any span of belt between 6-8 inches long can be used to splice a PTB. The PTB is prepped with a finger splice and fitted into the TBRA. Once the PTB is fitted in the TBRA a small, self-clamping, hand-held hot press is fitted on the TBRA. The PTB is then left to splice for a variable period of five to fifteen minutes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] 1. FIG. 1 is an isometric view of the TBRA assembled with a PTB in accordance with a preferred embodiment of the present invention.
[0012] 2. FIG. 2 is an exploded view of the TBRA showing all the individual components in accordance with a preferred embodiment of the present invention.
[0013] 3. FIG. 3 is a right side view of the TBRA assembled with a PTB in accordance with a preferred embodiment of the present invention.
[0014] 4. FIG. 4 is an isometric view of a cutting tool for the base and capture plates of the TBRA in accordance with a preferred embodiment of the present invention.
[0015] 5. FIG. 5 is a top view of the cutting tool for the base and capture plates of the TBRA in accordance with a preferred embodiment of the present invention.
[0016] 6. FIG. 6 is a projected right side view of the cutting tool for the base and capture plates of the TBRA in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION
[0017] The components of the TBRA consist of a single base plate, two capture plates, and a single cover plate held together by both integral and external clamps. The base has a mating profile to the teeth of the PTB machined in its top surface; this enables the PTB to be spliced without compromising the geometry of the teeth. The base is made large enough to accommodate the spliced area of the PTB, the capture plates, and the necessary clamps. When assembled for use, the capture plates are positioned on each side of a PTB. The capture plates have a mating profile to the base plate; this acts as a seal and prevents melted polyurethane from escaping the sides of the TBRA. The capture plates are clamped to be base and, by virtue of their mating profile, can be adjusted laterally on the base thus making the TBRA adjustable to accept a variety of widths utilizing the same base plate. The integrated clamps are fixed to the capture plates by threaded fasteners. The shape of the clamp is that of a “C”. The upper extension of the clamp is fastened to the capture plates and the lower extension of clamp has a thumb knob to apply pressure to the bottom of the base. The final component of the TBRA is the cover plate. The width of the cover plate is determined by the width of the timing belt to be spliced. The cover plate is placed over the PTB and makes contact on each side with the capture plates; this prevents polyurethane from escaping the top of the TBRA.
[0018] Polyurethane reaches a melting point at 338° F. [170° C.]. The plastic materials used to make the TBRA are capable of withstanding continuous temperatures above 420° F. [216° C.]. There are a variety of plastics that could be used; currently the plastic of choice for the base and capture plates is 25% glass filled Teflon [25GFT]. The cover plate is made from a glass filled grade of phenolic called G7. The thickness of the base and capture plates are made roughly the same to allow uniform heat transfer to the PTB; this helps create a uniform splice. The specific heat transfer properties of the 25GFT and G7 are not known, but have been deemed acceptable through independent testing of the splice. An important property of the material used for the base and the capture plates is its machinability. The geometry of the teeth are exacting and require close tolerances. If the plastic material does not lend itself to machining, the resulting splice may be compromised in either strength or function.
[0019] To utilize the TBRA, the width and style of the PTB is determined. The PTB is supplied with a finger splice. The length of the finger splice on the ends of the timing belt determines the length of the TBRA. Currently two lengths of fingers are offered, 35 mm and 85 mm. A metric finger splice is utilized in both standard PTB as well as metric PTB. Accordingly, the two sizes of TBRA currently offered are 5.5″ over all length and 8.5″ over all length. Once the PTB is fitted in the TBRA, the cover plate is laid on the top of the PTB. The capture plates are placed against the edges of the PTB, making sure the capture plates and the cover plate are touching. The clamping screws are tightened, securing the capture plates. A small spring clamping device is used on each end of the assembly to secure the cover plate. The TBRA is now ready to be placed into a hand-held hot press that will achieve a temperature of at least 338° F. [170° C.]. There are many hand-held hot pressing units on the market that meet the requirements of the TBRA. The PTB remains in the assembly for a length of time that will result in proper splicing of the polyurethane. The elapsed time is usually no more than 15 minutes and can be as short a 5 minutes. This “dwell time” or length of time the assembly must remain in the hand held press is determined by several factors: Pitch, cover, backing, tension member and width. Once the PTB has reached the correct temperature for the correct time, the hot press is removed from the TBRA. The assembly must now cool. This step is expedited by placing the TBRA between two pieces of metal to draw the heat out. Once the assembly has cooled to the touch, the TBRA is disassembled in the reverse order it was assembled. The timing belt is now endless and ready to perform the function it was designed to do.
[0000] Referring now to the drawings:
[0020] FIG. 1 shows an isometric view of the TBRA in accordance with a preferred embodiment. The major components of the TBRA are a base 100 , capture plates 101 , cover plate 102 , PTB 103 , integral clamps 104 , and external clamps 105 . A hot press is applied to the top surface of the cover plate 102 A and the bottom of the base 100 A, between the integral clamp surfaces 104 A, 104 B. The cover plate 102 and the PTB 103 are clamped to the base 100 by the external clamps 105 . The external clamps 105 are applied near the ends of the base 100 B, 100 C. The integral clamps 104 are fastened to the capture plates by threaded fasteners 106 .
[0021] FIG. 2 shows an exploded view of the TBRA in accordance with a preferred embodiment. The components of the TBRA are a base 200 , capture plates 201 , cover plate 202 , PTB 203 , integral clamps 204 , external clamps 205 , thumb knob 206 , fasteners 207
[0022] FIG. 3 is a right side view of the TBRA assembled with a PTB in accordance with a preferred embodiment of the present invention. The external clamps have not been shown for clarity. The components seen are the base 300 , capture plates 301 , cover plate, 302 , PTB 303 , integral clamps 304 , and thumb knobs 305 . A preferred embodiment has the PTB 303 surrounded on each side by the capture plate surfaces 301 A, 3011 B and the cover plate 302 . The inside surfaces of the capture plates 301 A, 301 B should contact the edges of the cover plate 302 A, 302 B. This will prevent melted polyurethane from escaping during splicing. The thumb knobs 305 are threaded into the lower extension of the integral clamp 304 A and press against the bottom surface of the base 300 A to hold the capture plates 301 in position. A preferred embodiment will allow clearance between the edges of the base 300 B, 300 C and the inside edges of the integral clamps 304 B, 304 C. This clearance will allow the capture plates 301 to be positioned for varying widths of PTB 303 .
[0023] FIG. 4 is an isometric view of a cutting tool for the base and capture plates of the TBRA in accordance with a preferred embodiment of the present invention. The cutter is used to form the recess in the base to receive the teeth of the PTB. The key elements to the cutter are the main body 400 , relief faces 401 A, 401 B, the cutting edge 402 , and a clearance face 403 . The purpose of this view is to better understand the geometry of the cutter, as FIG. 5 and FIG. 6 may need further clarification. The cutter is formed by grinding a high-speed steel end mill blank into the shown geometry. The actual size of the cutter varies by the pitch of the PTB. The angle between the relief faces 401 A, 401 B must create a positive rake for proper chip formation during machining. The clearance face must be formed so that only the cutting edges 402 of the cutter contact the material.
[0024] FIG. 5 is a top view of the cutting tool for the base and capture plates of the TBRA in accordance with a preferred embodiment of the present invention. The key elements of the cutter are the cutting edges 500 , relief faces 501 , and clearance faces 502 . The preferred rotation of the cutter is counterclockwise as shown in this view.
[0025] FIG. 6 is a projected right side view and a projected top view of the cutting tool for the base and capture plates of the TBRA in accordance with a preferred embodiment of the present invention. The components of the cutter are the main body 600 , cutting edge 601 , relief face 602 , and clearance face 603 . The included angle between the two cutting edges must be equal to the included angle of the teeth of the PTB. The distance between the ends of the cutting edges 601 A, 601 B must be smaller than the top of a single tooth on the PTB. This is to allow the cutter to make incremental passes to form the recess in the base of the TBRA during machining. If the distance is too great, it will be difficult to control the geometry of the recess. The surface 604 on the bottom of the cutter must be flat and perpendicular to the central axis of the cutter.
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Timing belts are used in industry for precise motion control on a variety of applications. The Timing Belt Rail Assembly facilitates the joining of a polyurethane timing belt of all pitches to be made endless with a hand held heater. The invention makes the disassembly of machinery unnecessary in order to install a timing belt.
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BACKGROUND
[0001] In the course of producing oil and gas wells, typically after the well is drilled the well may be completed. In many instances, in order to complete the well the well may be cased. In certain instances the process of installing casing into the wellbore may begin with a wet shoe placed at the lowest section of the casing. The casing may then be run into the wellbore.
[0002] Once the casing is located at the appropriate position in the wellbore cement may be pumped into down the interior of the casing. The cement may both anchor the casing into position as well as isolate the hydrocarbon bearing formation from another section of the same formation or from other formations that are penetrated by the same wellbore. Once the cement reaches the wet shoe the cement flows out of the casing and then into the annular area outside of the casing between the casing and the wellbore. The cement is forced into the annular area generally until the annular area is filled with cement. Once an appropriate amount of cement is pumped into the casing a wiper plug may then be used push the cement out of the casing and to eliminate as much of the remaining cement as possible from the interior of the casing.
[0003] Generally the next step in completing the well, after the cement is allowed to set or cure is to form ports in the casing to allow the fluids from the formation into the interior of the casing. One of the current methods of forming the ports in the casing is known as plug and perforate. Typically, to plug and perforate a casing a perforation assembly consisting of a packer, a setting tool, and a perforation gun are run into the casing together on an electric line. The perforation gun will typically have several sections or perforating charges on the same gun so that the perforation gun may be discharged multiple times, five sections per gun is usual.
[0004] The perforation assembly is lowered into the wellbore until it is located appropriately. Usually the packer will be located below the section of a formation is to be completed. With the packer in place the setting tool is activated to lock the packer into position and to seal the casing below the packer from the wellbore above the packer. The perforation gun and setting tool are then disconnected from the packer and may be moved uphole some distance where the first section of the perforating gun is discharged to form ports in the casing and through the cement to the formation. The perforating gun and setting tool are again moved some distance up the casing and the perforating gun is again activated. The process may be repeated until all of the perforating gun's sections have been utilized.
[0005] Once the perforating gun's sections been expended the perforating gun and the setting tool are removed from the casing. The formation may then be fractured and otherwise treated with the packer that was placed into the casing isolating the casing below the packer and allowing only the portion of the formation that was accessed by the perforating gun to be fractured.
[0006] After fracturing the formation a new perforation assembly is run into the casing where the new packer is set above the section previously perforated and the entire process is repeated until the desired number of perforations has been completed and the associated portions of the formations have been fractured and treated.
[0007] Once the process is complete the packers must be removed, typically by milling or drilling out each packer. It is not unusual for there to be ten or more packers that must be removed before the well may be produced. Removing each packer by milling it out takes a substantial amount of rig time incurring substantial cost.
[0008] It is desirable to be able to remove the packers from the casing without milling out each packer.
SUMMARY
[0009] In an embodiment of the present invention an erodible packer that seals the wellbore to block flow from above the packer to below the packer.
[0010] A first embodiment may consist of an easily erodible packer containing components that allow the packer to be anchored in place while allowing pressure isolation in one direction. The easily erodible packer may allow flow from below the packer to pass through the packer once the well is put on production. The flow from the formation into the casing and to the surface may carry the packer out of the well as it erodes eventually leading to full bore production from the well.
[0011] A packer deployed in a wellbore comprising a mandrel having an interior throughbore and an exterior. A one way valve may be in the interior throughbore of the mandrel. The one way valve may be closed to prevent fluid from above the valve from passing the one way valve and may be opened to allow fluid from below the valve to pass the one way valve. The packer has a sealing element is attached to the exterior of the mandrel and the packer has an anchor where the anchor fixes the mandrel in place longitudinally.
[0012] The packer's one way valve may be a flapper valve or it could be a ball and seat type valve. In some instances the mandrel is at least partially an erodible material, a combination of at least the erodible material and a polymer, or even a combination of at least the erodible material and a fiber. The erodible material may be polyglycolic acid or hydrocarbon soluble.
[0013] A downhole assembly may be a packer having a mandrel, a one way valve, a sealing element, and an anchor. The mandrel may have an interior throughbore and an exterior. A one way valve may be in the interior throughbore of the mandrel. The one way valve may be closed to prevent fluid from above the valve from passing the one way valve and may be opened to allow fluid from below the valve to pass the one way valve. A sealing element may be attached to the exterior of the mandrel; and the anchor may fix the mandrel in place longitudinally. The packer's one way valve may be a flapper valve or it may be a ball and seat type of valve.
[0014] A downhole assembly may be a packer having a mandrel, a sealing element, and an anchor. The mandrel may have an interior throughbore and an exterior. The sealing element may be attached to the exterior of the mandrel. The anchor may fix the mandrel in place longitudinally. The packer may be at least partially constructed of an erodible material.
[0015] The packer may be at least partially a combination of the erodible material and a polymer, a combination of the erodible material and a fiber. In certain instances the fiber may be glass fiber or it may be carbon fiber. While the erodible material may be polyglycolic acid or it may be hydrocarbon soluble.
[0016] A method of completing a well may have the steps of pumping a bottom hole assembly into a well, setting a packer, perforating the well, pumping in at least a second bottomhole assembly, setting the second packer, and producing the well. The packer may have a mandrel having a throughbore and a one way valve may be located in the throughbore. The second packer has a second mandrel having a second throughbore with a second one way valve in the second throughbore.
[0017] In many instances the one way valve may be a flapper valve or it may be a ball and seat type of valve. The mandrel may be at least partially an erodible material, a combination of at least the erodible material and a polymer, or a combination of at least the erodible material and a fiber. The erodible material may be polyglycolic acid or it may be hydrocarbon soluble.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 depicts a previously set packer and perforated casing section and a newly pumped in second bottom hole assembly.
[0019] FIG. 2 depicts an erodible packer with a one way flapper valve.
[0020] FIG. 3 depicts an erodible packer with a one way ball and seat valve.
[0021] FIG. 4 depicts an erodible packer with a one way flapper valve as it erodes in the presence of wellbore fluid.
DETAILED DESCRIPTION
[0022] The description that follows includes exemplary apparatus, methods, techniques, and instruction sequences that embody techniques of the inventive subject matter. However, it is understood that the described embodiments may be practiced without these specific details.
[0023] FIG. 1 depicts a completion where a bottom hole assembly 40 has already been pumped into the casing 14 a composite packer 44 has been set and left in position near the bottom of the casing and the casing perforated by a multi-stage perforating gun 46 . As the initial bottom hole assembly 40 was pumped into the casing 14 the fluid in the casing ws pushed ahead of the bottom hole assembly 40 and out of the casing 14 and into the adjacent formation via the wet shoe 16 . A second bottom hole assembly 40 is shown on location in the casing 14 located just above the perforations 52 in the casing 14 .
[0024] A wellbore 10 has been drilled through one or more formation zones 12 . A casing 14 may be run into the wellbore 10 . Typically the casing is assembled on the surface 20 with a wet shoe 16 on the lower end of the casing 14 . The casing 14 and wet shoe 16 are then lowered into the wellbore 10 by the rig 30 until the desired depth is reached.
[0025] Upon reaching the desired depth cement 22 is pumped from the surface 20 through the interior of the casing 14 out of the wet shoe 16 and into the annular area 24 formed between the casing 14 and the wellbore 10 . Once a predetermined amount of cement 22 is pumped in the casing 14 at the surface 20 a wiper plug may be pumped down through the casing to push the entire amount of cement out of the casing 14 and into the annular area 24 . Upon setting or curing the cement 22 may anchor the casing 14 into position as well as longitudinally isolating the various formations 12 or portions of a formation 12 from other formations 12 or portions of formations 12 .
[0026] Typically after the casing has been cemented or the various zones otherwise isolated from one another a bottom hole assembly may be run into the casing 14 on e-line 50 . The bottom hole assembly 40 , typically has a composite plug 42 on the lower end, a setting tool 44 just above the composite plug 42 , and a multi-stage perforating gun 46 just above the setting tool 44 . Once the bottom hole assembly 40 is properly located power is supplied via the e-line 50 to the setting tool 44 to set the composite plug 42 thereby blocking the low of fluid past the composite plug 42 is either direction.
[0027] The setting tool 44 is then disconnected from the composite plug 42 so that the remainder of the bottom hole assembly 40 , the setting tool 44 and the multi-stage perforating gun 46 may be raised to the desired location and power supplied to the first stage of the multi-stage perforating gun 46 so that the first stage may be discharged to form ports 52 through the casing 14 . The multi-stage perforating gun 46 may then be moved some distance and the next stage of the multi-stage perforating gun 46 is discharged. The process may be repeated until all of the stages of the multi-stage perforating gun 46 have been discharged.
[0028] Typically, once all of the stages of the multi-stage perforating gun 46 have been discharged the setting tool 42 and the now discharged multi-stage perforating gun 46 are raised to the surface 20 . A new or rebuilt bottom hole assembly 40 may then be pumped back down through the casing 14 . As the bottom hole assembly 40 is pumped down the casing any fluid in the casing is pushed ahead of the bottom hole assembly 40 and out of the casing 14 through the ports 52 and into the formation 12 .
[0029] Usually upon completion of the perforating and fracturing operations the operator will pull the last multi-stage perforating gun 46 and the setting tool 44 out of the casing 14 . However, the well cannot be produced as in inflow of fluids including hydrocarbons from the formation 12 through ports 52 into the casing 14 and to the surface is blocked by the packers 42 that remain in well and block fluid flow in both directions. The operator will typically run back into the casing with a drill or mill and proceed to drill out each of the individual packers 42 that remain in the well and block fluid flow to the surface. Such an operation takes time and is correspondingly expensive.
[0030] FIG. 2 depicts the packer 42 described above is replaced with an embodiment of the current invention. The bottom hole assembly described above has a packer 100 . The packer 100 has a mandrel 102 . The mandrel 102 has an interior bore 150 extending the length of the mandrel 102 . In the interior bore 150 of the mandrel 102 is a one way valve 160 . The one way valve may be a flapper type valve having a seat 162 , a flapper 164 , and a bias device such as a spring 166 . Typically the spring 166 will bias the flapper 164 in a closed condition so that any fluid from above the one way valve 160 will not be allowed to pass through the interior 150 of the packer 100 once the packer 100 is set.
[0031] At the lower end of the mandrel 100 is an angled mule shoe 104 that may be secured to the mandrel 102 by pins 106 , in some instance the muleshoe 106 may be secured by adhesives or may be manufactured as integral to the mandrel 102 . Just above the muleshoe 106 is a slip 110 . The slip 110 has an angled inner surface 112 that cooperates with the angled exterior surface 114 of the slip wedge 116 . The slip 110 has gripping teeth 120 to bite into or otherwise grip the casing 14 . The gripping teeth 120 may be buttons as shown or may be integral to the slip 110 . The slip 110 may be a frangible solid or it could be made of a multitude of individual segments. Typically just above the slip wedge 116 is a sealing element 122 . The sealing element 122 may be an elastomer or any other material that may be relatively easily deformed. Above the sealing element 122 may be a second slip wedge 124 . The second sip wedge 124 has an angled exterior surface 126 that cooperates with the angled inner surface 130 of the second slip 132 . The second slip 132 has gripping teeth 134 to bite into or otherwise grip the casing 14 . The gripping teeth 134 may be buttons as shown or may be integral to the second slip 132 . The second slip 132 may be a frangible solid or it could be made of a multitude of individual segments. Above the second slip 132 may be a push ring 136 .
[0032] Each of the slip 110 , the slip wedge 116 , the sealing element 122 , the second slip wedge 124 , the second slip, and the push ring 136 are slidably mounted on the mandrel 102 .
[0033] When the packer 100 is in position the setting tool is secured to the mandrel 100 and applies force in the direction of arrow 140 to the push ring 136 . As the push ring 136 is forced downwards along the mandrel 102 each of the slidably mounted components are also moved longitudinally downwards. The second slip 132 is pushed towards the second slip wedge 124 so that the angled exterior surface 126 that cooperates with the angled inner surface 130 of the second slip 132 force the second slip 132 to move radially outwards causing the gripping teeth 134 to bite into the casing 14 . The slip 110 is pushed towards the slip wedge 116 so that the angled exterior surface 114 cooperates with the angled inner surface 112 of the slip 110 to force the slip 110 to move radially outwards causing the gripping teeth 120 to bite into the casing 14 . At the same time as the sealing element 122 is longitudinally compressed it is force to expand radially outwards to seal against both the mandrel 102 and the casing 14 sealing the exterior of the mandrel 102 to fluid flow in either direction.
[0034] While one embodiment of a packer, a double slip type, is depicted the invention may be utilized with any style packer.
[0035] FIG. 3 depicts a packer 200 having ball type one way valve 168 . A ball 170 may land on the seat 172 which may be attached to the mandrel by screws, pins, adhesives, manufactured as integral to the mandrel 102 or otherwise fixed in place in the interior 150 of the mandrel 102 by known means. A pin 174 or other restraining device will trap the ball 170 in the vicinity of the seat when fluid flows from the bottom of the packer 100 towards the top of the packer such as when the packer 100 is being run into the casing 14 or when the well is put on production and fluid flows from the formation through the ports 52 into the casing 14 and to the surface 20 . However when fluid flows from the surface 20 towards the bottom of the casing 14 such as when the formation is being fractured the ball 170 will land on the seat 172 to prevent any flow through the interior 150 of the mandrel 102 .
[0036] FIG. 4 depicts the packer 100 of FIG. 2 with a one way flapper type valve 160 as it erodes or degrades in the casing 14 . Typically after the formations 12 have been treated or fractured the well may be put on production utilizing a one way valve 160 to allow the formation fluid to flow through the ports 12 into the casing 14 , through the one way valve 160 in packer 100 and then to the surface 20 . While the one way valve 160 allows the well to be put on production quickly many operators prefer the full bore of the interior, diameter 202 of the casing 14 to be utilized when the well is on production in order to maximize fluid flow from the formation 12 to the surface 20 . Previously the operator would have had to mill or drill the packers 100 out of the casing 14 in order to allow full bore, diameter 202 , access to the formation 20 . In the embodiment depicted in FIG. 4 the packer may be at least partially constructed of an erodible material, such as ployglycolic acid, although any material that is biodegradable, erodes over time, or in the presence of an activating chemical or enzyme, such as a hydrocarbon could be utilized. In certain instances it may be desirable to at least partially construct a packer 100 using a mixture of the erodible material, such as polyglycolic acid, with another material that may not be erodible. For instance, polyglycolic acid could be mixed with polylactic acid or other polymers. Additionally, the erodible material could be utilized as a binder in combination with a fiber such as carbon fiber or glass fiber to create an erodible composite packer. The erodible material may not be utilized to create the entire packer but it could be used to create most portions of the packer depending upon the relative strength of the materials required. When mixed with the appropriate elastomer or polymer the erodible material could be used as the sealing element 122 . An extensive use of erodible material would allow the formation fluid 206 to erode the packer 100 as they pass through the packer 100 forming eddy currents 204 accelerating the erosion of the packer 100 and thereafter carry the pieces of the packer 100 to the surface 20 .
[0037] Bottom, lower, or downward denotes the end of the well or device away from the surface, including movement away from the surface. Top, upwards, raised, or higher denotes the end of the well or the device towards the surface, including movement towards the surface. While the embodiments are described with reference to various implementations and exploitations, it will be understood that these embodiments are illustrative and that the scope of the inventive subject matter is not limited to them. Many variations, modifications, additions and improvements are possible.
[0038] Plural instances may be provided for components, operations or structures described herein as a single instance. In general, structures and functionality presented as separate components in the exemplary configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements may fall within the scope of the inventive subject matter.
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In order to overcome the need to remove each packer after a plug and perforate operation in order to produce a well it is desirable to utilize an erodible packer that may allow one way flow. An erodible packer may be constructed of a material such as polyglycolic acid as a binder. The same packer may also allow one way flow past the packer, such as flow from the casing below the packer to the casing above the packer. The packer may erode upon the expiration of a predetermined period of time or upon exposure to an activating agent.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an improved sock construction and is more particularly concerned with a triple roll, layered top sock and process of producing the same.
2. Description of the Prior Art
In the past, socks have been knitted using circular knitting machines in which the top has been formed using elastic yarn. Socks have also been produced in which the top is rolled to provide more than one rolled increment. Such prior art construction, however, does not employ the knitting techniques of the present invention or provide a sock which can be readily and inexpensively produced, using a single cylinder circular knitting machine.
SUMMARY OF THE INVENTION
Briefly described, the product of the present invention includes a sock known as a "footee" which is produced automatically on a circular knitting machine. The top of the sock is the novel portion and the body is conventional The top has a triple roll and is layered, being formed by three successively individually rolled strip or top increments. The yarns for all increments have at least one stripe yarn and one elastic yarn.
The first stripe increment has a welt at its first edge border or boundary portion and has a 3×1 mock rib construction. It is rolled back against itself with its first edge joined to the outer surface of the neck of the body, at the boundary portion of the body and the third stripe increment, by a first lock stitch formed by one or several, courses of the first stripe yarn and the elastic yarn.
The second stripe increment is of 1×1 mock rib construction and has common border or boundary portions with the first stripe increment and the third strip increment. Its boundary portions are joined together by the second lock stitches. The common boundary portion of the second and third stripe increments is also joined to the body by third lock stitches of one or several courses of the second stripe yarn and the elastic yarn. The second stripe increment is thus rolled back against itself and stands upright.
The third stripe increment is also of 1×1 mock rib construction and has common boundaries with the second stripe increment and the body of the sock. It is rolled against itself and is longer than the second stripe increment. The second and third stripe increments extend upwardly and the third strip increment downwardly. The second stripe increment thus circumscribes the lower portion of the third stripe increment. The first stripe increment circumscribes the upper portion or neck of the body. The body itself is of conventional knit construction, and usually includes a heel and toe. The body can be a tube.
The process of the present invention for producing the sock described above is carried out on the circular knitting machine, as follows:
1. Four courses of welt forming a single end of elastic yarn are layed in, using alternate needles, and the first elastic yarn finger is lifted.
2. The first stripe yarn finger and the second elastic yarn then drop down.
3. Every needle is selected "up" for one round, for laying in one course of a first stripe yarn to form with the four courses of first elastic yarn, the welt.
4. Next a 3×1 mock rib is sewn for 28 courses of the first stripe yarn and elastic yarn, knitting on groups of three needles and holding down on each fourth needle. Thus, the fourth needles hold the two ends of yarn in the first course for later producing the first lock stitches.
5. The second stripe yarn finger drops down and the first stripe yarn finger is withdrawn. This produces a change over of yarn from the first color to the second color and a course or two which has five ends of yarn therein, forming a first common boundary.
6. At about the same time as the change over from the first stripe yarn to the second stripe yarn, the machine shifts from the 3×1 mock rib operation to a 1×1 mock rib operation in which the originally held down needles remain down and the middle needles of each group of three needles from the 3×1 operation is held down. Thus, the then held down needles hold on course of yarn at the vicinity of the first boundary for use later in forming the second lock stitches.
7. The 1×1 operation runs for 28 courses.
8. Next the machine goes back to a 3×1 mock rib operation for four courses, thereby releasing second lock stitch course for being knitted into the fabric being formed. This sews the boundaries of the second strip increment together.
9. Next a color change takes place in which the second stripe yarn finger is withdrawn and the third stripe yarn finger is dropped down. Also, the machine goes to a 1×1 mock rib operation and runs for 28 courses. The change from the 3×1 mock rib operation to the 1×1 mock rib operation causes a third lock stitch yarn to be held down.
10. After the 28 courses of the third stripe yarns, the body yarn fingers drop in and the third stripe yarn finger is withdrawn. The machine begins knitting with all needles and in a conventional way the body of the sock is produced. When the machine begins knitting with all needles, the first lock stitches (for joining the welt to the body) are produced and the third lock stitches for joining the second boundary to the body are also produced.
Accordingly, it is an object of the present invention to provide a triple roll, layered top for sock construction which is inexpensive to manufacture, durable in structure and unusual in appearance.
Another object of the present invention is to provide a sock construction which has a plurality of rolled striping yarn increments which are joined together during the knitting operation and will maintain their shape through repeated washings.
Another object of the present invention is to provide a triple roll layered top for sock construction which can be readily and easily produced using a conventional single cylinder circular knitting machine.
Another object of the present invention is to provide a "footee" sock which has a top which will yieldably hold the sock against being gathered into a shoe.
Other objects, features and advantages of the present invention will become apparent from the following description when taken in conjunction with the accompanying drawings wherein like characters of reference designate corresponding parts throughout the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a sock constructed in accordance with the present invention;
FIG. 2 is an exploded vertical sectional view showing the courses of the top portion and upper part of the body of the sock shown in FIG. 1; and
FIG. 3 is a fragmentary perspective view of the upper portion of the body and the top of the sock shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now in detail to the embodiment chosen for the purpose of illustrating the present invention, numeral 10 in FIG. 1, 2 and 3 denotes generally the top of a "footee" sock, constructed in accordance with the present invention. Numeral 11 denotes the body of the sock. This sock is knitted on a conventional single cylinder circular knitting machine known as a CONCEPT T.S., made by H. E. Crawford Company of Kearnersville, N. C. Such a machine has a four inch cylinder and 108 needles.
When the machine is set up to run, it has eight yarns supplied to it through its various yarn fingers. In a typical set up, a first elastic yarn finger carries a 6/17 elastic yarn for forming only the welt of sock. A stripe finger, however, carries a second 6/17 elastic yarn which will run throughout the entire top 10. Another stripe finger is threaded with two ends of 1/18 dyed orlon yarn which, for this explanation, is aqua in color. These yarns form the first or outer, downwardly protruding rolled, top or stripe increment 12.
Still another stripe finger is provided with two ends of 10/1 polyester yarn which is, for example, white. These yarns form the upwardly rolled, second or outer top or stripe increment 13 of the sock.
Still another stripe finger carries two ends of 1/18 dyed orlon yarns. These yarns form the upwardly rolled third or inner top or stripe increment 14. These yarns are, for example, blue.
The body yarns are carried by two additional fingers, one finger carrying a 2×70/24 nylon and the other finger carrying a 14/1 ring spun cotton.
In commencing construction of the sock on the circular knitting machine, the elastic welt finger first moves in and the cylinder of the machine makes four complete revolutions. This lays in the elastic yarn for the welt or edge 15.
Thereafter, the first or stripe yarn finger and the second elastic finger drop in. The second elastic yarn thus remains "dropped in" for the entire top so that the top is produced using a combination of two striping yarns and the elastic yarn.
With the first stripe yarn finger down and the elastic finger down, the machine goes into a 3×1 mock rib operation and runs this 3×1 mock rib operation for a predetermined number of courses. Usually, about 28 courses are preferred; however, from 15 to about 30 courses can conveniently be used, for producing a tubular knitted section which forms the first stripe or top increment 12. When running the 3×1 mock rib, I hold, with the down needles, the two ends of stripe yarn and the end of elastic yarn which are created in the first course of the first 3×1 mock rib stripe increment 12 and then continue to hold this one course with the down needles throughout the knitting of substantially the entire top 10.
After the knitting of the frist increment 12, I then shift into a 1×1 mock rib knitting operation and change the stripe yarns to a different color. For the purpose of this explanation, the second color can be considered as white. At the time of the changeover, I continue to hold the aqua strip yarns and their accompanying elastic yarn with each fourth down needle, thereby permitting these yarns, when released, later to be knitted as second lock stitches 16 at completion of top 10. When the sock is completed, the first top increment 12 is held by stitches 16 and loops downward over the neck 17 of the body 11 and the welt portion 15. The changeover for the first border or boundary 19 causes one to several courses to be knitted having the first color (aqua) and the second color (white) yarns therein.
I then commence a 1×1 mock rib knitting operation and continue this for a predetermined number of courses, usually about 28 courses or from about 10 to about 30 courses, still holding down on each fourth needle. The shift from 3×1 mock rib construction to 1×1 mock rib construction at border 19, causes each middle needle of the group of three needles forming the 3×1 mock rib to go down, thereby permitting these needles to hold one course of yarns adjacent to border 19. This held yarn is destined to form the second lock loops or stitches 20. Thus, I produce an upwardly extending, rolled 1×1 mock rib second increment 13 which is of less length than the third increment 14.
Next there is a second stripe color change produced by movement of the white stripe finger out and the blue stripe finger in. This produces border or boundary 21 between the second increment 13 and the third increment 14. At about that time the machine goes back to a 3×1 mock rib construction for only about four (from about 2 to about 5) courses permitting, thereby, the middle needles to release the held course for producing the second lock stitches 20, as the 3×1 construction begins. Upon completion of the four courses, the machine returns to the 1×1 mock rib construction. This causes the middle needles to again hold a course of yarn which will subsequently produce the third lock stitch 22.
The release the held down middle needles, as the border 21 is produced, stitches border 19 to border 21. This action forms the rolled upstanding second or outer stripe increment 13.
When this third stripe increment 14 approaches completion, there is a changeover of yarn to a conventional body yarns, the machine producing the conventional body 12 of the sock, using a flat knit and body yarns. At the changeover or border 23 between the third or blue stripe yarns and the body yarns, the elastic yarn is discontinued and the held yarns are released, because all needles begin knitting. This causes tacking, sewing or knitting the lock stitches 16 and 22 at the boundary or border 23 between the third increment 14 and the body 11, at essentially common points, which are at the junction or boundary 23 of the body and the top.
In the process of knitting, since the body 11 of the sock and the third stripe increment 14 are knitted last, the first and second rolled increments are outwardly of the body 11 and the third increment 14, respectively. Since the first and second increments 12 and 13 are attached at their border 19 along a generally common course, the first increment 12 naturally extends downwardly, as illustrated in FIGS. 1, 2 and 3, and the second increment 13 naturally stands upright, being disposed outwardly of the taller or longer third increment 14.
The reason that the third increment 14 is longer than the second increment 13 and stands well above increment 13 is that it has larger yarns therein and is of looser knit. A greater number of courses in increment 14 than in increment 12 can also produce this effect.
The resulting sock thus has its borders 19, 21 and 23 at an essentially common plane or location, being attached or held to each other by the lock stitches 16, 20 and 22.
It will be obvious to those skilled in the art that many variations may be made in the embodiment here chosen for the purpose of illustrating the present invention without departing from the scope thereof as defined by the appended claims.
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The top of the sock is formed of a welt and then three successive rolled stripe increments formed of stripe yarn of different colors and an elastic yarn which is laid in continuously throughout the length of the top. All three striped increments are connected at about a common location to the upper portion of the body by lock stitches.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a color image forming apparatus in which images for respective color components are superposed in succession on a recording medium.
2. Related Background Art
Recently color printers have come into commercial use and are being utilized to create various color presentations. Particularly color page printers are attracting attention because of their quietness, high quality printing, and high speed in printing.
Among such color page printers, light (or lower) beam printers form color images by effecting a first step of scanning a photosensitive member with a light beam in a main scanning direction, effecting a first development to the image on the photosensitive member transferring the developed image from the photosensitive member onto a recording medium such as a recording sheet, and effecting second, third and fourth steps in succession in similar manner but with different colors, thereby recording a full color image.
In in more detail such a following there will be described the recording method for a color image, with reference to FIGS. 8 and 9.
At first a photosensitive drum 1, rotated at a predetermined speed in a direction indicated by an arrow in FIG. 8, is charged to a predetermined voltage of a predetermined polarity by a charger 4. Then, recording sheets P are fed one by one by a feeding roller 14 from a sheet cassette 15. When the leading end of the sheet is detected by a detector 2, a laser beam L modulated by an image signal VDO is emitted from a semiconductor laser 5 toward a polygon mirror 7 for diversion into scanning motion, and is guided through a lens 8 and a mirror 9 onto the photosensitive drum 1. A signal (referred to as TOPSNS hereinafter) from a detector 2 positioned at an end of the light scanning path is supplied, as a vertical synchronization signal, to an image data generation apparatus 50 (FIG. 8). The image signal VDO is supplied in succession to the laser 5, utilizing a BD signal to be described later, as a horizontal synchronization signal, succeeding to the TOPSNS signal.
A beam detect signal (referred to as the BD signal), constituting the horizontal synchronization signal, is obtained by detecting the laser beam L with a detector 17. The polygon mirror 7 is rotated by a scanner motor 6, which is so controlled, according to a signal S2 from a motor control circuit 25 provided with a frequency divider for dividing the frequency of a signal S1 from a reference oscillator 20, as to rotate with a predetermined constant speed.
Thus, the photosensitive drum 1 is scan-exposed in synchronization with the BD signal, and a first electrostatic latent image is developed with a developing unit 3Y to form a first toner image of yellow color on the photosensitive drum 1.
On the other hand, immediately before the leading end of the recording sheet P, fed at the predetermined timing, reaches a transfer start position, a predetermined transfer bias voltage of a polarity opposite to that of the toner is applied to a main body 28 of a transfer drum 16, whereby the recording sheet P is electrostatically attracted onto a surface 27 of the transfer drum 16, simultaneously with the transfer of the first toner image onto the recording sheet P.
Then, the photosensitive drum 1 is scanned with the laser beam L to form a second electrostatic latent image, which is developed with a developing unit 3M to form a second toner image of magenta color on the photosensitive drum 1. The second toner image is transferred onto the recording sheet P, in alignment with the first toner image already transferred onto the recording sheet P. The leading end of the image of each color is defined by the TOPSNS signal.
Similarly, a third electrostatic latent image is formed and developed with a developing unit 3C to form a toner image of cyan color, which is transferred, in registration, onto the recording sheet P. Subsequently, a fourth electrostatic latent image is formed and developed with a developing unit 3BK to form a black toner image which is transferred, in registration, onto the recording sheet P.
In this manner, the VDO signal of a page is supplied in succession to the semiconductor laser 5 for each step. Also, the untransferred toner is scraped by a cleaner 10 after each transfer step.
Subsequently, when the leading end of the recording sheet P, carrying toner images of four colors thereon, approaches the position of a separating finger 12, the finger 12 moves closer and touches the surface 27 of the transfer drum 16, thereby separating the recording sheet P therefrom. The front end of the separating finger 12 continues to be in contact with the transfer drum 16 until the rear end of the recording sheet P is separated from the transfer drum 16, and returns to the original position thereafter. A charger 11 eliminates the charge accumulated on the recording sheet P, thereby facilitating the separation thereof by the separating finger 12 and reducing the discharge in the air at the separation. The separated recording sheet P is discharged, by fixing rollers 13, onto a discharge tray 29.
FIG. 10 is a timing chart showing the relation between the above-mentioned TOPSNS signal and the VDO signal, wherein A1 to A4 respectively indicate the printing operations of the first to fourth colors, and sections A1 to A4 constitute the color printing operations of a page.
FIG. 11 is a timing chart indicating the timing of the BD signal and the VDO signal for respective colors with respect to the TOPSNS signal.
It is noted, in the above-mentioned conventional example, that there is generated an aberration of almost one l between the BD signals of the first and second colors, as indicated by (t2-t1), though the BD signals thereof are mutually aberrated only by a little. The aberration in colors is generated within a cycle time T1 of the BD signal from the leading end A of the TOPSNS signal. The aberration between the first and third colors, and that between the first and fourth colors respectively correspond to (t3-t1) and (t4-t1). Also, the VDO signal from A1 is aberrated by T2 from the TOPSNS signal, and the VDO signals from A2 to A4 are aberrated from the TOPSNS signal by (t2+T2), (t3+T2) and (t4+T2), respectively.
The color image finally fixed on the recording sheet has to have precise registration of different colors, but is deteriorated in quality in case that a color is significantly aberrated as described above. In FIG. 5, C4 indicates the first line of a color showing aberration, while C5 indicates the first line of another color, and l indicates the pitch of lines.
In the color recording, the precision of alignment of respective colors is generally important, as described in "Imaging Part 2", pages 38 to 39 (published by Shashin Kogyo Shuppan Co.).
In the human visual system, the contrast sensitivity is highest in a spatial frequency region of 50-100 dpi, and the sensitivity becomes lower as the spatial frequency increases. However, the contrast sensitivity is still practically high even in a range of 400-800 dpi. In correlation of the precision of registration and the image quality, which is rated as 100 points for the perfect quality, a quality of 95 points requires a precision of about 90 μm while a quality of 100 points requires a precision of 75 μm or less. Thus, in an equipment of 300 dpi, since one dot corresponds to 85 μm, an aberration of one dot deteriorates the quality rating. Also, in an equipment of higher resolution, the aberration of one dot is detectable as described above, so that the print quality is deteriorated.
The tolerance in registration is far narrower in the characters and line images (which are binary, or black-and-white images than in multi-level images, and the aberration in the registration results not only in the deterioration of resolution but also in the aberration in the hue of fine lines, thus giving rise to deteriorated print quality.
Aberration in color can be prevented by improving the individual accuracy of the rotation control of the driving systems for the scanning optical system and the photosensitive and transfer drums. However it is almost impossible to improve the accuracy of the rotation control so as to eliminate aberration smaller than one l as described above.
SUMMARY OF THE INVENTION
The object of the present invention is to resolve the above-mentioned drawbacks in the prior art and to provide a color image forming apparatus capable of minimizing the color aberration.
The above-mentioned object can be attained, according to the present invention by a color image forming apparatus provided with light scanning means for deflecting a light beam, modulated according to image signals, by a rotary polygon mirror and guiding the light beam to an image carrying member to thereby scan the image carrying member, light detection means for detecting a light scanning start position of the light scanning means, a group of developing means for developing latent images, formed on the image carrying member by the scanning of the light scanning means, with plural developing materials, and transfer means for transferring visible images, obtained by the development with the group of developing means, onto a same transfer material after the respective developments, the color image forming apparatus comprising front end detection means for detecting the front end of the transfer material prior to the transfer by the transfer means, measuring means for measuring the aberration in synchronization between the detection of the front end of the transfer material by the front end detection means and the horizontal synchronization of the light scanning by the light detection means, and signal output means for generating a signal defining the front end of the image and the horizontal synchronization signal, after a predetermined time from the detection of the front end by the front end detection means, in response to the aberration in synchronization, measured by the measuring means.
According to the present invention, the front end of the transfer material is detected by the front end detection means, prior to the transfer by the transfer means, then the aberration between the detection of the front end of the transfer material by the front end detection means and the horizontal synchronization of light scanning detected by the light detection means is measured by the measuring means, and the signal defining the front end of the image and the horizontal synchronization signal are generated after a predetermined time from the detection of the front end by the front end detection means, according to the aberration in synchronization measured by the measuring means.
Other objects of the present invention, and the advantages and features thereof, will become fully apparent from the following detailed description to be taken in conjunction with the attached drawings, and also from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a first embodiment of the present invention;
FIG. 2 is a block diagram of a control unit in the first embodiment;
FIG. 3 is a timing chart showing the functions of the control unit of the first embodiment;
FIG. 4 is a schematic view showing aberration in colors in the present invention;
FIG. 5 is a schematic view showing aberration in colors in the conventional example;
FIG. 6 is a block diagram of the control unit in a second embodiment;
FIG. 7 is a timing chart showing the functions of the control unit of the second embodiment;
FIG. 8 is a view showing the configuration of a conventional light beam color printer;
FIG. 9 is a block diagram of a conventional configuration;
FIG. 10 is a timing chart showing the relation of the horizontal synchronization signal BD, vertical synchronization signal TOPSNS and image signal VDO in the conventional configuration; and
FIG. 11 is a timing chart showing the relation of the color aberration, horizontal synchronization signal BD, vertical synchronization signal TOPSNS and image signal VDO in the conventional configuration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, the present invention will be clarified in detail by preferred embodiments thereof shown in the attached drawings.
FIG. 1 shows a first embodiment of the present invention applied to a color light beam printer.
The mechanical configuration of the present embodiment is similar to that of FIG. 8, and the same components as those in FIG. 8 are represented by the same reference numerals or symbols. After receiving the TOPSNS signal from a detector 2 and after a predetermined time from the reception of the BD signal from a detector 17, an output control unit 30 sends to an image data generation apparatus 50 a VSYNC signal, defining the front end of the image. The image data generation apparatus 50 sends the VDO signal to a semiconductor laser 5, based on a BD signal succeeding to the VSYNC signal from the output control unit 30.
FIG. 2 shows the configuration of the output control unit 30. A delay device 31 delays the entered TOPSNS signal by a theoretical cycle time T1 of the BD signal, and then supplies the delayed TOPSNJ signal to an AND gate 37. A counter 32, constituting the measuring means of the present invention, counts the aberration from the entered TOPSNS signal to the first BD signal, for supply to an operation unit 33. The operation unit 33 calculates, from the entered aberration time (T1+t1), a value (T1/2+t1) for supply to a delay device 34. The calculation of the operation unit 33 is conducted only when a control circuit 35 identifies the printing operation for the first color. In the succeeding printing operations, the calculation is not conducted and the calculated value for the first color is retained. The delay device 34 delays the TOPSNS signal supplied to an AND gate 38, by the output value of the operation unit 33. The control circuit 35 discriminates whether the printing operation of the printer is for the first color or not, and respectively sends to an inverter 36 a LOW level signal in case of the first color or a HIGH level signal in case of the second or subsequent colors. The AND gate 37 sends the output of the delay device 31 to an OR gate 39 or intercepts the output, depending on the signal from the inverter 36. Also, the AND gate 38 sends the output of the delay device 34 to the OR gate 39 or intercepts the output, depending on the signal from the control circuit 35. The OR gate 39 releases the entered signal as the VSYNC signal. Thus, the inverter 36, AND gates 37, 38 and OR gate 39 select either the output of the delay device 31 or 34, depending on the output signal of the control circuit 35. The output of the delay device 31 or 34 is released as the VSYNC signal from the OR gate 39, respectively if the output of the control circuit 35 is LOW or HIGH.
FIG. 3 is a timing chart for explaining the function of the control unit 30 described above. The timing chart shows an example of the BD and VDO signals for respective colors with respect to the TOPSNS signals, when the TOPSNS signals for different colors are made to mutually coincide. In FIG. 3, A1, A2, A3 and A4 indicate the printing periods for respective colors as already described in the conventional example. In the following the functions of the control unit 30 will be described with reference to FIGS. 2 and 3.
In the period A1, the control circuit 35 identifies that the printer initiates the printing operation for the first color and sends the LOW level signal to the inverter 36 and the AND gate 38, whereby the OR gate 39 is prepared to send the output signal of the delay device 31 as the VSYNC signal to the image data generation apparatus 50. The delay device 31 releases the entered TOPSNS signal to the AND gate 37, with a delay corresponding to the cycle time of the BD signal, and the released signal is supplied, as the VSYNC signal, from the OR gate 39 to the image data generation apparatus 50. In response to the VSYNC signal, the image data generation apparatus 50 supplies the laser 5 with the VDO signal by a line at a time, in synchronization with the succeeding BD signals, starting after a predetermined timing (cycle time) T1.
On the other hand, in response to the entered TOPSNS signal, the counter 32 counts the aberration to the first succeeding BD signal, and sends the count to the operation unit 33. The operation unit 33 calculates, from the entered count (T1+t1)-T1/2, a value (T1/2+t1) for supply to the delay device 34. This operation is executed before the start of the printing operation for the second color. The calculation is not conducted in the subsequent printing operations, during which the calculated value for the first color is retained.
In the subsequent printing operation period A2 for the second color, the control circuit 35 identifies that the printer is not in the printing operation for the first color, and sends the HIGH level signal to the inverter 36 and the AND gate 38, whereby the OR gate 39 is prepared to release the output signal of the delay device 34, as the VSYNC signal, to the image data generation apparatus 50. The delay device 34 sends the entered TOPSNS signal to the AND gate 38, with a delay by a time (T1/2+t1) retained in the operation unit 33. The signal is supplied, as the VSYNC signal, from the OR gate 39 to the image data generation apparatus 50, which, in response, releases the VDO signal to the laser 5 by a line at a time, in synchronization with the succeeding BD signal starting after a predetermined time (T1/2+t1).
The subsequent operations will not be described as they are similar to the operation for the second color. Through the above-mentioned operations, the printing of the second or subsequent color is started within ±l/2, namely between B and C in FIG. 3, with respect to the print start position D for the first color. FIG. 4 illustrates that lines C2, C3 for the second and subsequent colors are printed within ±l/2, with respect to the line C1 for the first color. Thus, the aberration in each color is maintained within l/2.
In the foregoing description, it is assumed that T1+t1 is larger than T1, but, the color aberration is naturally retained within l/2 even in case that T1+t1 is smaller than T1, namely in case that tl is negative.
[Second Embodiment]
In the following there will be explained a second embodiment of the present invention, with reference to the attached drawings.
FIG. 6 is a block diagram showing the configuration of a control unit 30 in the second embodiment, and FIG. 7 is a timing chart showing the functions thereof.
In FIG. 6, a signal generator 40 generates, based on the entered TOPSNS signal, delayed signals TOP1, TOP2, TOP3 and TOP4 respectively delayed from the leading edge of the TOPSNS signal by T1/2, T1×3/4, T1 and T1×5/4 as shown in FIG. 7, for supply to switch means 47, which selects one of the delayed signal for supply to the image data generating apparatus 50.
A signal generator 41 generates, as shown in FIG. 7, signals CHK1, CHK2, CHK3 and CHK4 of a pulse duration of T1/4 respectively delayed from the leading edge of the TOPSNS signal by T1, T1×5/4, T1×6/4 and T1×7/4 for supply respectively to AND gates 43, 44, 45 and 46. The AND gates 43-46 produce logic products of the signals CHK1-CHK4 with the entered BD signal, for supply to the control unit 42.
The control unit 42, upon identifying the TOPSNS signal for the first color, discriminates the true output of the AND gates 43-46, and, for the VSYNC signal for the second or subsequent color, selects one of the signals TOP1-TOP4 as the VSYNC signal by the switch means 47 according to the following logic.
In the following there will be described the control of the control unit 42 in more detail.
Control unit 42 causes the switch means 47 to select the signal TOP1, TOP2, TOP3 or TOP4 respectively if the AND gate 43, 44, 45 or 46 is true.
Thus, the color aberration of the second or subsequent color is (T1/8±T1/2). Though the amount of aberration is somewhat larger than that of aberration in the first embodiment, the circuit configuration can be simplified as the counter is not used.
As described in the foregoing, the present invention can reduce the aberration in colors, thereby enabling color printing of extremely high quality.
The present invention is not limited to the foregoing embodiments, but is subjected to various modifications within the spirit and scope of the appended claims.
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A color image forming apparatus forms a color image by superposing images of plural colors in plane-sequential manner. In the color image forming apparatus, the amount of aberration between the detection signal for the recording medium for the first color and the horizontal synchronization signal is measured by a counter, and the start timing of image formation of the second and subsequent colors is controlled by a delay device, according to the measured amount of aberration.
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FIELD OF THE INVENTION
The present invention is directed generally to wagering systems, and more particularly to wagering systems that involve pari-mutuel wagering on the performance statistics of sports teams, individual sports players or athletes, or groups of such players.
BACKGROUND OF THE INVENTION
Although the current landscape provides some options for the sports gaming enthusiast to wager on sports, the options that exist are limited. There is a continuing need for a sports wagering game that has the following attributes:
High odds payout potential for every game, regardless of event type, game type, sport or length of game Allows a single correct choice to be a sufficient condition for payout eligibility, without, in addition, having to beat a house imposed handicap or spread No limitations with respect to choice of wagers or sport participants by the bettor Ability for the bettor to apply knowledge and skill Ability for the bettor to rely on random chance, if desired No requirement for the bettor to have an expert knowledge of a sport in order to be successful
Currently choices for wagering on sports are limited by the drawbacks associated with fixed odds wagering. The profitability of providing fixed odds wagering on a given group of outcomes depends on the ability of the casino or “house” to reliably split the betting money into offsetting groups corresponding to each outcome as weighted by the odds offered by the house. The house needs to do this “offsetting” because with fixed odds wagering each individual player is in effect betting against the house. Accordingly, the ability of the house to minimize the risk to its own capital is limited by its ability to split the betting pool into appropriately weighted and offsetting groups. As a result of these limitations of fixed odds wagering, sports betting casinos typically offer sports betting in relation to only a very limited range of choices and do not commonly offer high odds payouts.
With respect to football, for example, the house conventionally sets a point spread, which is a point handicap placed against the perceived stronger team, in an attempt to attract an equal quantity of wagering on each team. With other sports, odds are conventionally set that have a higher level of payout for the perceived weaker team. From time to time the house may adjust the point spreads and payout odds offered on future sports wagers in an attempt to maintain a balance between wagers on both sides. However, for a given sports wager, the terms or payout odds are conventionally fixed, so that the bettor is in effect wagering against the house. With conventional fixed odds sports wagering, in order to hedge its risks and maintain profitability, the house must be able to reliably divide the betting money into offsetting groups.
Such fixed odds methods lack the flexibility to efficiently accommodate a sports wagering game structure involving a larger number of players.
SUMMARY OF THE INVENTION
The present invention improves upon typical casino sport wagering in part by incorporating a pari-mutuel wagering system and method. This type of wagering, although applied in horse and dog racing, is uncommon in other contexts.
Pari-mutuel betting (sometimes referred to as “para-mutual” betting) is a more efficient betting system than fixed odds wagering in that the house does not have to rely on its ability to divide the betting pool in order to avoid risk to its own capital. The term pari-mutuel derives from the French expression meaning “a wager among ourselves”.
The basic principle of pari-mutuel wagering is that the winners share the total stakes wagered on an event minus a fixed commission for the house. Another way of stating this is that pari-mutuel wagering is a form of betting in which the losers' wagers (less a percentage for the house) are distributed among the winners. The bettors compete against each other rather than against the house. Although pari-mutuel wagering has been applied to horse race betting, it has not been applied to wagering on the performance of human sports players as proposed herein.
Unlike fixed odds wagering, with pari-mutuel wagering, the house does not win money directly from the players, but rather only collects a commission on wagers. While the house will not win money directly from the bettors in this type of system, it will not lose money to the bettors. The house inherently has a far lower level of risk to its capital with pari-mutuel wagering than with fixed odds wagering. This fact in turn means that, with pari-mutuel wagering, the house is much more able to offer a wide variety of betting options as well as betting options with high odds payouts than is the case with fixed odds wagering. The reason this is so is that the house's flexibility in providing betting options is not limited by the need to divide the betting stakes into offsetting groups in order to hedge the house's risk to capital.
By definition, pari-mutuel type wagering in essence is a system where all bettors are competing for a common pool of funds. Bettor skills are pitted against one another rather than against the house.
Wagering games according to the invention deal with the performance statistics of the human sport players and teams, which are much more plentiful in type and number than are game scores. These games and statistics often are related to the performance of a single player. By focusing on the performance of a single player, a bettor can more easily apply his or her skill and knowledge.
The invention offers the possibility of high odds payouts with every game offered, as opposed to the even money payouts typical of casino sports wagering. The bettor does not have to select a multi-event parlay in order to potentially receive a large odds payout. A single correct choice by the bettor may result in a high-odds payout without the handicap of a point spread. In addition, high odds payouts are possible, even if the selected player does not finish in first place, enhancing bettor enjoyment. Also, the bettor can place wagers on a wider number of finish positions, providing greater utility and enhancing the bettor's ability to apply knowledge and skill.
In addition, the invention does not rely on newspapers and other print media as the primary means to communicate how to interact with the game. In addition, the invention does not need a mechanical apparatus as the focus of bettor play and enjoyment. Rather the invention provides an automated, electronic design that allows improved communications accuracy of the individual games and estimated payouts, with rapid display of changing odds, player scratches, and the like. It is possible for bettors to enjoy the games enabled by the invention anywhere there is a communications connection.
According to one aspect of the present invention, a pari-mutuel wagering method is provided for enabling a plurality of bettors to place wagers on a human contest or sporting event. The method includes the steps of: offering to the bettors a plurality of wagering options pertaining to the human contest or sporting event; taking wagers from the bettors to create of pool of wagers on the human contest or sporting event; allocating a portion of the pool of wagers as commission to an operator; allocating the remainder of the pool of wagers as a common pari-mutuel fund for paying winning wagers; determining whether each wager is a winning wager; and paying each bettor an amount from the common pari-mutuel fund for each winning wager respectively made by the bettor.
According to another aspect of the present invention, a system for pari-mutuel sports wagering is provided. The system includes at least one processing element which is adapted to receive wagers on human sporting events, to calculate odds relating to the wagers based on a pari-mutuel wagering strategy, to determine whether the received wagers are winning wagers, and to determine a payout amount for the winning wagers based on the pari-mutuel wagering strategy; a plurality of linking elements which are communicatively coupled to the at least one processing element and which are adapted to allow for communication with the at least one processing element; and a plurality of input elements which are communicatively coupled to the plurality of linking elements and which allow bettors to communicate with the at least one processing element in order to place wagers.
The present invention enables these and many other benefits to be obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing a preferred embodiment of the present invention implemented over alternative communication pathways.
FIG. 2 is a block diagram showing a sample menu structure representing a telephone interface for use by a bettor according to another aspect of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides a pari-mutuel sports wagering system and method. In the preferred embodiment, the system and method are implemented on one or more computer systems and/or networks. Particularly, the system and method may be implemented using software, hardware, firmware or any combination thereof, as would be apparent to those of ordinary skill in the art, and the figures and examples below are not meant to limit the scope of the present invention. Moreover, where certain elements of the present invention can be partially or fully implemented using known components and processes, only those portions of such known components and processes that are necessary for an understanding of the present invention will be described, and detailed descriptions of other portions will be omitted so as not to obscure the invention.
The following description will include: (I) a discussion of the general architecture and function of a preferred embodiment of a pari-mutuel sports wagering system as shown in FIG. 1 ; (II) a detailed description of how a user may interact with the pari-mutuel sports wagering system; and (III) some examples of various embodiments of the sports wagering system corresponding to different types of sports betting.
I. General System Architecture and Function
FIG. 1 illustrates the general architecture of a sports wagering system 200 , which is made in accordance with a preferred embodiment of the present invention, and which is implemented over a computer network.
The wagering system host 10 is the core processing element in the wagering game system, and is adapted to handle wagering, gaming and bettor accounting functions. Host 10 may comprise a conventional microprocessor based system and/or server. The game/wager database 20 , account database 30 and performance statistics database 40 are communicatively coupled to host 10 , which selectively accesses, maintains, updates and modifies the databases in a conventional manner. It should be appreciated that the wagering system host 10 need not be a single piece of equipment. Host 10 may comprise a combination of disparate devices that operate under together under stored program control to perform the described functions.
In the preferred embodiment, the system 200 is communicatively and operatively connected to various networks, such as the Internet, the Public Switched Telephone Network (PSTN), and the Public Switched Mobile Network (PLMN).
The system host 10 is programmed to segregate individual bettors and accept, process and pay wagers. Host 10 is able to electronically process wagers and payouts for individual bettors. The host 10 is further able to register individual bettors, create individual accounts, receive funds and disburse funds.
The system host 10 may be configured to allow or disallow access to wagering functionality based on bettor location, allowing wagering activity only in proper and legally permissible locations. The wagering game operator may have the ability to select, remove and modify the locations where access to gaming functionality is allowed.
In the preferred embodiment, the system host 10 will further be adapted to handle electronic transfers of funds associated with the operation of the wagering game to include, but not limited to, wire transfers, electronic funds transfer, credit cards, debit cards and smart cards. In addition, the system 200 will preferably have sufficient manual capability in order to allow manual handling of financial transactions associated with the operation of the wagering game. For instance, the system 200 may be adapted to handle the manual transfer of funds including, but not limited to, cash, checks, money orders, traveler's checks, credit cards, debit cards and smart cards. The majority of the manual handling will be comprised of wagering processing tasks performed by casino sportsbook personnel.
A bettor can access, interface with and place bets on system 200 by use of conventional wireless and landline communications devices, such as wireless phones 80 , two-way pagers 90 , personal digital assistants (PDAs) 100 , internet-accessible computers 110 , voice-over-IP (VoIP) phones 120 , and conventional landline telephones 130 .
System 200 may further include human interfaces, such as a casino sportsbook operator 140 and a wagering system operator 160 , which the bettor can use to interface with the wagering system 200 . The casino sportsbook operator 140 will usually interface with the wagering game system via an internet-accessible computer 150 . The wagering system operator may interface with the wagering game system 200 via an internet-accessible computer 170 .
Wireless communications network 70 provides a means or channel by which communications between the wireless devices and the wagering game system is established and a means or channel by which the wireless communications devices interface with the wagering game system 200 .
System 200 further includes a conventional gateway 50 , which acts as a communications and security interface for the host 10 . System 200 may further include an IVR processor/voice portal 60 , which may comprise a device or combination of devices that handle certain wagering game voice interface functions from bettors that are using voice devices.
The components of the wagering game system can be categorized into three basic elements: (A) input elements, (B) linking elements, and (C) processing elements. These elements will be discussed in more detail below.
A. Input Elements
The input elements include various communication devices used by bettors to interact with wagering system 200 , such as wireless phones 80 (e.g., cellular, PCS, and the like), two-way pagers 90 , personal digital assistants (PDAs) 100 , internet-accessible computers 110 , voice-over-IP (VoIP) phones 120 , and conventional landline telephones 130 .
The bettor can interface indirectly via personal interaction with a casino sportsbook operator 140 . The casino sportsbook operator will interface directly with the wagering game system via one of the direct methods, usually via an internet-accessible computer 150 . Hence, computer 150 may also be classified as an input element.
The bettor can interface indirectly via interaction with a wagering system operator 160 . The wagering system operator 160 may be a casino sportsbook operator that interfaces with customers that communicate with the wagering game system via a voice network device such as a wireless phone, VoIP phone or landline telephone. This approach is a hybrid approach since the bettor uses electronic communications devices to verbally communicate with a live operator in order to interface with the wagering game system, with the wagering system operator interfacing with the wagering game system via one of the direct methods, usually via an internet-accessible computer 170 . In this manner, computer 170 also acts as an input element.
B. Linking Elements
In the preferred embodiment of the present invention, system 200 includes several linking elements including wireless network 70 , gateway 50 , and portal 60 . The linking elements may further include conventional wired networking elements, the internet, and other conventional communications conduits and elements. The linking elements are communicatively coupled to the input elements and the processing elements, and allow for communication between the input and processing elements, thereby allowing bettors to place wagers from the input elements onto the processing elements.
The wireless communications network 70 may comprise a number of base stations, base station controllers, mobile switches and gateways, and provides for communications between the wireless devices and the wagering game system established and the means or channel by which the wireless communications devices interface with the wagering game system.
The gateway 50 may comprise a conventional gateway device that acts as a communications interface and firewall. Gateway 50 ties the wagering game host and IVR processor/voice portal to the internet and internet-capable devices in a conventional manner.
The IVR processor/voice portal 60 may comprise a device or combination of devices that provides the interface functionality between certain input elements and the processing elements.
The IVR processor provides interface functionality to the processing elements for bettors using voice devices such as a wireless phone 80 , VoIP phone 120 or landline phone 130 . The IVR processor allows the bettor to interact with the wagering game by pressing numbers on a telephone keypad, which will allow the bettor to navigate the various menus and processes, place wagers, and perform other suitable interactions. The IVR processor allows direct interaction with the game from bettors using a wireless phone 80 , voice-over-IP (VoIP) phone 120 , or landline telephone 130 .
The voice portal provides interface functionality to the processing elements for bettors using certain internet-capable devices such as two-way pagers 90 or wireless PDAs 100 . The voice portal allows the bettor to interact with the wagering game by speaking directly into the telephone. The voice portal has the ability (e.g., through conventional speech recognition software) to recognize speech and take action based on that speech. Typical actions include such tasks as navigating selection menus, placing bets, entering passwords, and the like. The voice portal may also have the ability to recognize a particular bettor, through his or her speech, adding an additional layer of security.
C. Processing Elements
The wagering system host 10 is the core processing element in the wagering game system, handling wagering gaming and bettor accounting functions. The wagering system host handles the processing functions associated with bettors' wagering accounts. Such functions may include game accounting, wager accounting, odds determination, winning wager determination, payout determination, system security, access permission and performance statistics accounting.
The wagering system host 10 may be a single server, device, or a combination of devices that collectively perform the functions described. The wagering system host's processing ability can be scaled in order to meet bettor demand with respect to the described functions. In addition, the wagering system host's processing ability can be scaled in order to meet bettor demand with respect to a particular game or demand with respect to new games.
The game/wager database 20 is a database and storage element for the wagering game system. The game/wager database 20 is connected to, and functions in conjunction with, the wagering system host 10 , the account database 30 and the performance statistics database 40 .
The game/wager database 20 stores information regarding current and past games, such as type of game, game field, amounts wagered per game field participant per type of wager, calculated odds, game results and game payouts. The game/wager database 20 stores information regarding the wagers for current and past games, such as wager records by bettor account number, wager records by game and wager history by bettor account number. The account database 30 is a database and storage element for the wagering game system. The account database 30 is connected to, and functions in conjunction with, the wagering system host 10 , the game/wager database 20 and the performance statistics database 40 .
The account database 30 stores information regarding individual bettor accounts. The information stored includes financial transaction history, wager history, payout history, financial withholding information, financial reporting information and current wagers.
The performance statistics database 40 is a database and storage element for the wagering game system. The performance statistics database 40 is connected to, and functions in conjunction with, the wagering system host 10 , game/wager database 20 and the account database 30 .
The performance statistics database 40 stores information regarding the statistical performance of sport or event participants that are related to current and past games. The information stored would include all statistics that are pertinent to current and past games that are involved in the processing of ranking participants in order to determine wagers eligible for payout. Historical performance statistics covering periods of time before offering particular wagering games may be stored in order to provide additional information so bettors can make more informed decisions, enhancing the ability of bettors to employ knowledge and skill.
D. Interfacing with Wagering System 200
In operation, a bettor can interact with the wagering system 200 by interfacing either directly or indirectly with the wagering system host 10 . Having several independent interface methods and conduits allows bettors more convenience and availability, greater control of the gaming experience and greater enjoyment.
The bettor can interface indirectly with the system through personal interaction with a casino sportsbook operator 140 . The casino sportsbook operator may in turn interface directly with the wagering game system by way of one of the direct methods, usually through an internet-accessible computer 150 . In such case, the casino sportsbook operator will perform the wagering processing function as an intermediary between the bettor and the system 200 .
The bettor may also interface indirectly through interaction with a wagering system operator 160 . The wagering system operator is a casino sportsbook operator that interfaces with customers that communicate with the wagering game system via a voice network device such as a wireless phone, VoIP phone or landline telephone. This approach is a hybrid approach since the bettor uses electronic communications devices to verbally communicate with a live operator in order to interface with the wagering game system, with the wagering system operator interfacing with the wagering game system by a direct method, usually via an internet-accessible computer 170 . The wagering system operator will interface with the wagering game system as an intermediary between the bettor and the system.
E. Typical Wagers that can be placed through System 200
In the preferred embodiment, system 200 is adapted to allow bettors to wager on human sporting events. In this context, the term “human sporting events” should be understood to include sports or sporting events in which the primary participants (e.g., athletes) are humans, as opposed to horse and dog-racing, where the primary participants are animals. Examples of such human sporting events and wagers that may be established for such events are set forth below in Section III.
Wagers according to the present invention may typically fall into two broad categories. For a particular wagering game, a bettor can make the various wagers with regard to participants' (e.g., athletes') performance statistics with respect to the rest of the betting field. Various examples of the types of statistics and games that may be implemented through system 200 are set forth in Section III below. Based upon the participants' performance, the participants may be ranked by system 200 relative to other participants. Some examples of rankings are shown below:
Finish Position
Finish Position (Reference Name)
First Place
Win
Second Place
Place
Third Place
Show
Fourth Place
Clear
Next to Last Place
Lag
Last Place
End
This assumes that there are sufficient participants in the betting field that there is no possibility of a participant filling more than one payout position. For example, in a two participant field, the first place finisher is also the next to last place finisher. Not all of the shown wagers may be allowed, or more wagers may be allowed, based on field size and bettor interest. Note that the position wagers shown here are not the only wagers of this type possible. For example, position wagers for fifth place, six place, and the like, are possible, depending on field size and bettor interest.
For a particular wagering game, a bettor can make the following wagers with regard to two or more participants' performance statistics with respect to the rest of the betting field for that game:
Finish Position
Name of Wager (Reference Name)
First and Second Place
Exacta
First, Second and Third Place
Trifecta
First, Second, Third and Fourth Place
Perfecta
Last and Next to Last Place
Closing
Note that the position wagers shown here are not the only wagers of this type possible. For example, wagers on first place through fifth place, etc., are possible, depending on field size and bettor interest. Also, wagers predicting the finish positions of players in reverse order or wagers that payout based on the selected players all finishing in the selected range, or in any order, are possible.
F. Wagers Eligible for Payout
In general, to be eligible for payout, the bettor's wager must be correct. For example, an Exacta wager for Player A to win and Player B to place is eligible for payout only if Player A finishes in first and Player B in second. As opposed to contest games, the bettor does not have to prevail over other bettors; the bettor only has to be correct.
In some cases, similar to pari-mutuel wagering systems used in horse racing, a bettor's wager may be eligible for payout if the bettor's wager is partially correct. For example, a wager for Player A to show would be eligible for payout if the player finishes in first, second or third. The wager is not eligible for payout if the player finishes in a position less than third.
Example Wagers Eligible for Payout:
Type of Wager
Wager Eligible for Payout if
Win
Selected player finishes first
Place
Selected player finishes first or second
Show
Selected player finishes first, second or third
Clear
Selected player finishes first, second, third or fourth
Lag
Selected player finishes next to last or last
End
Selected player finishes last
Exacta
Selected players finish first and second in order
Trifecta
Selected players finish first, second and third in
order
Perfecta
Selected players finish first, second, third and fourth
in order
Closing
Selected players finish last and next to last in order
The types of wagers eligibility for payout can be expanded or reduced, depending on the field size and bettor interest.
G. Additional Host Functionality
Host 10 may further include some additional capabilities that are described below. The capabilities described herein are not to be assumed to be inclusive of the full capabilities or sole capabilities of the host 10 .
In the preferred embodiment, the host 10 may have the capability to uniquely identify each game and uniquely identify every betting pool corresponding to each game. The host 10 will automatically register the total amount wagered in each betting pool, register the total amount wagered on each entry in a game for each finish position (e.g., win, place) and combinational finish position offered (e.g., exacta, trifecta).
The host 10 may further have the ability to segregate a portion of the amounts wagered in the various betting pools as the house pool and calculate approximate odds and payouts based on the betting pools after taking the deduction of the house pool funds into account. The mathematical and statistical algorithms that are used to perform these calculations are well known in the art of pari-mutuel wagering.
The host 10 may further have the ability to generate sufficient records of individual wagers to properly handle the various means of placing wagers as well as properly handle the various means of paying winning wagers and refunds, if necessary.
The host 10 may periodically update or recalculate the total amounts in each pool, the amounts wagered on each entrant or combination and the resulting payouts as wagering progresses. The host 10 may further have the ability to export those calculations to various devices for the purpose of displaying the winning odds on each entrant or combination during the progress of wagering.
The host 10 may also be adapted to terminate acceptance of additional wagers at the start of the first event that is involved in the outcome of a particular game.
H. Sample Payout Calculation Methodologies
Although not inclusive, the host 10 may calculate payouts based upon various calculation methodologies specific to a particular finish position. For purposes of illustration, calculation methodologies for win, place and show are described. Payout odds are determined by the amounts in the betting pools after taking the house pool deduction into account. As previously described, the host 10 may periodically update or recalculate payouts as wagering progresses and may be adapted to export those payouts to various devices for display purposes.
In one embodiment, host 10 calculates the following payouts for the following wagers, which are described above in section F:
First Place (“Win”)
The payoff amount per dollar wagered (which will include the gross dollars wagered on the winner) for each gross dollar wagered on the winner is determined by dividing the win betting pool by the sum wagered on the winner.
Second Place (Place)
A. The payoff amount per dollar wagered on the winning entrant, which will include the gross dollar wagered upon the winning entrant to place, will be determined by:
dividing the amount wagered upon the winner to place into the sum of: the amount wagered upon the winner to place, plus one-half of the difference between the place betting pool and the combined sum wagered on the winning and placing entrants to place.
B. The payoff amount per dollar wagered on the placing (i.e., second place) entrant, which will include the gross dollar wagered upon the placing entrant to place, will be determined by:
dividing the gross amount wagered upon the placing entrant to place into the sum of: the gross amount wagered upon the placing entrant to place, plus one-half of the difference between the place betting pool and the combined sum wagered on the winning and placing entrants to place.
Third Place (Show)
A. The payoff amount per dollar wagered on the winning entrant, which will include the gross dollar wagered upon the winning entrant to show, will be determined by:
dividing the gross amount wagered upon such winning entrant to show into the sum of: the gross amount wagered on the winning entrant to show, plus one-third of the difference between the show betting pool and the combined sums wagered on the entrants which placed first, second, and third to show.
B. The payoff amount per dollar wagered on the second place entrant, which will include the gross dollar wagered upon the second place entrant to show, will be determined by:
dividing the gross amount wagered upon such entrant to show into the sum of: the gross amount wagered on the second place entrant to show, plus one-third of the difference between the show betting pool and the combined sums wagered on the entrants which placed first, second and third to show.
C. The payoff amount per dollar wagered, which will include the gross dollar wagered upon the third place entrant to show, will be determined by:
dividing the gross amount wagered upon such entrant to show into the sum of: the gross amount wagered on the third place entrant to show, plus one-third of the difference between the show betting pool and the combined sums wagered on the entrants which placed first, second and third to show.
Other mechanics and calculations of pari-mutuel wagering are well known to those skilled in the art and need not be discussed in further detail.
II. Interacting with the Wagering System
Bettors may interact with system 200 in order to perform the following tasks:
1. Establishing, withdrawing and replenishing accounts 2. Selecting particular sport or event wagering games 3. Examining performance statistics 4. Examining odds 5. Placing wagers 6. Collecting winning wagers and account funds
Depending upon the input element chosen by the bettor, some tasks may be performed in different manners. For example, when the bettor communicates directly with a sportsbook operator, the gaming process, from the bettor's viewpoint, will be predominantly manual, with the bettor communicating directly with a human operator. When the bettor uses an electronic input element, IP compliant signals, human voice or DTMF signals will be the predominant means of performing these tasks.
Internet protocol technology, m-commerce systems, e-commerce systems, voice response systems, voice recognition systems and voice portal systems are well known in the art and need not be described in detail here. These technologies and systems are used by the input, linking and processing elements previously described and additionally shown in FIG. 1 .
A. Selected Task Lists by Interface Method
For illustrative purposes, selected tasks that may be performed by a bettor in the various interface methods are listed below. These lists are non-exhaustive and should not be considered to imply that all of the tasks illustrated are needed to implement the new wagering game or that the items shown are the only items that may be used to implement the illustrated tasks.
1. In Person
If the bettor wishes to place wagers on a cash basis in person in a casino sportsbook, no account needs to be established. The bettor can place cash wagers on the games offered by the casino following the procedures established by the casino sportsbook.
Establishing a Wagering Account
The following steps may be performed in order for a bettor to establish a wagering account in person through a wagering system operator: a. Bettor provides personal identification information b. Wagering system operator sets up bettor's account c. Wagering system operator provides account information to bettor d. Bettor communicates amount of initial deposit e. Bettor provides initial deposit f. Wagering system operator provides deposit confirmation to bettor
Placing Wagers
The following steps may be performed when a bettor places wagers in person through a wagering system operator: a. Bettor communicates wager to wagering system operator b. Bettor communicates account information to wagering system operator c. Wagering system operator inputs account and wager information into wagering system d. Wagering system operator provides wager confirmation/receipt to bettor
Collecting Winning Wagers and Account Funds
The following steps may be performed for a bettor to collect wagers and account funds through a wagering system operator: a. Bettor provides account information to wagering system operator b. Bettor requests amount of funds to disburse c. Wagering system operator confirms that sufficient funds are available d. Wagering system deducts funds from bettor's account e. Wagering system operator pays requested funds to bettor
2. Telephone
Interacting with the game system via telephone may be accomplished by the bettor interfacing with a menu-based, interactive voice response system (IVR) with the option of speaking to a live operator. FIG. 2 is a block diagram of an example of a menu structure that may be implemented within the present invention as a telephone interface for use by bettors.
Establishing a Wagering Account
The following steps may be performed in order for a bettor to establish a wagering account over a telephone:
a. Bettor accesses wagering system telephone menu (e.g., block 210 ) b. Bettor selects account menu (e.g., block 212 ) c. Bettor provides personal identification information d. Wagering system sets up bettor's account (e.g., block 214 ) e. Wagering system provides account information to bettor f. Bettor communicates amount of initial deposit g. Bettor provides payment information h. Wagering system provides deposit confirmation to bettor
Placing Wagers
The following steps may be performed in order for a bettor to place wagers over a telephone:
a. Bettor accesses wagering system telephone menu (e.g., block 210 ) b. Bettor selects wagering menu (e.g., block 232 ) c. Bettor inputs account access information to wagering system d. Bettor selects sport of interest (e.g., block 234 , 242 or 244 ) e. Bettor selects type of game (e.g., block 236 , 238 , or 240 ) f. Bettor selects type of bet g. Bettor selects desired player or team h. Bettor inputs amount of bet i. Wagering system checks account balance to verify sufficient funds available j. If sufficient, wagering system deducts amount of bet from bettor's account k. Wagering system creates bet record in game/wager database and account database l. Wagering system provides wager confirmation to bettor
Collecting Winning Wagers and Account Funds
The following steps may be performed in order for a bettor to collect winning wagers and account funds over a telephone:
a. Bettor accesses wagering system telephone menu (e.g., block 210 ) b. Bettor selects account menu (e.g., block 212 ) c. Bettor selects distribution menu (e.g., block 218 ) d. Bettor inputs account access information to wagering system e. Bettor inputs amount of funds to disburse f. Wagering system checks account balance to verify sufficient funds available g. If sufficient, wagering system deducts amount of bet from bettor's account h. Wagering system processes disbursement i. Wagering system provides disbursement confirmation to bettor
The bettor may also receive statistics by selecting a statistics menu (block 220 ). The statistics menu will allow the bettor to obtain statistics related to various sports or sporting events by selecting a specific sport or event (e.g., block 220 , 228 or 230 ). Once a bettor has selected the event, the bettor can also obtain statistics relating to individual players and teams by selecting a player (e.g., block 224 ) or team (e.g., block 226 ).
As shown in FIG. 2 , blocks including an asterisk (*) require an account and password to access. Furthermore, all of the foregoing interactions can be performed through a live operator if the bettor selects the live operator menu (e.g., block 246 ).
3. Internet
Interacting with the game system via the internet may be accomplished by the bettor interfacing with the game system or casino website. The websites will have the appropriate links to allow the bettor to appropriately interface with the game system.
Establishing a Wagering Account
The following steps may be performed in order for a bettor to establish a wagering account over the internet:
a. Bettor accesses wagering game website b. Bettor selects account establishment link c. Bettor inputs personal identification information d. Wagering system sets up bettor's account e. Wagering system provides account information to bettor f. Bettor inputs amount of initial deposit and payment information g. Wagering system processes payment and credits bettor's account h. Wagering system provides deposit confirmation to bettor
Placing Wagers
The following steps may be performed in order for a bettor to place wagers over the internet:
a. Bettor accesses wagering game website b. Bettor selects wagering link c. Bettor inputs account access information into wagering system d. Bettor inputs wager information and wager amount into wagering system e. Wagering system checks account balance to verify sufficient funds available f. If sufficient, wagering system deducts amount of bet from bettor's account g. Wagering system creates bet record in game/wager database and account database h. Wagering system provides wager confirmation to bettor
Collecting Winning Wagers and Account Funds
The following steps may be performed for a bettor to collect winning wagers and account funds over the internet:
a. Bettor accesses wagering game website b. Bettor selects account link c. Bettor selects distribution menu d. Bettor inputs account access information into wagering system e. Bettor inputs amount of funds to disburse f. Wagering system checks account balance to verify sufficient funds available g. If sufficient, wagering system deducts amount of bet from bettor's account h. Wagering system processes disbursement i. Wagering system provides disbursement confirmation to bettor
III. Examples of Pari-Mutuel Wagering Applications
This section provides some examples of specific pari-mutuel wagering applications that can be performed by the present pari-mutuel wagering system and method.
A. National Football League
For purposes of illustration, an embodiment of a wagering game according to the present invention will be described with respect to the National Football League (NFL). Wagers may be placed on where an individual player's statistics will rank compared to the statistics of other players of the same position (e.g., 1 st , 2 nd , 3 rd ). The positions of highest interest are likely those offensive positions used as a basis for fantasy football games. These positions may include quarterback, running back, wide receiver, tight end and kicker. Each position may be the basis of a game, with time, player grouping, team and statistical methodology variants. Certain defensive player positions as well as team offensive and defensive statistics can also be the basis of a game.
Example: Quarterback Game
Time-Based Game (Baseline Game)
In this game, the bettor may place wagers on where a particular quarterback's statistics will rank (e.g., 1 st , 2 nd , 3 rd ) compared to other quarterbacks for a given period of time. Suitable time periods may include:
Pre-season (e.g., all pre-season games) Post-season (e.g., playoffs and Super Bowl) Weekly (e.g., each week during the 17 week NFL regular season) Monthly (e.g., games played in September, October, November and December) Quarter season (e.g., weeks 1-4, weeks 5-8, weeks 9-12 and weeks 13-17) Half season (e.g., weeks 1-8 and weeks 9-17)
Providing many choices of time-based games enhances bettor enjoyment because the bettor can participate during the pre-season, regular season and post-season to any extent desired. Providing many choices for time-based games also permits a more varied application of bettor knowledge and skill because the skilled bettor can use his or her knowledge of the strength of the NFL schedule, bye weeks, player injury, team standings, and the like, to adjust his or her betting strategy among the various games.
The field for each game could contain all quarterbacks, regardless of standing with respect to being on an active NFL roster or being a free agent. However, although all quarterbacks are eligible for wagers, for ease of playability, the house may designate a number of quarterbacks for discrete wagers, with all other quarterbacks as a single combined entity as “other.” In this manner, the bettor can place wagers on any quarterback.
All games may have a time-based component, whether the component is a single event, game, season, or the like.
Example: Player Grouping Game
In this game, the bettor can place wagers on where a particular grouping of quarterbacks' statistics will rank (e.g., 1 st , 2 nd , 3 rd ) compared to other groupings of quarterbacks for a given number of games. The player grouping-based game can be combined with the various time-based variants to create more games.
Assume, for example, that in the National Football League, there are 32 teams. Sixteen groups of two players could become the field for the game. Other pairing combinations could be used to create additional games. Another game could include all quarterbacks in a particular NFL division or NFL conference as a group.
There are variants with respect to determining the top performers. One variant ranks the groups by using the best performance statistics from the various groups' quarterbacks. Another variant combines the performance statistics of all the quarterbacks in a group before ranking the groups.
Example: Team-Based Game
In this game, the bettor can place wagers on where the combined quarterback statistics for an entire team will rank (e.g., 1 st , 2 nd , 3 rd ) compared to the combined quarterback statistics of the other teams for a given number of games. The team-based game can be combined with the various time-based variants to create more games.
This variant is different from the player grouping-based game because quarterback statistics contributed by all players is included. In other words, quarterback statistics accrued by non-quarterbacks is included in the ranking determination. This variant will have more utility when played with respect to rushing statistics and receiving statistics. It is more common to have quarterbacks and receivers run the ball and more common to have running backs catch the ball than it is to have running backs and receivers throw the ball.
Statistical Performance Measures and Variants
Statistical performance measures may be used to rank quarterbacks and groups to determine place of finish. Different performance criteria and weightings may be used to create different games, enhancing player utility, enjoyment and ability to apply knowledge and skill. As described, each game has a statistical performance scoring methodology in order to be able to rank performances.
For the quarterback games, a quarterback's statistical measures such as passing yards, pass completions, completion percentage, interceptions and touchdown passes can be used in various weightings to determine a score that can be ranked against others. In some games, other measures such as rushing yards and rushing touchdowns can be included.
For games involving the other positions, statistical measures applicable to those positions will be used. Rushing yards and touchdowns for running backs, receiving yards and touchdowns for wide receivers and tight ends, field goals and extra points for kickers, and the like, are measures that are typically associated with those positions and may be included as part of the scoring formulae for those positions.
Typical Quarterback Scoring Formulae
Example 1 - Pass performance:
Passing yards
0.04
points per yard
Passing touchdowns
3
points each
Pass completions
0.1
point each
Pass interceptions
minus 1
point each
Completion percentage
>= 65%
2 points
>= 60%
1 point
>= 50%
0 points
<= 50%
minus 2 points
Example 2 - Total performance:
Passing yards
0.04
points per yard
Rushing yards
0.1
point per yard
Passing touchdowns
3
points each
Rushing touchdowns
6
points each
Pass completions
0.1
point each
Pass interceptions
minus 1
point each
A sample quarterback performance is calculated under both given scoring criteria. Quarterback John Doe's performance for a game is as follows:
Pass attempts
30
Pass completions
18
Passing yards
220
Passing touchdowns
2
Pass interceptions
1
Rushing yards
15
Rushing touchdowns
1
Under the scoring formula shown in Example 1, John Doe's score would be (0.04*220)+(3*2)+(0.1*18)+(−1*1)+(1) or 16.6. Under the scoring formula shown in Example 2, John Doe's score would be (0.04*220)+(0.1*15)+(3*2)+(6*1)+(0.1*18)+(−1*1) or 23.1. This shows that depending on scoring methodology, there can be a wide variance of results based on the same performance. In these examples, one formula emphasizes throwing performance while the other recognizes the full contribution of the quarterback. The bettor can apply his or her skill and knowledge to place wagers on quarterbacks that reflect these differences, depending on the particular game the bettor is playing.
Sample Portfolio of Quarterback Games
To illustrate the large number of games available, providing greater bettor utility and enjoyment, a sample portfolio of the “Weekly” Quarterback Game is shown; by using what sample variants have been previously discussed as a guide. As stated earlier, the “Weekly” game is a game conducted each week during the NFL regular season. The time interval of interest is one week's slate of games. The games are:
1. Individual quarterback, Pass performance 2. Individual quarterback, Total performance 3. Combination quarterback, Best performance, Pass performance 4. Combination quarterback, Best performance, Total performance 5. Combination quarterback, Combination performance, Pass performance 6. Combination quarterback, Combination performance, Total performance 7. NFL Division combination quarterback, Best performance, Pass performance 8. NFL Division combination quarterback, Best performance, Total performance 9. NFL Division combination quarterback, Combination performance, Pass performance 10. NFL Division combination quarterback, Combination performance, Total performance 11. NFL Conference combination quarterback, Best performance, Pass performance 12. NFL Conference combination quarterback, Best performance, Total performance 13. NFL Conference combination quarterback, Combination performance, Pass performance 14. NFL Conference combination quarterback, Combination performance, Total performance 15. Team quarterback, Pass performance 16. Team quarterback, Total performance
Just with the limited number of variants mentioned, 16 different quarterback games may be simultaneously offered each week during the NFL regular season. This number may be higher if more combinations of quarterbacks and more scoring methodologies are offered.
By considering the other time-based and player position variants that are possible, the bettor who has a wagering interest in this sport will have an extremely large selection of games from which to choose during the entire NFL season, not just at the beginning. This gives the bettor a consistent, wide range of choices, providing the bettor greater utility, enjoyment and potential to apply his or her knowledge and skill.
Furthermore, unlike horse and dog pari-mutuel wagering, the present system does not rely on a single statistic (i.e., time) to determine the winners and losers. The only element considered in horse and dog pari-mutuel wagering is time (i.e., the horses and dogs are ranked solely by the time it takes for them to complete a race). With the present invention, a plurality of different statistics may be employed to determine rank. For example, a quarterback may pass for 300 yards and throw for 4 touchdowns, but that does not necessary correlate to whether the quarterback will win his or her game. The same is true for baseball players who hit multiple home runs in a game. This provides bettors and system operators a much wider variety of options and considerations when placing and crafting different types of wagers.
Moreover, with horse and dog pari-mutuel type wagering, all contestants (i.e., horses and dogs) are directly competing with each other at the same place and time. In the present system and method, the contestants (i.e., athletes) may or may not be playing against each other, may or may not be playing at the same location or time, and may be accumulating statistics that are not the sole and/or key drivers of individual or team success.
Other Sports as the Basis of Games
2. Other Football Leagues
Games can be created based on other professional football leagues, such as the Canadian Football League, NFL Europe and the Arena Football League. These leagues have calendar schedules that differ from the NFL's schedule, resulting in wagering games based on this sport to be possible approximately 10 months a year.
College football is also a candidate for games, with games based on Division I, II and III teams and players, conferences, bowl games and championship playoffs.
The same type of variants will apply as in the NFL-based games, with changes, as necessary, due to differing regular season schedules, pre-seasons, post-seasons, playoffs, bowl games and league structures.
3. Baseball
Several baseball leagues exist worldwide that may be of interest to bettors. Games can be created based on professional baseball leagues in the United States (major league and minor league), Japan, Korea and Mexico as well as college baseball in the United States.
Wagers can be placed on where an individual player's statistics will rank compared to the statistics of other players of the same position (e.g., 1 st , 2 nd , 3 rd ). The positions of highest interest are likely those positions used as a basis for fantasy baseball games. These positions typically fall into two types, pitcher and position player. Each type may be the basis of a game, with time, player grouping, team and statistical methodology variants.
For the pitcher position games, a pitcher's statistical measures such as wins, losses, saves, innings pitched, strikeouts, walks, hits, earned runs, earned run average, and errors can be used in various weightings to determine a score that can be ranked against others. For the position player games, a player's statistical measures such as hits, home runs, stolen bases, walks, batting average, runs batted in, runs scored and errors can be used in various weightings to determine a score that can be ranked against others.
4. Basketball
Several basketball leagues exist worldwide that can be of interest to bettors. Games can be created based on men's professional basketball leagues in the United States and Europe, women's professional basketball in the United States, plus men's and women's college basketball in the United States.
Wagers can be placed on where an individual player's statistics will rank compared to the statistics of other players (1 st , 2 nd , 3 rd , etc.). Although there are generally three positions in basketball (i.e., guard, forward and center), the statistics for those positions are similar. Therefore, all positions may be grouped together, with no separate games based on separate positions. The games may have, like the other games, time, player grouping, team and statistical methodology variants.
For the basketball-based games, a player's statistical measures such as minutes played, shooting percentage, free throw percentage, rebounds, assists, personal fouls and points can be used in various weightings to determine a score that can be ranked against others.
5. Hockey
Several hockey leagues exist worldwide that can be of interest to bettors. Games can be created based on professional hockey leagues in Canada and the United States (NHL and minor league), and Europe as well as college hockey in the United States.
Wagers can be placed on where an individual player's statistics will rank compared to the statistics of other players of the same type position (e.g., 1 st , 2 nd , 3 rd ). The positions of highest interest are likely those positions used as a basis for fantasy hockey games. These positions typically fall into two types, goaltender and position player. Each type will be the basis of a game, with time, player grouping, team and statistical methodology variants.
For the goaltender games, a goaltender's statistical measures such as goals allowed, saves, goals against average and save percentage can be used in various weightings to determine a score that can be ranked against others. For the position player games, a player's statistical measures such as goals, assists, penalty minutes and plus/minus may be used in various weightings to determine a score that can be ranked against others.
6. Other Sports and Events
Other human sporting events may have utility with respect to the game, depending on bettor interest. These sports include golf, tennis, soccer, vehicle (e.g., auto) racing, Australian football, rugby, cricket, jai-alai, hurling, lacrosse and others. The game types, statistics considered, scoring formulae, and the like, will vary depending on the sport.
Other human contests or events, such as political elections or beauty pageants, also have utility with respect to the present invention. For example, consider an American Presidential election. The presidential election process has a primary process and a general election process. Opportunities exist in both processes for wagering games based on the statistics of the participants.
Typical statistics for a candidate include popular votes and vote percentage. These statistics can be weighted in various fashions to create games. In addition, the candidates can be grouped to create additional games.
For example, assume that in a state primary there are twenty-four total candidates, representing six political parties. In addition to the basic game, where each candidate's statistics are ranked against each other, candidates can be grouped, as well as parties, to create additional games. In this case, a bettor may place wagers on an individual candidate, a party, or groups of parties.
With the wide range of sports and events that occur worldwide, a large number of games will be available throughout the year to provide bettor enjoyment and potential to apply the bettor's knowledge and skill.
According to the present invention, sports wagering is based on a pari-mutuel wagering system, which, by definition, is a system where all bettors are competing for a common pool of funds. Bettors compete against one another rather than against the house.
The scope of the present invention is meant to be that set forth in the claims that follow and equivalents thereof, and is not limited to any of the specific embodiments described above.
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This invention relates to sports and event wagering, particularly to a new sport and event wagering game and system. This game and supporting system allows pari-mutuel wagering with respect to new areas other than horse or dog racing, which will expand the sports wagering industry to encompass new areas of interest and enjoyment to bettors. Specifically, pari-mutuel wagering is enabled with respect to the performance statistics of individual sport or event participants, combinations of sport participants, combinations of event participants, and sport teams. This wagering game is supported by an electronic system, which allows interaction with the game via various communications methods, remotely or in-person, which can allow or restrict wagering activity based upon bettor location.
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FIELD OF THE INVENTION
[0001] This invention is related to the field of nanoweb structures and in particular nanowebs bonded to substrates by needlepunching.
BACKGROUND
[0002] “Nanowebs” are nonwoven webs comprising primarily, or even exclusively, fibers that have a number average diameter of less than one micrometer. Due to their extremely small pore dimensions and high surface area to volume ratio, nanowebs have been expected to be utilized as substrates for many applications such as, for example, hot gas filtration, high performance air filtration, waste water filtration, filtration membranes for biological contaminants, separators for batteries and other energy storage devices. However, one disadvantage of nanowebs for these applications is their poor mechanical integrity.
[0003] The number average diameter of nanofibers are less than 1000 nm and sometimes as small as 20 nm. In this dimension, even if they are layered and formed as thick membranes, the mechanical strength of the resulting structures is not sufficient to withstand macroscopic impacts for filtration applications such as normal liquid or gas flows passing through them or higher strength required for winding and handling during end use manufacturing steps. Nanowebs made, for example, by electrospinning or electroblowing also tend to have low solids volume content (solidity), typically less than about 20%.
[0004] Unsupported nanowebs also exhibit an excessive reduction in width (“necking”) when tension is applied in the machine direction (MD), such as when winding or post processing, for example, when applying surface treatments and laminating for some product applications. Where the material is unwound and wound again, varying tensions can result in different widths and potentially create variations in sheet properties. A material is desired which is more robust with regard to applied tension. Such a material can be obtained by bonding the nanoweb to a supporting web or scrim.
[0005] Needlepunching is a form of mechanical bonding of fibers which have normally been produced by a card or other equipment. The process converts the web of loose fibers into a coherent nonwoven fabric using a needle loom. Needle looms of various types are well known in the art and function to bond a nonwoven web by mechanically orienting fibers through the web. The process is called needling, or needlepunching. Barbed needles, set into a board, punch fiber into the batt and withdraw, leaving the fibers entangled. The needles are spaced in a nonaligned arrangement. By varying the strokes per minute, the number of needles per loom, the advance rate of the batt, the degree of penetration of the needles, and the weight of the batt, a wide range of fabric densities can be made. The needle loom can be operated to produce patterned or unpatterned products.
[0006] It is known in the art that needlepunching generally increases the air permeability of a nonwoven web. However, it is possible to use needlepunching to reduce the permeability of a nonwoven web under certain conditions. According to literature published by Foster Needle Co. on their website “Lower permeability is more difficult to achieve than higher permeability”. The key to lower permeability in a fabric, is to “close” the felt up as much as possible. The more the felt is “closed” (in other words, needled tightly and as densely as possible) the lower the permeability. Using this logic a person skilled in the art would expect a large amount of needle penetrations per square inch in order to just maintain the small pore structure of a web comprised of fibers with diameters of less than 1 micron.
SUMMARY OF THE INVENTION
[0007] A first embodiment of the present invention is a composite sheet comprising a first web of polymer fibers having a fiber diameter less than or equal to one micron bonded to a second web of fibers having a fiber diameter greater than one micron, wherein some of the fibers of the second web protrude through the first web of polymer fibers at a multiplicity of discontinuous regions.
[0008] Another embodiment of the present invention is a process for bonding a polymeric nanoweb to a felt to form a composite sheet, the process comprising providing the nanoweb and the felt in a face-to-face relationship and needlepunching the felt to the nanoweb, such that some fibers from the felt protrude through the nanoweb.
[0009] The composite sheets of the current invention may be useful for many filtration applications, such as, but not limited to, bag house filters, vacuum cleaner filters, air purification filters and other gas or liquid filtration applications.
DETAILED DESCRIPTION
[0010] The term “nonwoven” means a web including a multitude of randomly distributed fibers. The fibers generally can be bonded to each other or can be unbonded. The fibers can be staple fibers or continuous fibers. The fibers can comprise a single material or a multitude of materials, either as a combination of different fibers or as a combination of similar fibers each comprised of different materials.
[0011] “Calendering” is the process of passing a web through a nip between two rolls. The rolls may be in contact with each other, or there may be a fixed or variable gap between the roll surfaces. An “unpatterned” roll is one which has a smooth surface within the capability of the process used to manufacture them. There are no points or patterns to deliberately produce a pattern on the web as it passed through the nip, unlike a point bonding roll.
[0012] A “scrim” is a support layer and can be any planar structure with which the nanoweb can be bonded, adhered or laminated. Advantageously, the scrim layers useful in the present invention are spunbond nonwoven layers, but can be made from carded webs of nonwoven fibers and the like. Scrim layers useful for some filter applications require sufficient stiffness to hold pleats and dead folds.
[0013] The term “nanofiber” as used herein refers to fibers having a number average diameter or cross-section less than about 1000 nm, even less than about 800 nm, even between about 50 nm and 500 nm, and even between about 100 and 400 nm. The term diameter as used herein includes the greatest cross-section of non-round shapes. A nanoweb is defined as a web of fibers wherein the number average fiber diameter is less than 1 micron.
[0014] An as-spun nanoweb typically comprises primarily or exclusively nanofibers that are produced by electrospinning, such as classical electrospinning or electroblowing, and in certain circumstances, by meltblowing processes. Classical electrospinning is a technique illustrated in U.S. Pat. No. 4,127,706, incorporated herein in its entirety, wherein a high voltage is applied to a polymer in solution to create nanofibers and nonwoven mats. However, total throughput in electrospinning processes is too low to be commercially viable in forming heavier basis weight webs.
[0015] The “electroblowing” process is disclosed in World Patent Publication No. WO 03/080905, incorporated herein by reference in its entirety. A stream of polymeric solution comprising a polymer and a solvent is fed from a storage tank to a series of spinning nozzles within a spinneret, to which a high voltage is applied and through which the polymeric solution is discharged. Meanwhile, compressed air that is optionally heated is issued from air nozzles disposed in the sides of, or at the periphery of the spinning nozzle. The air is directed generally downward as a blowing gas stream which envelopes and forwards the newly issued polymeric solution and aids in the formation of the fibrous web, which is collected on a grounded porous collection belt above a vacuum chamber. The electroblowing process permits formation of commercial sizes and quantities of nanowebs at basis weights in excess of about 1 gsm, even as high as about 40 gsm or greater, in a relatively short time period.
[0016] Handling of nanowebs is extremely difficult due to their fragility. For this reason, it is sometimes advantageous to deposit the nanoweb directly onto a scrim to ease the handling of the nanoweb. Accordingly, the composite sheet of the present invention can further include a scrim upon which the nanoweb is supported prior to needlepunching with a felt or support scrim. The scrim can be arranged on the collector to collect and combine the nanofiber web spun on the scrim.
[0017] Examples of the scrim may include various nonwoven cloths, such as meltblown nonwoven cloth, needle-punched or spunlaced nonwoven cloth, woven cloth, knitted cloth, paper and the like, and can be used without limitations so long as a nanofiber layer can be added on the scrim.
[0018] Polymer materials that can be used in forming the nanowebs of the invention are not particularly limited and include both addition polymer and condensation polymer materials such as, polyacetal, polyamide, polyester, cellulose ether and ester, polyalkylene sulfide, polyarylene oxide, polysulfone, modified polysulfone polymers and mixtures thereof. Preferred materials that fall within these generic classes include, poly (vinylchloride), polymethylmethacrylate (and other acrylic resins), polystyrene, and copolymers thereof (including ABA type block copolymers), poly (vinylidene fluoride), poly (vinylidene chloride), polyvinylalcohol in various degrees of hydrolysis (87% to 99.5%) in crosslinked and non-crosslinked forms. Preferred addition polymers tend to be glassy (a T g greater than room temperature). This is the case for polyvinylchloride and polymethylmethacrylate, polystyrene polymer compositions or alloys or low in crystallinity for polyvinylidene fluoride and polyvinylalcohol materials. One preferred class of polyamide condensation polymers are nylon materials, such as nylon-6, nylon-6,6, nylon 6,6-6,10 and the like. When the polymer nanowebs of the invention are formed by meltblowing, any thermoplastic polymer capable of being meltblown into nanofibers can be used, including polyolefins, such as polyethylene, polypropylene and polybutylene, polyesters such as poly (ethylene terephthalate) and polyamides, such as the nylon polymers listed above.
[0019] It can be advantageous to add known-in-the-art plasticizers to the various polymers described above, in order to reduce the T g of the fiber polymer. Suitable plasticizers will depend upon the polymer to be electrospun or electroblown, as well as upon the particular end use into which the nanoweb will be introduced. For example, nylon polymers can be plasticized with water or even residual solvent remaining from the electrospinning or electroblowing process. Other known-in-the-art plasticizers which can be useful in lowering polymer T g include, but are not limited to aliphatic glycols, aromatic sulphanomides, phthalate esters, including but not limited to those selected from the group consisting of dibutyl phthalate, dihexl phthalate, dicyclohexyl phthalate, dioctyl phthalate, diisodecyl phthalate, diundecyl phthalate, didodecanyl phthalate, and diphenyl phthalate, and the like. The Handbook of Plasticizers , edited by George Wypych, 2004 Chemtec Publishing, incorporated herein by reference, discloses other polymer/plasticizer combinations which can be used in the present invention.
[0020] The as-spun nanoweb (and scrim) can be calendered prior to the needling process, in order to impart desired improvements in physical properties. In one embodiment of the invention the as-spun nanoweb is fed into the nip between two unpatterned rolls in which one roll is an unpatterned soft roll and one roll is an unpatterned hard roll, and the temperature of the hard roll is maintained at a temperature that is between the T g , herein defined as the temperature at which the polymer undergoes a transition from glassy to rubbery state, and the T om , herein defined as the temperature of the onset of melting of the polymer, such that the nanofibers of the nanoweb are at a plasticized state when passing through the calendar nip. Further, the nonwoven web can be stretched, optionally while being heated to a temperature that is between the T g and the lowest T om of the nanofiber polymer. The stretching can take place either before and/or after the web is fed to the calender rolls, and in either or both of the MD or CD.
[0021] In the needlepunching process of the invention, the diameter of the needles used in the needlepunching operation is at least 500 times the average diameter of the nanofibers of the nanowebs, and preferably at least 1000 times the average diameter of the nanofibers.
[0022] According to the present process, rather than the intermingling of coarse and fine fibers that is typical of prior art needled fiber structures, the coarse fibers are preferentially pushed through the nanoweb structure as though it were a solid sheet being perforated by the needles. The coarse fibers remain anchored in the coarse fiber web while having a portion of their length pushed through the nanoweb, such that they protrude beyond the surface of the nanoweb. The coarse fibers act to fill the holes left in the nanoweb by the needles, thereby reducing the impact of the needling on the pore structure of the fine fiber web. In this manner, the mean pore size of the bonded, composite sheet can be equal to or less than the mean pore size of the nanoweb and the coarse fiber web before needlepunching.
[0023] The amount of needling is not limited in the current invention. As in other needling operations, however, numerous factors must be optimized to provide the desired pore structure and amount of bonding between the nanoweb and the coarse fiber web. Those factors include the size and type of the needles, the amount of needling, the depth of needling, selection of appropriate coarse fibers in terms of fiber type, length, denier and web density.
[0024] The process of the present invention can further include heat treating of the composite sheet after needlepunching, such as by hot roll calendering or heating in an oven.
EXAMPLES
Example 1
[0025] A 24% solution of polyamide-6,6 in formic acid was spun by electroblowing as described in WO 03/080905 into a nanoweb. The number average fiber diameter was about 422 nm. Nominal basis weight of the nanoweb was 28.5 grams per square meter (gsm), and thickness was 60 microns.
[0026] Four layers of a backing material made of 80% Kevlar® fibers and 20% polyester fibers, with a basis weight of approximately 2 oz per square yard, were needled using a hand needle loom to the polyamide nanoweb at various levels of penetrations per square inch. Needles in the loom were 38 gauge (0.5 mm diameter) which is approximately 1185 times the average fiber diameter of the nanoweb. Measurements were then made of the pore structures using standard capillary flow porometry instruments manufactured by PMI (Porous Materials Incorporated)
[0027] Optional calendering was carried out by delivering the hand sheet laminate samples to a two steel roll calender nip. The calender was set to a gap of 0.045 inches, a nip pressure of 850 pounds per linear inch and was operated at room temperature.
[0000]
TABLE 1
Mean Flow
Minimum Pore
Maximum Pore
Pore
Material
Extent of
Diameter,
Diameter,
Diameter,
Sample
Construction
Needling
microns
Microns
microns
A
Single backing
none
4.321
246.5
46.5
layer
B
4 layers of
800 ppsi
1.3794
455.0
29.0
backing
C
4 layers backing + nanoweb
none
0.7708
14.5
5.9
D
4 layers backing + nanoweb
200 ppsi
0.6617
216.9
5.3
E
4 layers backing + nanoweb
800 ppsi
0.957
110.8
15.4
calendered.
[0028] It can be seen from Samples A and B, that the mean flow pore diameters of the materials made only from the coarser fibers are well above the diameters required to meet the conditions for the small pore layers of the desired composite sheet material. Simply stacking the coarse and fine fiber materials without needling (Sample C) establishes the pore structure contributed by the fine fiber material. Sample D illustrates that despite needling, the mean flow pore diameter of the unbonded composite can be essentially sustained. Note, however, that the maximum pore diameter is increased, although not to the extent that is found without the fine fiber material. Sample E illustrates that with additional needling, the mean flow pore diameter begins to increase. However, calendering of the material successfully limits the maximum pore diameter.
[0029] Example 1 illustrates that, contrary to expectations, needles sized for the coarse fiber material may be used to laminate a nanoweb to one or more webs of coarser fibers without negatively impacting the pore structure of the nanoweb and without requiring a dense amount of needling to close up the felt.
Example 2
[0030] Nanoweb with a basis weight of 10 gsm was spun from polyamide-6,6 using the process of World Patent Publication No. WO 03/080905 onto a 33.9 gsm polyester spun lace (Sontara®, Du Pont, Wilmington, Del.). Mean fiber diameter was 400 nm. The nanoweb was bonded to a 14 oz polyester partially consolidated felt (Southern Felt) by needlepunching.
[0031] Needlepunching entailed bringing the felt and the scrim+nanoweb structure together with the nanoweb on the inside against the felt and needlepunching from the felt side. Line speed was 1.5 meter/min. The number of penetrations per inch (PPI) was 383. The air permeability of the laminate was 32 cubic feet per minute (cfm).
Example 3
[0032] Nanoweb with a basis weight of 5 gsm was spun from polyamide-6,6 using the process of World Patent Publication No. WO 03/080905 onto a 33.9 gsm polyester spun lace (Sontara®). Mean fiber diameter was 400 nm. The nanoweb was bonded to a 14 oz partially consolidated polyester felt (Southern Felt) by needlepunching.
[0033] Needlepunching entailed bringing the felt and the scrim+nanoweb structure together with the nanoweb on the inside against the felt and needlepunching from the felt side. Line speed was 1.5 meter/min. The number of penetrations per inch (PPI) was 383. The air permeability of the laminate was 37 cubic feet per minute (cfm).
Example 4
[0034] Nanoweb with a basis weight of 10 gsm was spun from polyamide-6,6 using the process of World Patent Publication No. WO 03/080905 onto a 33.9 gsm polyester spun lace (Sontara®). Mean fiber diameter was 400 nm. The nanoweb was bonded to a 14 oz fully consolidated polyester felt (Southern Felt) by needlepunching.
[0035] Needlepunching entailed bringing the felt and the scrim+nanoweb structure together with the nanoweb on the inside against the felt and needlepunching from the felt side. Line speed was 1.5 meter/min. The number of penetrations per inch (PPI) was 383. The air permeability of the laminate was 26.1 cubic feet per minute (cfm).
|
A composite sheet of a nanoweb bonded to a second web, such that fibers from the second web protrude through the nanoweb in a multiplicity of discontinuous regions.
| 3
|
TECHNICAL FIELD
[0001] The present invention relates to a novel antitumor agent that targets a cell cycle-dependent protein and acts through a novel mechanism. The present invention also relates to a screening method including selecting an antitumor agent capable of suppressing cancer cell invasion and/or metastasis through a novel mechanism.
[0002] The present application claims priority from Japanese Patent Application No. 2012-015982, which is incorporated herein by reference.
BACKGROUND ART
[0003] When cells proliferate, the cells undergo a regular process called a cell cycle. That is, the cells proliferate by regularly repeating the cell cycle in the order of G1 phase (gap 1)→S phase (DNA synthesis)→G2 phase (gap 2)-M phase (mitosis)→G1 phase. One important point for progression of the cell cycle exists at the boundary between the G1 phase and the S phase. In mammalian cultured cells, this point is called a restriction point (R point). Once having passed the R point, the cell cycle is directed to progress. Then, the cells immediately enter the S phase, then enter the G2 phase and the Mphase, and return to the G1 phase. Under an environment in which the cells do not proliferate, the cells remain in the G1 phase without entering the S phase or exit the cell cycle to enter a special state called a resting phase (resting state; G0 phase), falling in a quiescent state. Depending on the environment in which the cells are placed, the cells may receive a signal for progression to differentiation, senescence, apoptosis, meiosis, or the like. It is currently considered that a branching point leading to these states also exists before the R point of the G1 phase.
[0004] Cancer cells are cells with abnormal cell cycle control that continue proliferating while ignoring a signal for division arrest derived from surrounding cells. The cancer cells proliferate unlimitedly and eventually cause dysfunction of organs throughout the body by invasion/metastasis, leading to the death of a patient. Hitherto, therapeutic drugs for a malignant tumor, such as a conventionally used anti-malignant tumor agent and a cancer cell-specific molecular-targeted drug for suppressing a proliferation signal, have each been one for impeding highly proliferative cancer cells. In addition, recently, there has also been available a therapy involving suppressing angiogenesis around a malignant tumor tissue to cut off a supply route to the malignant tumor tissue engaged in active metabolism. Specific examples thereof include: trastuzumab, which targets HER2 expressed in breast cancer; gefitinib, which inhibits a kinase activity of an epidermal growth factor receptor (EGFR); imatinib mesylate, which inhibits a tyrosine kinase activity of Bcr-Abl chimeric gene derived from a chromosomal translocation in chronic myelogenous leukemia (CML); tuximab, which recognizes CD20 antigen specific for B-cell lymphoma; rituximab, which contains a monoclonal antibody against cell surface antigen CD33 expressed in acute myelogenous leukemia cells (AML); erlotinib, which inhibits tyrosine kinase enzyme of EGFR; and bevacizumab, which is formed of a monoclonal antibody against a vascular endothelial growth factor (VEGF). There has also been used bortezomib, which inhibits a protein required for cell cycle progression to induce apoptosis. In addition, there has also been developed a therapy involving enhancing antitumor immunity of a host, such as a vaccine therapy.
[0005] Meanwhile, the most important process through which a malignant tumor leads to a fatal condition is invasion/metastasis. In particular, even when cells that have become cancerous are locally generated, there are various structural restrictions on the proliferation of the cells in vivo, and hence without sufficient invasive capacity, the cancer cells are locally confined and unable to proliferate/progress. The cancer cells separate from the primary tumor, and invade vessels by destroying the surrounding stroma and basement membrane through production of a protease. The cancer cells then migrate through the vessels to adhere to vascular endothelial cells of a target organ, and invade a tissue through blood vessels on the basis of a similar mechanism. It is considered that the cancer cells then proliferate at the site to form a metastasis focus. In recent years, it has been considered that a cell adhesion molecule and a special protease play large roles in the processes of the separation from the primary tumor and the adhesion to and invasion into the target tissue.
[0006] However, drugs for suppressing cancer cell invasion and/or metastasis cannot be said to be sufficient, and there is a demand for further development.
CITATION LIST
Non Patent Literature
[0000]
[NPL 1] NK4 (HGF-antagonist/angiogenesis inhibitor) in cancer biology and therapeutics. Matsumoto K, Nakamura T. (2003) Cancer Science 94: 321-327.
SUMMARY OF INVENTION
Technical Problem
[0008] An object of the present invention is to provide a novel antitumor agent that targets a cell cycle-dependent protein and acts through a novel mechanism. Another object of the present invention is to provide a screening method including selecting an antitumor agent capable of suppressing cancer cell invasion and/or metastasis through a novel mechanism.
Solution to Problem
[0009] The inventors of the present invention have made extensive studies in order to achieve the objects. As a result, the inventors have found for the first time that a certain Rho GTPase activating protein (RhoGAP, hereinafter sometimes referred to simply as “RhoGAP”) is regulated in a cell cycle-dependent manner and plays an important role in a process through which cancer cells acquire invasive capacity (cell mobility). The inventors have confirmed that the mobility and/or metastasis of cancer cells can be controlled by targeting the RhoGAP. Thus, the present invention has been completed.
[0010] That is, the present invention includes the following.
1. A novel antitumor agent, including as an active ingredient a substance capable of inhibiting a cell cycle-dependent Rho GTPase activating protein (RhoGAP). 2. A novel antitumor agent according to the above-mentioned item 1, in which the substance capable of inhibiting a cell cycle-dependent RhoGAP includes a substance capable of inhibiting ARHGAP11A. 3. A novel antitumor agent according to the above-mentioned item 2, in which the substance capable of inhibiting ARHGAP11A includes any one selected from: an antisense oligonucleotide against a gene encoding the ARHGAP11A; an oligonucleotide that induces RNA interference of the gene encoding the ARHGAP11A; and a low-molecular-weight compound and a natural polymer each capable of binding to a transcription product or translation product of the gene encoding the ARHGAP11A. 4. A novel antitumor agent according to the above-mentioned item 3, in which the substance capable of inhibiting ARHGAP11A includes the antisense oligonucleotide against the gene encoding the ARHGAP11A, the oligonucleotide including from 14 bases to 200 bases, the base sequence including at least one or more artificial nucleic acids. 5. A novel antitumor agent according to the above-mentioned item 4, in which the antisense oligonucleotide includes an oligonucleotide including a base sequence set forth in any one of the following items 1) to 13):
[0000]
1) ARHGAP-625-BNA-16:
(SEQ ID NO: 10)
5(L)T(L)5(L)aaatttgaa5(L)T(L)5(L)c;
2) ARHGAP-969-BNA-16:
(SEQ ID NO: 13)
T(L)5(L)5(L)gaaaaagcc5(L)T(L)T(L)c;
3) ARHGAP-1344-BNA-16:
(SEQ ID NO: 16)
T(L)5(L)T(L)tttcatgtc5(L)T(L)T(L)c;
4) ARHGAP-1447-BNA-16:
(SEQ ID NO: 17)
T(L)5(L)5(L)aggataaaaT(L)5(L)T(L)g;
5) ARHGAP-1748-BNA-16:
(SEQ ID NO: 19)
5(L)T(L)T(L)gatggactt5(L)5(L)T(L)t;
6) ARHGAP-1931-BNA-16:
(SEQ ID NO: 21)
T(L)T(L)T(L)gcctgcaatT(L)5(L)T(L)t;
7) ARHGAP-2032-BNA-16:
(SEQ ID NO: 22)
5(L)5(L)T(L)agattgaatT(L)T(L)5(L)a;
8) ARHGAPv1-3484-BNA-16:
(SEQ ID NO: 30)
T(L)T(L)5(L)gagggtaacT(L)5(L)5(L)a;
9) ARHGAPv2-2215-BNA-16:
(SEQ ID NO: 34)
5(L)T(L)5(L)taacagtagT(L)A(L)T(L)g;
10) ARHGAPv2-2285-BNA-16:
(SEQ ID NO: 35)
T(L)5(L)T(L)agaacagtaA(L)A(L)T(L)t;
11) ARHGAPv2-2306-BNA-16:
(SEQ ID NO: 36)
T(L)T(L)5(L)aaacatgaa5(L)T(L)T(L)t;
12) ARHGAPv2-2355-BNA-16:
(SEQ ID NO: 37)
T(L)5(L)5(L)caattgttgA(L)T(L)A(L)g;
and
13) ARHGAPv2-2404-BNA-16:
(SEQ ID NO: 38)
T(L)T(L)T(L)taacataagA(L)A(L)T(L)g,
where N(L) represents artificial nucleic acid BNA, 5 (L) represents L-mC (methylated artificial nucleic acid BNA), T(L) represents artificial nucleic acid thymidine, and A(L) represents artificial nucleic acid adenine.
6. A novel antitumor agent according to the above-mentioned item 3, in which the substance capable of inhibiting ARHGAP11A includes the oligonucleotide that induces RNA interference, the oligonucleotide including a base sequence set forth in the following item 14) or 15):
[0000]
14) ARHGAP11A #1 (TRCN0000047281):
(SEQ ID NO: 1)
CCGGCGGTATCAGTTCACATCGATACTCGAGTATCGATGTGAACTGATAC
CGTTTTTG;
or
15) ARHGAP11A #2 (TRCN0000047282):
(SEQ ID NO: 2)
CCGGCCTTCTATTACACCTCAAGAACTCGAGTTCTTGAGGTGTAATAGAA
GGTTTTTG.
7. A novel antitumor agent according to anyone of the above-mentioned items 1 to 6, in which the antitumor agent has a metastasis inhibitory action on a malignant tumor and/or an invasion inhibitory action on a malignant tumor.
8. A screening method for a novel antitumor agent, including selecting a substance capable of inhibiting a cell cycle-dependent RhoGAP.
9. A screening method according to the above-mentioned item 8, in which the cell cycle-dependent RhoGAP includes ARHGAP11A.
10. A screening method according to the above-mentioned item 9, including at least the following steps A) to D):
A) a step of culturing a candidate substance together with a cancer cell line, followed by measurement of an expression level of a gene encoding the ARHGAP11A in the cell; B) a step of measuring an expression level of the gene encoding the ARHGAP11A measured by the same technique as that of the step A) in a control system; C) a step of comparing the expression levels of the gene encoding the ARHGAP11A measured in the steps A) and B) to each other; and D) a step of selecting a candidate substance in a case where the expression level of the gene measured in the step A) is lower than the expression level of the gene measured in the step B).
11. A method of testing for a malignant tumor, including quantifying a cell cycle-dependent RhoGAP in a biological specimen.
12. A method of testing for a malignant tumor according to the above-mentioned item 11, in which the cell cycle-dependent RhoGAP includes ARHGAP11A.
13. A method of testing for a malignant tumor according to the above-mentioned item 11 or 12, in which the malignant tumor includes one or more kinds selected from colorectal cancer, pancreatic cancer, prostate cancer cells, breast cancer, head and neck cancer, melanoma, ovarian cancer, lung cancer, brain cancer, pancreatic cancer, hepatocellular carcinoma, renal cell carcinoma, and skin cancer.
14. A method of testing for a malignant tumor according to any one of the above-mentioned items 11 to 13, in which the testing for the malignant tumor includes a test for predicting a stage of progression and/or prognosis of cancer.
15. A metastasis inhibitor and/or invasion inhibitor for a malignant tumor, including a substance capable of inhibiting a cell cycle-dependent RhoGAP.
16. A metastasis inhibitor and/or invasion inhibitor for a malignant tumor according to the above-mentioned item 15, in which the substance capable of inhibiting a cell cycle-dependent RhoGAP includes a substance capable of inhibiting ARHGAP11A.
17. A metastasis inhibitor and/or invasion inhibitor for a malignant tumor according to the above-mentioned item 16, in which the substance capable of inhibiting ARHGAP11A includes any one selected from: an antisense oligonucleotide against a gene encoding the ARHGAP11A; an oligonucleotide that induces RNA interference of the gene encoding the ARHGAP11A; and a low-molecular-weight compound and a natural polymer each capable of binding to a transcription product or translation product of the gene encoding the ARHGAP11A.
18. A metastasis inhibitor and/or invasion inhibitor for a malignant tumor according to the above-mentioned item 17, in which the substance capable of inhibiting ARHGAP11A includes the antisense oligonucleotide against the gene encoding the ARHGAP11A, the oligonucleotide including from 14 bases to 200 bases, the base sequence including at least one or more artificial nucleic acids.
19. A metastasis inhibitor and/or invasion inhibitor for a malignant tumor according to the above-mentioned item 18, in which the antisense oligonucleotide includes an oligonucleotide including a base sequence set forth in any one of the following items 1) to 13):
[0000] 1) ARHGAP-625-BNA-16: (SEQ ID NO: 10) 5(L)T(L)5(L)aaatttgaa5(L)T(L)5(L)c; 2) ARHGAP-969-BNA-16: (SEQ ID NO: 13) T(L)5(L)5(L)gaaaaagcc5(L)T(L)T(L)c; 3) ARHGAP-1344-BNA-16: (SEQ ID NO: 16) T(L)5(L)T(L)tttcatgtc5(L)T(L)T(L)c; 4) ARHGAP-1447-BNA-16: (SEQ ID NO: 17) T(L)5(L)5(L)aggataaaaT(L)5(L)T(L)g; 5) ARHGAP-1748-BNA-16: (SEQ ID NO: 19) 5(L)T(L)T(L)gatggactt5(L)5(L)T(L)t; 6) ARHGAP-1931-BNA-16: (SEQ ID NO: 21) T(L)T(L)T(L)gcctgcaatT(L)5(L)T(L)t; 7) ARHGAP-2032-BNA-16: (SEQ ID NO: 22) 5(L)5(L)T(L)agattgaatT(L)T(L)5(L)a; 8) ARHGAPv1-3484-BNA-16: (SEQ ID NO: 30) T(L)T(L)5(L)gagggtaacT(L)5(L)5(L)a; 9) ARHGAPv2-2215-BNA-16: (SEQ ID NO: 34) 5(L)T(L)5(L)taacagtagT(L)A(L)T(L)g; 10) ARHGAPv2-2285-BNA-16: (SEQ ID NO: 35) T(L)5(L)T(L)agaacagtaA(L)A(L)T(L)t; 11) ARHGAPv2-2306-BNA-16: (SEQ ID NO: 36) T(L)T(L)5(L)aaacatgaa5(L)T(L)T(L)t; 12) ARHGAPv2-2355-BNA-16: (SEQ ID NO: 37) T(L)5(L)5(L)caattgttgA(L)T(L)A(L)g; and 13) ARHGAPv2-2404-BNA-16: (SEQ ID NO: 38) T(L)T(L)T(L)taacataagA(L)A(L)T(L)g,
where N(L) represents artificial nucleic acid BNA, 5 (L) represents L-mC (methylated artificial nucleic acid BNA), T(L) represents artificial nucleic acid thymidine, and A(L) represents artificial nucleic acid adenine.
20. A metastasis inhibitor and/or invasion inhibitor for a malignant tumor according to the above-mentioned item 17, in which the substance capable of inhibiting ARHGAP11A includes the oligonucleotide that induces RNA interference, the oligonucleotide including a base sequence set forth in the following item 14) or 15):
[0000]
14) ARHGAP11A #1 (TRCN0000047281):
(SEQ ID NO: 1)
CCGGCGGTATCAGTTCACATCGATACTCGAGTATCGATGTGAACTGATAC
CGTTTTTG;
or
15) ARHGAP11A #2 (TRCN0000047282):
(SEQ ID NO: 2)
CCGGCCTTCTATTACACCTCAAGAACTCGAGTTCTTGAGGTGTAATAGAA
GGTTTTTG.
21. A therapeutic and/or prophylactic method for a malignant tumor, including using the novel antitumor agent according to any one of the above-mentioned items 1 to 7.
Advantageous Effects of Invention
[0036] The novel antitumor agent containing as an active ingredient a substance capable of inhibiting a cell cycle-dependent RhoGAP of the present invention suppresses cancer cell invasion and/or metastasis in, for example, cancer cells derived from cancer capable of expressing ARHGAP11A, such as colorectal cancer, pancreatic cancer, prostate cancer cells, breast cancer, head and neck cancer, melanoma, ovarian cancer, lung cancer, brain cancer, pancreatic cancer, hepatocellular carcinoma, renal cell carcinoma, or skin cancer. Hitherto, there has been almost no effective drug that is an antitumor agent capable of suppressing cancer cell invasion and/or metastasis. The provision of the drug capable of suppressing cancer cell invasion and/or metastasis affecting malignant progression of cancer enables an effective cancer therapy.
[0037] Further, as a result of testing the expression of ARHGAP11A in a biological specimen on the basis of, for example, mRNA, significant differences have been found in association with the stage of cancer progression (staging) and relapse free survival. Thus, a test for a malignant tumor can be performed by quantifying the cell cycle-dependent RhoGAP in a biological specimen.
BRIEF DESCRIPTION OF DRAWINGS
[0038] FIG. 1 is a photographic view showing a tissue based on tissue immunity of metastatic/invasive cancer cells in a cancer tissue (Reference Example 1).
[0039] FIG. 2 are photographic views confirming the gene introduction of Fucci for real-time visualization of a cell cycle into human colorectal cancer cells by a fluorescence microscope and FACS (Reference Example 2).
[0040] FIG. 3 is a photographic view confirming that human colorectal cancer cells implanted into a NOD/SCID mouse have different cell tracking velocities depending on the cell cycle of the cells. Cells in the S/G2/M phases have a higher cell mobility as compared to cells in the G1 phase (Reference Example 2).
[0041] FIG. 4 are photographic views confirming the expression of ARHGAP11A at the mRNA level and as a protein for cells in the S/G2/M phases (mAG) and cells in the G1 phase (mKO2) (Reference Example 2).
[0042] FIG. 5 illustrate a relationship between the presence of a cell cycle-dependent transcription factor and the expression of ARHGAP11A (Reference Example 3).
[0043] FIG. 6 is a graph confirming the expression of ARHGAP11A in various cells (Reference Example 4).
[0044] FIG. 7 are graphs confirming cell proliferation rates and mobilities for mutant lines of human colorectal cancer cells in which ARHGAP11A is inhibited by shRNA (Example 1).
[0045] FIG. 8 is a graph showing the results of confirming the size of a tumor in the case of implanting human colorectal cancer cells of a wild-type line into an immunocompromised mouse (NOD/SCID), and then locally administering shRNA against ARHGA11A (Example 2).
[0046] FIG. 9 are graphs confirming the expression of ARHGAP11A at the mRNA level against the stage of colorectal cancer (Example 3).
[0047] FIG. 10 is a graph showing the results of confirming the relapse free survivals of patients who have undergone the surgical resection of colorectal cancer in a patient group with lower than average ARHGAP11A expression (n=38) and a patient group with higher than average ARHGAP11A expression (n=26) (Example 4).
[0048] FIG. 11 is a graph showing the results of confirming suppressive effects on the expression of ARHGAP11A exhibited by 35 kinds of artificial nucleic acid-containing antisense oligonucleotides (antisense BNAs) in HCT116 (human colorectal cancer cell line) (Example 5).
[0049] FIG. 12 are photographic views showing the results of confirming suppressive effects on the expression of ARHGAP11A exhibited by 5 kinds of artificial nucleic acid-containing antisense oligonucleotides (antisense BNAs) in various cancer cells by western blotting (Example 6).
[0050] FIG. 13(A) are photographic views confirming suppressive effects on the expression of ARHGAP11A in HCT116 having introduced therein antisense BNA (#1748). In addition, FIG. 13(B) are photographic views confirming the incorporation of antisense BNA (#1748) into HCT116 using fluorescein isothiocyanate (FITC)-labeled antisense BNA (#1748) (Example 7).
[0051] FIG. 14 is a graph showing an in vivo antitumor effect exhibited by FITC-labeled antisense BNA (#1748) administered into an immunocompromised mouse (NOD/SCID) (Example 8).
[0052] FIG. 15 are photographic views showing the results of confirming the incorporation of an FITC label into various organs on day 14 after the administration of FITC-labeled antisense BNA (#1748) into an immunocompromised mouse (NOD/SCID) (Example 8).
[0053] FIG. 16 is a diagram illustrating an administration schedule of drugs, for confirming a tumor metastasis suppressive effect of antisense BNA (#1748) (Example 9).
[0054] FIG. 17 are photographic views showing the results of confirming the size of a lung metastasis tumor by imaging in the case of administering antisense BNA (#1748) into a nude mouse into which human fibrosarcoma cells have been intravenously injected (Example 9).
[0055] FIG. 18 are graphs showing the results of measuring lung weights and body weights in the case of administering antisense BNA (#1748) into nude mice to which human fibrosarcoma cells have been intravenously injected (Example 9).
DESCRIPTION OF EMBODIMENTS
[0056] The present invention relates to a novel antitumor agent containing as an active ingredient a substance capable of inhibiting a cell cycle-dependent RhoGAP. In the present invention, an example of the cell cycle-dependent RhoGAP is Rho GTPase activating protein 11A (ARHGAP11A).
[0057] While specific experimental results are described in detail in Examples and experimental examples to be described later, how the present invention has been made is briefly described in this section. The inventors of the present invention have used an intravital imaging experimental system for a cancer tissue established by themselves to perform real-time analysis of the manner in which cancer cells invade a normal tissue, and have found that cells in the S/G2/M phases have a higher mobility as compared to cells in the G1 phase. The inventors have sorted the S/G2/M cells and the G1 cells out of cancer cells and subjected the cells to microarray analysis, to thereby extract cell cycle-dependent genes, and have found for the first time that among the genes, ARHGAP11A associated with the mobility is expressed at a high level in the cells in the S/G2/M phases. The inventors have confirmed that cancer cells in which ARHGAP11A is inhibited through the use of small hairpin RNA (shRNA) have a lower mobility than that of cancer cells of a wild-type line and thus are reduced in tumor progression rate. Further, tumor expansion has been able to be significantly suppressed by implanting cancer cells of the wild-type line into immunocompromised mice (NOD/SCID), followed by in vivo local administration of small interfering RNA (siRNA) against ARHGA11A.
[0058] Cancer cells are free of spatial restrictions when proliferating in an incubator, but in order to proliferate in vivo, the cancer cells need to invade surrounding normal tissues simultaneously with cell division. The inventors of the present invention have incorporated a fluorescent protein for visualizing the cell cycle of colorectal cancer cells and have performed intravital imaging using a multiphoton excitation microscope. As a result, the inventors have found for the first time that the ability of cancer cells to invade/migrate, i.e., cell mobility is enhanced in the S/G2/M phases depending on the cell cycle ( FIGS. 2 and 3 ). As a result of analyzing molecules expressed in cells in the G1 phase and cells in the S/G2/M phases by a microarray method, it has been confirmed that “ARHGAP11A” as one kind of Rho GTPase activating protein (RhoGAP), which reduces the cell mobility, is expressed in the cells in the S/G2/M phases at a level 10-fold or more higher than in the cells in the G1 phase.
[0059] In the present invention, a typical example of ARHGAP11A is a human-derived protein synthesized from mRNA having a base sequence identified by GenBank Accession No. NM — 014783.3 (variant 1) or GenBank Accession No. NM — 199357.1 (variant 2). In addition, when defined from a different perspective, ARHGAP11A includes a protein having an amino acid sequence translated from the base sequence identified by GenBank Accession No. NM — 014783.3 or NM — 199357.1, or an amino acid sequence having, in the above-mentioned amino acid sequence, deletions, additions, substitutions, or insertions of one or more amino acids, and having cell cycle-dependent Rho GTPase activating property. Further, the ARHGAP11A of the present invention may also encompass ARHGAP11A derived from a non-human mammal.
[0060] In the present invention, an ARHGAP11A gene may encompass not only DNA that encodes mRNA having the base sequence identified by GenBank Accession No. NM — 014783.3 or NM — 199357.1, but also DNA having a similar sequence to these sequences. In this context, the “similar sequence” may be DNA having a base sequence having deletions, additions, substitutions, or insertions of one or more nucleotides in the base sequence identified by GenBank Accession No. NM — 014783.3 or NM — 199357.1, and being capable of synthesizing a protein having a cell cycle-dependent RhoGAP activity. Further, the ARHGAP11A gene of the present invention also encompasses: DNA having the base sequence identified above; or DNA having a base sequence having deletions, additions, substitutions, or insertions of one or more nucleotides in the identified base sequence, and being capable of synthesizing a protein having a cell cycle-dependent RhoGAP activity; or DNA having a sequence capable of hybridizing with a partial sequence of the above-mentioned sequence under stringent conditions. The stringent conditions are generally defined by the salt concentration and temperature of a buffer to be used in hybridization or in washing. The salt concentration may be generally “1×SSC, 0.1% SDS”, “0.5×SSC, 0.1% SDS” as a more stringent condition, or “0.1×SSC, 0.1% SDS” as a still more stringent condition. The temperature may be generally 37° C., 42° C. as a stringent condition, 55° C. as a more stringent condition, or 65° C. as a still more stringent condition.
[0061] Herein, the substance capable of inhibiting the cell cycle-dependent Rho GTPase activating protein, that is, the cell cycle-dependent RhoGAP refers to a substance that inhibits the function of the RhoGAP and/or inhibits the expression of the RhoGAP. The inhibition of the function of the RhoGAP refers to the inhibition of the function of the RhoGAP as a protein, and the inhibition of the expression of the RhoGAP has the same meaning as the inhibition of the biosynthesis of the RhoGAP. A substance capable of inhibiting the biosynthesis of the RhoGAP is, for example, a substance capable of binding to a RhoGAP gene, or a transcription product or translation product thereof. Specific examples of the transcription product of the RhoGAP gene include RhoGAP mRNA and precursor RNA. An antitumor effect can be expected of the substance capable of inhibiting the biosynthesis of the RhoGAP. A more specific example thereof is any one selected from an antisense oligonucleotide against a gene encoding the RhoGAP, an oligonucleotide that induces RNA interference (RNAi) of the gene (shRNA, siRNA, or microRNA), and a low-molecular-weight compound or natural polymer capable of binding to a transcription product or translation product of the gene.
[0062] When the RhoGAP is ARHGAP11A, the substance capable of inhibiting ARHGAP11A refers to a substance capable of inhibiting the function of the ARHGAP11A and/or inhibiting the expression of the ARHGAP11A. The inhibition of the function of the ARHGAP11A refers to the inhibition of the function of the ARHGAP11A as a protein, and the inhibition of the expression of the ARHGAP11A has the same meaning as the inhibition of the biosynthesis of the ARHGAP11A. A substance capable of inhibiting the biosynthesis of the ARHGAP11A is, for example, a substance capable of binding to an ARHGAP11A gene, or a transcription product or translation product thereof. A more specific example thereof is any one selected from an antisense oligonucleotide against a gene encoding the RhoGAP, an oligonucleotide that induces RNA interference (RNAi) of the gene (shRNA, siRNA, or microRNA), and a low-molecular-weight compound or natural polymer capable of binding to a transcription product or translation product of the gene. It should be noted that herein, the “nucleic acid”, “nucleotide”, and “nucleoside” include not only a deoxyribonucleic acid (DNA) and a ribonucleic acid (RNA), but also artificially synthesized nucleic acids (hereinafter referred to as “artificial nucleic acid”) such as a peptide nucleic acid (PNA), a bridged nucleic acid (BNA), and analogs thereof. As the BNA, for example, there may be used a nucleic acid produced by GeneDesign Inc. (bridged nucleic acid).
[0063] The sequence of the antisense oligonucleotide may be designed, for example, on the basis of the sequence of the ARHGAP11A gene transcription product so that the antisense oligonucleotide can hybridize with the transcription product. The antisense nucleotide may be constituted of DNA or RNA, and is suitably an oligonucleotide containing an artificial nucleic acid that does not occur naturally. An oligonucleotide having higher stability can be obtained by incorporating the artificial nucleic acid. In addition, the length of the base sequence of the oligonucleotide is not particularly limited and has only to be a length that allows the retention of at least specificity for a gene of interest. The upper limit of the length may be set to a length comparable that of mRNA. The length may be generally from 14 bases to 200 bases, preferably from 15 bases to 50 bases.
[0064] Double-stranded RNA (dsRNA) that induces RNA interference (RNAi) is known to have forms such as siRNA, shRNA, and microRNA, and the present invention may encompass all of such forms. The dsRNA is constituted of an antisense strand that can be complementary to a partial region of the transcription product of the ARHGAP11A gene, and a sense strand having a sequence capable of hybridizing with the antisense strand. That is, the double-stranded region of the dsRNA corresponds to a sequence obtained by changing the DNA sequence of a target region on the ARHGAP11A gene to a ribonucleic acid. It should be noted that as long as the expression of ARHGAP11A can be inhibited, the sequence of the antisense strand may contain a sequence not complementary to the target ARHGAP11A gene, and the sequence of the sense strand may contain a sequence that does not hybridize with the antisense strand. The length of the double-stranded region of the dsRNA may be, for example, from 16 to 49 base pairs, suitably from 16 to 30 base pairs, more suitably from 19 to 21 base pairs. In view of the fact that long dsRNA has cytotoxicity, the upper limit of the length may be determined to the extent that the toxicity is not provided. In addition, the lower limit of the length of the dsRNA may be adjusted to the extent that specificity can be retained.
[0065] The sequence of, for example, the target region on the ARHGAP11A gene or specific shRNA, siRNA, or microRNA for effectively inhibiting the expression of the cell cycle-dependent RhoGAP such as ARHGAP11A may be designed by utilizing a design tool known per se available from, for example, DHARMACON (http://design.dharmacon.com), Ambion (http://www.ambion.com/techlib/misc/siRNA_finder.html), or TAKARA BIO INC. (http://www.takara-bio.co.jp/rnai/intro.htm). In addition, artificially synthesized synthetic oligo dsRNA may be prepared by means of a synthesizer or the like. Alternatively, there may be adopted a construction in which siRNA is expressed in cells from an expression vector carrying DNA that encodes dsRNA. The vector for expressing dsRNA in cells may be arbitrarily selected depending on, for example, the cells into which the vector is to be introduced. For example, examples of the vector in mammalian cells include virus vectors such as a retrovirus vector, an adenovirus vector, an adeno-associated virus vector, a vaccinia virus vector, a lentivirus vector, a herpes virus vector, an alphavirus vector, an EB virus vector, a papilloma virus vector, and a foamy virus vector. Any such expression vector may include a promoter for transcribing dsRNA and DNA that encodes the dsRNA linked downstream of the promoter. In addition, a method known per se may be applied as, for example, a method of constructing the promoter or the dsRNA.
[0066] When the “substance capable of inhibiting a cell cycle-dependent RhoGAP” contained as an active ingredient in the novel antitumor agent of the present invention is a nucleic acid substance such as an antisense oligonucleotide, shRNA, siRNA, or microRNA against the gene encoding the cell cycle-dependent RhoGAP such as ARHGAP11A, the nucleic acid substance is preferably introduced into cells on which the nucleic acid substance is intended to act. Asa technique for introducing the nucleic acid substance, there may be applied a method known per se such as a lipofection method, a calcium phosphate method, electroporation, or a gene gun, or a gene transfer technology to be developed, and a commercially available gene transfection reagent or kit may be utilized. In addition, in the case of, for example, a dsRNA expression vector using a viral vector retaining an infectious capacity, the vector may be incorporated into cells by means of the infectious capacity of the virus.
[0067] Among the “substances capable of inhibiting a cell cycle-dependent RhoGAP” to be contained as an active ingredient in the novel antitumor agent of the present invention, the natural polymer is exemplified by an antibody. The antibody may be a polyclonal antibody or a monoclonal antibody. The antibody may be obtained by production by a method known per se.
[0068] The novel antitumor agent of the present invention described above can markedly reduce the mobility/invasive capacity of cancer cells, thereby suppressing invasion and/or metastasis. Therefore, the present invention also encompasses a metastasis inhibitor and/or invasion inhibitor for a malignant tumor, including the “substance capable of inhibiting a cell cycle-dependent RhoGAP.”
[0069] Cancer cells to be targeted by the novel antitumor agent containing as an active ingredient a “substance capable of inhibiting a cell cycle-dependent RhoGAP” of the present invention are not particularly limited, and examples thereof may include cancer cells whose metastasis or invasion may be induced by the expression of the cell cycle-dependent RhoGAP such as ARHGAP11A. Specific examples thereof may include cancer cells derived from colorectal cancer, pancreatic cancer, prostate cancer cells, breast cancer, head and neck cancer, melanoma, ovarian cancer, lung cancer, brain cancer, pancreatic cancer, hepatocellular carcinoma, renal cell carcinoma, and skin cancer, and a particularly suitable example thereof is colorectal cancer or pancreatic cancer.
[0070] Further, it is considered that the novel antitumor agent containing as an active ingredient a “substance capable of inhibiting a cell cycle-dependent RhoGAP” of the present invention can act more effectively on cancer at the T2, T3, or T4 stage (according to the TNM classification of the UICC), at which the cancer invades a tissue to reach the muscularis propria, the serosa, or the outside of the serosa, respectively. This is because in the present invention, it has been elucidated that the expression level of the RhoGAP such as ARHGAP11A serving as a therapeutic target increases in cancer at the T2, T3, or T4 stage.
[0071] The novel antitumor agent containing as an active ingredient a “substance capable of inhibiting a cell cycle-dependent RhoGAP” of the present invention may be formulated by mixing this ingredient with other ingredients as necessary. In addition, the novel antitumor agent may also be formulated by utilizing a known pharmaceutical production method. Depending on the active ingredient, the novel antitumor agent may be formulated as a nucleic acid formulation or a low-molecular-weight compound formulation. In the formulation, the novel antitumor agent may be formulated in combination with, for example, a medium or carrier to be generally used in a drug, specifically, sterile water, physiological saline, a plant oil, an emulsifier, a suspension, a surfactant, a stabilizer, or the like as appropriate. Therefore, the present invention also encompasses a therapeutic and/or prophylactic method for a malignant tumor, including using the novel antitumor agent containing as an active ingredient a “substance capable of inhibiting a cell cycle-dependent RhoGAP” of the present invention.
[0072] The present invention also encompasses a screening method for a novel antitumor agent, including selecting a “substance capable of inhibiting a cell cycle-dependent RhoGAP.” Herein, a typical example of the cell cycle-dependent RhoGAP is ARHGAP11A as described above. The present invention specifically encompasses a screening method including at least the following steps A) to D). Any one of the step A) and the step B) may be performed before the other, or the steps may be simultaneously performed. Herein, a candidate substance to be selected by the screening may be, for example, a nucleic acid substance, a low-molecular-weight compound, or a natural polymer. Specific examples thereof include an antisense oligonucleotide, shRNA, siRNA, and microRNA against a gene encoding the ARHGAP11A, and a low-molecular-weight compound or natural polymer capable of binding to a transcription product or translation product of the gene. An example of the natural polymer is an antibody. The antibody may be a polyclonal antibody or a monoclonal antibody. The antibody may be obtained by production by a method known per se.
[0073] A) A step of culturing a candidate substance together with a cancer cell line, followed by measurement of an expression level of a gene encoding a given cell cycle-dependent RhoGAP (such as ARHGAP11A) in the cell;
[0074] B) a step of measuring an expression level of the gene encoding the given RhoGAP measured by the same technique as that of the step A) in a control system;
[0075] C) a step of comparing the expression levels of the gene encoding the given RhoGAP measured in the steps A) and B) to each other; and
[0076] D) a step of selecting a candidate substance in a case where the expression level of the gene measured in the step A) is lower than the expression level of the gene measured in the step B).
[0077] The step B) of the screening method refers to a step including culturing cancer cells in a system free of the candidate substance and measuring the expression level of the gene encoding the given RhoGAP measured by the same technique as that in the step A). The cancer cells that may be used in the step A) and the step B) have only to be cells capable of expressing a given RhoGAP (such as ARHGAP11A), and are not particularly limited. Examples thereof include cell lines derived from, for example, colorectal cancer, pancreatic cancer, prostate cancer cells, breast cancer, head and neck cancer, melanoma, ovarian cancer, lung cancer, brain cancer, pancreatic cancer, hepatocellular carcinoma, renal cell carcinoma, and skin cancer, and a preferred example is colorectal cancer or pancreatic cancer. Particularly specifically, it is most suitable to use HCT116, which is a colorectal cancer cell line.
[0078] The expression level of the gene encoding the cell cycle-dependent RhoGAP such as ARHGAP11A may be confirmed by a technique known per se such as a real-time RT-PCR method, northern blotting, western blotting, or immunostaining or a novel technique to be developed in the future.
[0079] The present invention also encompasses a method of testing for a malignant tumor, including quantifying an expression level of a gene encoding a cell cycle-dependent RhoGAP such as ARHGAP11A in a biological specimen. An example of the cell cycle-dependent RhoGAP is ARHGAP11A. The expression level of the gene may be measured by a technique known per se such as a microarray method, a real-time RT-PCR method, northern blotting, western blotting, or immunostaining or a novel technique to be developed in the future.
[0080] In the present invention, the biological specimen has only to be a biological specimen in which the above-mentioned protein can be detected, and is not particularly limited. Examples thereof include a wide range of biological specimens such as a tissue, blood such as plasma and serum, spinal fluid, lymph, urine, lacrimal fluid, and milk, and a suitable example of the biological specimen is a tissue. The tissue may be acquired by means of, for example, a removed diseased tissue, a biopsy, or circulating tumor cells (CTC). As shown in Examples to be described later as well, for example, when the relapse free survivals of patients who have undergone the surgical resection of colorectal cancer in a patient group with lower than average ARHGAP11A expression and a patient group with higher than average ARHGAP11A expression were confirmed, it was confirmed that the patient group with the lower expression of ARHGAP11A had a significantly lower percent relapse free survival ( FIG. 10 ). Thus, the stage of progression or prognosis of cancer can be predicted by the method of testing of the present invention for a malignant tumor that is considered to express ARHGAP11A, such as one or more kinds selected from colorectal cancer, pancreatic cancer, prostate cancer cells, breast cancer, head and neck cancer, melanoma, ovarian cancer, lung cancer, brain cancer, pancreatic cancer, hepatocellular carcinoma, renal cell carcinoma, and skin cancer.
EXAMPLES
[0081] Hereinafter, the results of experiments performed to complete the present invention are shown as Reference Examples, and the present invention is more specifically described in Examples. However, the present invention is not limited thereto, and various applications are possible without departing from the technical concept of the present invention.
Reference Example 1
Confirmation of Cell Cycle
[0082] First, cells of a surgically excised colorectal cancer tissue classified on the basis of the presence of Geminin (cell cycle: S/G2/M stages) were stained by a tissue immunostaining method using an anti-Geminin (S/G2/M) polyclonal antibody to confirm a non-cancer portion (A), a cancer cell invasion head portion (B), and a cancer central area (C). As a result, Geminin was most intensely stained at the portion (B), confirming that the cells in the S/G2/M phases were abundantly present in the cancer cell invasion head portion ( FIG. 1 ).
Reference Example 2
Analysis of Motile Cells
[0083] An intravital imaging experimental system for a cancer tissue was used to perform real-time analysis of the manner in which HCT116 (human colorectal cancer cell line) invaded a normal tissue. S/G2/M cells and G1 cells were sorted and subjected to microarray analysis to extract cell cycle-dependent genes, and it was found for the first time that among the genes, ARHGAP11A associated with the mobility was expressed at a high level in the cells in the S/G2/M phases.
[0084] Fluorescent probe (Fucci: fluorescent ubiquitination-based cell cycle indicator)-expressing HCT116 was implanted into the cecum or subcutaneous tissue of a NOD/SCID mouse to visualize the cell cycle progression of HCT116. Fucci caused red emission from nuclei in the G1 phase (mKO2) and green emission from nuclei in the S/G2/M phases (mAG). Part of Cdt1 protein was used in the visualization of the G1 phase, and part of Geminin protein was used in the visualization of the S/G2/Mphases Fucci-expressing cells were separated with FACSAria II (BD Biosciences) into mAG-positive cells in the S/G2/M phases and mKO2-positive cells in the G1 phase. Constitutive expression of Fucci allows stable visualization of a cell cycle. As a result, it was confirmed that the cells in the S/G2/M phases migrated to a great extent in HCT116 ( FIG. 2 ). As a result of confirming cell tracking velocities, it was confirmed that the cells in the S/G2/M phases had a larger mean migration distance, thus being more mobile cells as compared to the cells in the G1 phase ( FIG. 3 ).
[0085] Next, a cDNA microarray was used to analyze mRNA expressed in the cells in the S/G2/M phases and the cells in the G1 phase. In the microarray analysis, 1,656 genes that were statistically significant by showing 2-fold or more increases were extracted (Table 1). As a result, it was confirmed that ARHGAP11A, a RhoGAP, was particularly intensely expressed in the cells in the S/G2/M phases at the gene level and the protein level (Table 1, FIG. 4 ).
Reference Example 3
On Expression Control of ARHGAP11A by Cell Cycle-Dependent Transcription Factor E2F
[0086] The E2F family is known to include cell cycle-dependent transcription regulators. It was noticed that there was a sequence to which E2Fs bound at −20 to −28 b (chr15: 32907663-32907671) from the start point of transcription of ARHGAP11A (chr15: 32907691), and it was confirmed by a luciferase reporter assay ( FIG. 5A ) and a chromatin immunoprecipitation method (ChIP) that the expression of ARHGAP11A was controlled by the cell cycle-dependent transcription factor E2F. It was confirmed that the inhibition of the expression of ARHGAP11A reduced the migratory/invasive capacity of cancer cells, indicating that ARHGAP11A was a promising therapeutic target ( FIG. 5B ).
[0000]
TABLE 1
Rho GAPs
Rank
Gene
FC
5
ARHGAP11A
18.85
12
ARHGAP11A
14.90
41
ARHGAP11A
11.03
57
DEPDCID
9.84
106
IQGAP3
7.47
Reference Example 4
On Target Diseases
[0087] In this reference example, cancer cells to be targeted by the novel antitumor agent of the present invention were confirmed. That is, it was considered that cancer cells whose metastasis or invasion might be induced by the expression of ARHGAP11A were cancer cells to be targeted by the novel antitumor agent containing as an active ingredient a substance capable of inhibiting ARHGAP11A of the present invention. For human colorectal cancer cells (HCT116), human liver cancer cells (HepG2), lymphatic fibroblasts (Human Lymphatic Fibroblasts: HLF), and human pancreatic adenocarcinoma cells (PSN1, MiaPaca2, Panc1), the expression of ARHGAP11A was confirmed by a quantitative real-time PCR method. β-Actin was used as an internal control, and the results were shown as values relative to the expression level of β-actin defined as 1. As a result, the expression of ARHGAP11A was found in cancer cells derived from the human colorectal cancer cells in which the expression of ARHGAP11A was found and the human pancreatic adenocarcinoma cells (HCT116, PSN1) ( FIG. 6 ). Thus, it is considered that the novel antitumor agent of the present invention can act effectively on these cancer cells.
[0088] In addition, referring to GeneCards ID: GC15P032907 of GeneNote, microarray expression of ARHGAP11A has been found in cancer cells derived from, for example, colorectal cancer, pancreatic cancer, prostate cancer, breast cancer, head and neck cancer, melanoma, ovarian cancer, lung cancer, brain cancer, pancreatic cancer, hepatocellular carcinoma, renal cell carcinoma, and skin cancer. Accordingly, it is considered that the novel antitumor agent of the present invention can act effectively on these cancer cells. It should be noted that in GeneCards ID: GC15P032907 of GeneNote, it is only described that expression has been found in the cancer cells, and no mention is made of an influence of the expression of ARHGAP11A on the cancer cells or an effect in the case where ARHGAP11A is inhibited.
Example 1
Confirmation of Antitumor Effect Based on ARHGAP11A Inhibitory Action
[0089] In this example, an effect of the novel antitumor agent of the present invention was confirmed by confirming the function of ARHGAP11A out of the cell cycle-dependent RhoGAPs. Lentiviral vectors containing two kinds of shRNAs (SH) having a base sequence set forth in SEQ ID NO: 1 or 2 below were produced, and were each introduced into HCT116 (human colorectal cancer cell line) to construct lines with inhibitedARHGAP11Aexpression (SH#1 and SH#2). As a control, a lentiviral vector containing an oligonucleotide having a base sequence set forth in SEQ ID NO: 3 below was produced, and was introduced into HCT116 by the same technique. For each of the lines with inhibited ARHGAP11A expression (SH#1 and SH#2), cell proliferative capacity and cell invasion were confirmed.
[0090] Cell proliferation was analyzed by a BrdU proliferation assay method involving adding a precursor substance (5-bromo-2′-deoxyuridine: BrdU) for label DNA to cells, and analyzing quantified incorporation thereof into genomic DNA in the S phase of the cell cycle (replication). A cancer cell invasion assay was performed using BD BioCoat™ Matrigel Invasion Chamber in accordance with the method of the instruction manual. As a result, no difference from the control was found in cell proliferative capacity ( FIG. 7A ). For the cell invasive capacity, the lines with inhibited ARHGAP11A expression (SH#1 and SH#2) were found to have low values as compared to the control ( FIG. 7B ). Thus, the suppression of invasion was observed in the lines with inhibited ARHGAP11A expression ( FIGS. 7A and 7B ). In view of the foregoing, an anticancer therapy involving inhibiting ARHGAP11A is considered to be a breakthrough therapeutic method by which invasion by human colorectal cancer is suppressed, and drug development is strongly expected in the future.
[0091] The DNA sequences of the shRNAs against ARHGAP11A and the control are as follows.
[0000]
shRNA target: Sequence Strand (5′-3′)
1) ARHGAP11A #1 (TRCN0000047281):
(SEQ ID NO: 1)
CCGGCGGTATCAGTTCACATCGATACTCGAGTATCGATGTGAACTGATAC
CGTTTTTG
2) ARHGAP11A #2 (TRCN0000047282):
(SEQ ID NO: 2)
CCGGCCTTCTATTACACCTCAAGAACTCGAGTTCTTGAGGTGTAATAGAA
GGTTTTTG
3) Control (SHC002):
(SEQ ID NO: 3)
CCGGCAACAAGATGAAGAGCACCAACTCGAGTTGGTGCTCTTCATCTTGT
TGTTTTT
(Example 2) Confirmation of antitumor effect based on ARHGAP11A inhibitory action
[0092] In this example, an in vivo antitumor effect based on the ARHGAP11A inhibitory action was confirmed.
[0093] 1×10 6 HCT116 cells of a wild-type line having introduced therein no lentiviral vector were implanted into immunocompromised mice (NOD/SCID) by local injection.
[0094] After that, the lentiviral vector containing shRNA (SH) having the base sequence set forth in SEQ ID NO: 1 or 2 (SH#1 or SH#2) produced in Example 1 was locally injected using AteloGene™ (Koken), an in vivo siRNA transfection kit (siRNA-administered group). As a control group, (a) the lentiviral vector containing shRNA having the base sequence set forth in SEQ ID NO: 3 produced in Example 1 (control shRNA group) or (b) a lentiviral vector 1 subjected to no genetic recombination was introduced in the same manner as above using AteloGene™ (Koken) (gene transfection reagent control group). Further, (c) a system into which no lentivirus was locally injected (control group) was also used as a control. The expansion of the tumor cells 4 weeks after the implantation was confirmed on the basis of the magnitude of the size of the tumor. The administration of shRNA against ARHGAP11A into the tumor was able to significantly suppress the expansion of the tumor ( FIG. 8 ).
Example 3
Relationship Between Expression of ARHGAP11A and Colorectal Cancer Staging
[0095] Cancer tissue portions were separated from surgical specimens of patients who had undergone the surgical resection of colorectal cancer by a laser microdissection method, mRNA was isolated therefrom, and the expression of ARHGAP11A was confirmed by a microarray method. Comparing the surgically excised specimens of colorectal cancer and normal colon mucosa, the expression of ARHGAP11A was increased at the cancer portion, and it was confirmed by colorectal cancer staging that the expression of ARHGAP11A was increased with stage progression. For example, it was revealed that the expression was increased at the T2, T3, and T4 stages as compared to the 11 (according to the TNM classification of the UICC), at which cancer invades a tissue to reach the muscularis propria ( FIG. 9 ).
Example 4
Test for Prognostic Prediction of Cancer Surgical Resection
[0096] Patients who had undergone the surgical resection of colorectal cancer in the cases where cancer surgical resection (definitive surgery) was possible were classified into a high expression group and a low expression group and subjected to the analysis of relapse free survival. Cancer tissue portions were separated from surgical specimens by a laser microdissection method, mRNA was isolated therefrom, and the expression of ARHGAP11A was confirmed by a microarray method. As a result, the confirmation of relapse free survivals in the patient group with lower than average ARHGAP11A expression (n=38) and the patient group with higher than average ARHGAP11A expression (n=26) showed a significantly higher percent survival in the patient group with lower ARHGAP11A expression, confirming poor prognosis in the high expression group ( FIG. 10 ). Thus, it is considered that cancer prognosis can be predicted by confirming the expression level of ARHGAP11A. It should be noted that the contents of Example 3 and 4 are based on the results of experiments conducted at the Medical Institute of Bioregulation at Kyushu University with the approval of an ethics committee of the university.
Example 5
Antisense Oligonucleotide (BNA) Against ARHGAP11A
[0097] In this example, suppressive effects of 35 kinds of antisense oligonucleotides each containing BNA, an artificial nucleic acid ((hereinafter referred to as “antisense BNAs”) on the expression of ARHGAP11A in HCT116 (human colorectal cancer cell line) were confirmed.
[0098] First, 35 kinds of antisense BNAs having base sequences set forth in SEQ ID NOS: 4 to 38 below and oligonucleotides having base sequences set forth in SEQ ID NOS: 39 to 41 were produced. An example of ARHGAP11A is a human-derived protein synthesized from mRNA having a base sequence identified by GenBank Accession No. NM — 014783.3 (variant 1) or GenBank Accession No. NM — 199357.1 (variant 2). The antisense BNAs identified by SEQ ID NOS: 4 to 23 are each an antisense oligonucleotide strand against a sequence portion common to the variant 1 and the variant 2, the antisense BNAs identified by SEQ ID NOS: 24 to 33 are each an antisense oligonucleotide strand against the variant 1, and the antisense BNAs identified by SEQ ID NOS: 34 to 38 are each an antisense oligonucleotide strand against the variant 2.
[0099] In each of the sequences shown below, N(L) represents artificial nucleic acid BNA, 5 represents 5-mC (methylcytosine), (L) represents L-mC (methylated artificial nucleic acid BNA), T(L) represents artificial nucleic acid thymidine, and T(A) represents artificial nucleic acid adenine. The BNAs used in this example are ones produced by GeneDesign Inc.
[0000]
ARHGAP-47-BNA-16:
(SEQ ID NO: 4)
T(L)5(L)5(L)gcccccagcT(L)5(L)5(L)t
ARHGAP-126-BNA-16:
(SEQ ID NO: 5)
5(L)T(L)5(L)ccccatcag5(L)5(L)T(L)g
ARHGAP-203-BNA-16:
(SEQ ID NO: 6)
5(L)T(L)5(L)aggcaactcT(L)T(L)5(L)c
ARHGAP-382-BNA-16:
(SEQ ID NO: 7)
T(L)5(L)T(L)attgccagaT(L)T(L)5(L)t
ARHGAP-406-BNA-16:
(SEQ ID NO: 8)
5(L)T(L)T(L)tctgattctT(L)T(L)5(L)g
ARHGAP-591-BNA-16:
(SEQ ID NO: 9)
5(L)5(L)5(L)gtctggcacT(L)T(L)5(L)t
ARHGAP-625-BNA-16:
(SEQ ID NO: 10)
5(L)T(L)5(L)aaatttgaa5(L)T(L)5(L)c
ARHGAP-720-BNA-16:
(SEQ ID NO: 11)
T(L)5(L)T(L)gatcccacaT(L)T(L)5(L)c
ARHGAP-843-BNA-16:
(SEQ ID NO: 12)
T(L)T(L)T(L)taccccctaT(L)T(L)T(L)c
ARHGAP-969-BNA-16:
(SEQ ID NO: 13)
T(L)5(L)5(L)gaaaaagcc5(L)T(L)T(L)c
ARHGAP-1006-BNA-16:
(SEQ ID NO: 14)
T(L)T(L)5(L)tttagtgctT(L)T(L)T(L)a
ARHGAP-1162-BNA-16:
(SEQ ID NO: 15)
T(L)T(L)T(L)tcctctgtg5(L)5(L)T(L)a
ARHGAP-1344-BNA-16:
(SEQ ID NO: 16)
T(L)5(L)T(L)tttcatgtc5(L)T(L)T(L)
ARHGAP-1447-BNA-16:
(SEQ ID NO: 17)
T(L)5(L)5(L)aggataaaaT(L)5(L)T(L)g
ARHGAP-1538-BNA-16:
(SEQ ID NO: 18)
T(L)T(L)5(L)accaggagtT(L)T(L)5(L)a
ARHGAP-1748-BNA-16:
(SEQ ID NO: 19)
5(L)T(L)T(L)gatggactt5(L)5(L)T(L)t
ARHGAP-1849-BNA-16:
(SEQ ID NO: 20)
5(L)T(L)5(L)tgagatgac5(L)5(L)T(L)t
ARHGAP-1931-BNA-16:
(SEQ ID NO: 21)
T(L)T(L)T(L)gcctgcaatT(L)5(L)T(L)t
ARHGAP-2032-BNA-16:
(SEQ ID NO: 22)
5(L)5(L)T(L)agattgaatT(L)T(L)5(L)a
ARHGAP-2176-BNA-16:
(SEQ ID NO: 23)
T(L)T(L)T(L)tcatcaacaT(L)5(L)T(L)g
ARHGAPv1-2262-BNA-16:
(SEQ ID NO: 24)
T(L)5(L)5(L)ggtaatttgT(L)T(L)5(L)c
ARHGAPv1-2311-BNA-16:
(SEQ ID NO: 25)
T(L)T(L)T(L)gcatctactT(L)5(L)T(L)t
ARHGAPv1-2628-BNA-16:
(SEQ ID NO: 26)
5(L)5(L)T(L)ctgggctat5(L)T(L)T(L)c
ARHGAPv1-2808-BNA-16:
(SEQ ID NO: 27)
T(L)T(L)T(L)catgttccaT(L)5(L)T(L)t
ARHGAPv1-2942-BNA-16:
(SEQ ID NO: 28)
T(L)T(L)5(L)catcatatt5(L)T(L)5(L)a
ARHGAPv1-3278-BNA-16:
(SEQ ID NO: 29)
5(L)5(L)5(L)tgtaggttgT(L)5(L)T(L)g
ARHGAPv1-3484-BNA-16:
(SEQ ID NO: 30)
T(L)T(L)5(L)gagggtaacT(L)5(L)5(L)a
ARHGAPv1-4399-BNA-16:
(SEQ ID NO: 31)
5(L)T(L)T(L)gctccattcT(L)T(L)T(L)c
ARHGAPv1-5140-BNA-16:
(SEQ ID NO: 32)
5(L)T(L)T(L)cctctacaa5(L)5(L)T(L)a
ARHGAPv1-5194-BNA-16:
(SEQ ID NO: 33)
T(L)5(L)T(L)aacaaccaaT(L)5(L)T(L)
ARHGAPv2-2215-BNA-16:
(SEQ ID NO: 34)
5(L)T(L)5(L)taacagtagT(L)A(L)T(L)g
ARHGAPv2-2285-BNA-16:
(SEQ ID NO: 35)
T(L)5(L)T(L)agaacagtaA(L)A(L)T(L)t
ARHGAPv2-2306-BNA-16:
(SEQ ID NO: 36)
T(L)T(L)5(L)aaacatgaa5(L)T(L)T(L)t
ARHGAPv2-2355-BNA-16:
(SEQ ID NO: 37)
T(L)5(L)5(L)caattgttgA(L)T(L)A(L)g
ARHGAPv2-2404-BNA-16:
(SEQ ID NO: 38)
T(L)T(L)T(L)taacataagA(L)A(L)T(L)g
ARHGAP-1931-BNA-16-cont1:
(SEQ ID NO: 39)
T(L)tT(L)gccT(L)gcaaT(L)t5(L)T(L)t
ARHGAP-1931-BNA-16-cont2:
(SEQ ID NO: 40)
T(L)tgT(L)ccT(L)gcT(L)aat5(L)T(L)t
ARHGAP-1931-BNA-16-cont3:
(SEQ ID NO: 41)
T(L)5(L)T(L)caatgcctgT(L)T(L)T(L)t
[0100] The antisense BNAs having the respective sequences shown above were each introduced into HCT116 using Lipofectamine reagent, and antisense BNAs capable of suppressing the mRNA expression of ARHGAP11A were confirmed by a qPCR method. GAPDH was used as an internal control, and the results were shown as values relative to the expression level of GAPDH defined as 1. As a result, it was confirmed that the antisense BNAs set forth in SEQ ID NOS: 10, 13, 16, 17, 19, 21, 22, 30, 34, and 35 to 38 effectively suppressed the expression of ARHGAP11A ( FIG. 11 ).
Example 6
Confirmation of Suppressive Effect on Expression of ARHGAP11A Exhibited by Artificial Nucleic Acid-Containing Antisense BNA
[0101] In this example, suppressive effects on the expression of ARHGAP11A in various cancer cells were confirmed for the antisense BNAs found in Example 5 to have suppressive effects on the expression of ARHGAP11A.
[0102] As the antisense BNAs, ARHGAP-625-BNA-16 (#625: SEQ ID NO: 10), ARHGAP-969-BNA-16 (#969: SEQ ID NO: 13), ARHGAP-1344-BNA-16 (#1344: SEQ ID NO: 16), ARHGAP-1447-BNA-16 (#1447: SEQ ID NO: 17), ARHGAP-1748-BNA-16 (#1748: SEQ ID NO: 19), ARHGAP-1931-BNA-16 (#1931: SEQ ID NO: 21), and ARHGAP-2032-BNA-16 (#2032: SEQ ID NO: 22) were used. As a control, ARHGAP-1931-BNA-16-cont2 set forth in SEQ ID NO: 40 was used. In addition, cancer cells to which no antisense BNA or control oligonucleotide was added were defined as wild type (wt). The suppressive effects were confirmed for the following four kinds of cancer cells: DLD1 (human colon adenocarcinoma cell line), HT29 (human colon adenocarcinoma cell line), Panc1 (human pancreatic adenocarcinoma cell line), and PSN1 (human pancreatic adenocarcinoma).
[0103] The antisense BNAs were each introduced into each kind of cancer cells by the same technique as the method described in Example 5 using Lipofectamine reagent, and their suppressive effects on the expression of ARHGAP11A were confirmed by western blotting.
[0104] As a result, in each kind of cells, the suppression of the expression of ARHGAP11A by antisense BNA was found, and particularly strong expression suppression was found in the case of ARHGAP-1748-BNA-16 (#1748: SEQ ID NO: 19) ( FIG. 12 ).
Example 7
Confirmation of Incorporation Amount of Antisense BNA into Cells (In Vitro)
[0105] In this example, the incorporation amount of FITC-labeled antisense BNA (ARHGAP-1748-BNA-16: #1748) into HCT116 was confirmed using Lipofectamine reagent. As a control, the oligonucleotide having the base sequence set forth in SEQ ID NO: 40 produced in Example 1 was used.
[0106] As a result, it was confirmed that the expression of ARHGAP11A was suppressed in the cells into which ARHGAP-1748-BNA-16 had been introduced ( FIG. 13(A) ). In addition, the incorporation amount of ARHGAP-1748-BNA-16 into the cells was comparable to that of the control ( FIG. 13(B) ).
Example 8
Confirmation of Tumor Cell Proliferation Suppressive Effect of Antisense BNA (In Vivo)
[0107] In this example, an in vivo antitumor effect of antisense BNA (ARHGAP-1748-BNA-16: #1748) was confirmed. HCT116 of a wild-type line was implanted into immunocompromised mice (NOD/SCID) by the same technique as that of Example 2, and then FITC-labeled ARHGAP-1748-BNA-16 was locally injected around the tumor by the same technique as that of Example 2 using AteloGene™ (Koken). It was confirmed that the administration of ARHGAP-1748-BNA-16 significantly suppressed the expansion of the tumor ( FIG. 14 ). Further, on day 14 after the administration of ARHGAP-1748-BNA-16, incorporation of FITC-labeled ARHGAP-1748-BNA-16 into various organs (brain, liver, spleen, lung, kidney, and intestine) and tumor portion of the mice was confirmed. As a result, it was confirmed that ARHGAP-1748-BNA-16 reached only the tumor portion and did not reach the other organs ( FIG. 15 ).
Example 9
Confirmation of Tumor Metastasis Suppressive Effect of Antisense BNA (In Vivo)
[0108] In this example, an in vivo metastasis suppressive effect of antisense BNA (ARHGAP-1748-BNA-16: #1748) on malignant tumor cells was confirmed. A lentivirus containing a luciferase-encoding gene was produced, and allowed to infect HT1080 (human fibrosarcoma cells) to introduce the luciferase gene. Thus, cells having introduced therein luciferase (HT1080/Luc) were produced. 5×10 6 HT1080/Luc cells were intravenously injected into nude mice. 14 days after the injection of HT1080/Luc, 8 mg/kg of Adriamycin or 10 mg/kg of the antisense BNA were intravenously injected. After an additional 7 days, 150 mg/kg of luciferin were administered, and lung metastasis of HT1080/Luc was confirmed by luminescence imaging ( FIG. 16 ). As a result, the tumor was smaller in the antisense BNA-administered group (n=3) than in the Adriamycin-administered group (n=3) ( FIG. 17 ). In addition, the weight of the lung of each of the mice was measured, and the results showed that the weight of the lung was smaller in the antisense BNA-administered group than in the Adriamycin-administered group. On the other hand, a difference in body weight was not found between the two groups ( FIG. 18 ). This suggested that tumor cell metastasis was suppressed to a greater degree in the antisense BNA-administered group than in the Adriamycin-administered group.
INDUSTRIAL APPLICABILITY
[0109] As described in detail above, the novel antitumor agent containing as an active ingredient a substance capable of inhibiting a cell cycle-dependent RhoGAP of the present invention suppresses cancer cell invasion and/or metastasis in, for example, cancer cells derived from cancer capable of expressing the cell cycle-dependent RhoGAP, specifically, cancer capable of expressing ARHGAP11A, such as colorectal cancer, pancreatic cancer, prostate cancer cells, breast cancer, head and neck cancer, melanoma, ovarian cancer, lung cancer, brain cancer, pancreatic cancer, hepatocellular carcinoma, renal cell carcinoma, or skin cancer. Hitherto, there has been almost no effective drug that is an antitumor agent capable of suppressing cancer cell invasion and/or metastasis. The provision of the drug capable of suppressing cancer cell invasion and/or metastasis affecting malignant progression of cancer enables an effective cancer therapy. Accordingly, the present invention is useful.
[0110] Further, as a result of testing the expression of the cell cycle-dependent RhoGAP such as ARHGAP11A in a biological specimen on the basis of, for example, mRNA, significant differences have been found in association with the stage of cancer progression (staging) and relapse free survival. Thus, a test for a malignant tumor can be performed by quantifying the cell cycle-dependent RhoGAP in a biological specimen. Further, in terms of the expression of the cell cycle-dependent RhoGAP such as the mRNA level of ARHGAP11A in the biological specimen, significant differences are found in association with the stage of malignant tumor progression (staging) and relapse free survival. Thus, it is considered that the stage of progression and/or prognosis of cancer can be predicted by measuring the expression of the cell cycle-dependent RhoGAP such as ARHGAP11A in the biological specimen. Accordingly, the present invention is useful.
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The present invention provides a novel antitumor agent that acts through a novel mechanism. The novel antitumor agent contains as an active ingredient a substance capable of inhibiting a cell cycle-dependent Rho GTPase activating protein (RhoGAP). The RhoGAP is cell cycle-dependent and plays an important role in a process through which cancer cells acquire invasive capacity and/or metastatic capacity. The invasion and/or metastasis of cancer cells can be controlled by targeting the RhoGAP. Examples of the substance capable of inhibiting a cell cycle-dependent RhoGAP include an antisense oligonucleotide against a gene encoding the RhoGAP and an oligonucleotide that induces RNA interference of the gene. As the oligonucleotide, one containing an artificial nucleic acid such as BNA is preferred because of its excellent stability. The present invention also provides a screening method including selecting an antitumor agent capable of suppressing cancer cell invasion and/or metastasis through a novel mechanism. The screening method is a screening method for a novel antitumor agent, including selecting a substance capable of inhibiting a cell cycle-dependent Rho GTPase activating protein.
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RELATED APPLICATIONS
[0001] This application is a Divisional of Application of: Choong-Chin Liew, Filed: March 12, 2004, Serial No.: Not Yet Assigned, Entitled: A Method for the Detection of Coronary Artery Disease Related Gene Transcripts in Blood, Our Reference No.: 4231/2055B, which a continuation in part of application Ser. No. 10/601,518, filed on Jun. 20, 2003, which is a continuation-in-part of application Ser. No. 10/085,783, filed on Feb. 28, 2002, which claims the benefit of U.S. Provisional Application No. 60/271,955, filed on Feb. 28, 2001, U.S. Provisional Application No. 60/275,017 filed Mar. 12, 2001, and U.S. Provisional Application No. 60/305,340; filed Jul. 13 2001, and is also a continuation-in-part of application Ser. No. 10/268,730 filed on Oct. 9, 2002, which is a continuation of U.S. application Ser. No. 09/477,148 filed Jan. 4, 2000, now abandoned, which claims the benefit of U.S. Provisional Application No. 60/115,125 filed on Jan. 6, 1999. Each of these applications is incorporated herein by reference in their entirety, including figures and drawings.
TABLES
[0002] This application includes a compact disc in duplicate (2 compact discs: Tables—Copy 1 and Tables—Copy 2), which are hereby incorporated by reference in their entirety. Each compact disc is identical and contains the following files (corresponding to Tables 2-4):
TABLE DESCRIPTION SIZE CREATED Text File Name 1 2 multi-gene comparison 371,563 Mar. 25, 2004 TABLE2.TXT 2 3A GLF 8 - hypertension 138,940 Mar. 28, 2004 TABLE3A.TXT 3 3AA GLF 29 - asthma 36,121 Mar. 27, 2004 TABLE3AA.TXT 4 3AB multi OA 29,898 Mar. 27, 2004 TABLE3AB.TXT 5 3AC GL MDS vs. schizo 114,078 Mar. 27, 2004 TABLE3AC.TXT 6 3AD steroid differential 64,646 Mar. 27, 2004 TABLE3AD.TXT 7 3B GLF 9 - obesity 147,421 Mar. 25, 2004 TABLE3B.TXT 8 3C GLF 10 - allergies 95,700 Mar. 25, 2004 TABLE3C.TXT 9 3D GLF 11 - steroids 93,808 Mar. 25, 2004 TABLE3D.TXT 10 3E GLF 12 - hypertension 314,854 Mar. 25, 2004 TABLE3E.TXT 11 3F GLF 13 - obesity 181,310 Mar. 25, 2004 TABLE3F.TXT 12 3G GLF 14 - diabetes 146,212 Mar. 26, 2004 TABLE3G.TXT 13 3H GLF 15 - hyperlipidemia 165,909 Mar. 26, 2004 TABLE3H.TXT 14 3I GLF 16 - lung 92,936 Mar. 25, 2004 TABLE3I.TXT 15 3J GLF 17 - bladder 1,143,423 Mar. 26, 2004 TABLE3J.TXT 16 3K GLF 18 - bladder 953,119 Mar. 26, 2004 TABLE3K.TXT 17 3L GLF 19 - Coronary Art Dis. 246,178 Mar. 26, 2004 TABLE3L.TXT 18 3M GLF 20 - rheumarth 329,672 Mar. 26, 2004 TABLE3M.TXT 19 3N GLF 21 - depression 153,108 Mar. 26, 2004 TABLE3N.TXT 20 3O GLF 22 - rheumarth 49,043 Mar. 26, 2004 TABLE3O.TXT 21 3P GLF hypertension 577 only 84,945 Mar. 26, 2004 TABLE3P.TXT 22 3Q GLF OA hypertension shared 33,081 Mar. 26, 2004 TABLE3Q.TXT 23 3R GL obesity 519 79,544 Mar. 26, 2004 TABLE3R.TXT 24 3S GL obesity shared 152 24,583 Mar. 26, 2004 TABLE3S.TXT 25 3T GL allergy specific 39,547 Mar. 25, 2004 TABLE3T.TXT 26 3U GL allergy OA shared 241 35,603 Mar. 25, 2004 TABLE3U.TXT 27 3V GL steroid 362 54,954 Mar. 26, 2004 TABLE3V.TXT 28 3W GL OA steroid shared 31,459 Mar. 27, 2004 TABLE3W.TXT 29 3X GLF 26 - liver cancer 435,093 Mar. 27, 2004 TABLE3X.TXT 30 3Y GLF 27 - schizophrenia 578,949 Mar. 26, 2004 TABLE3Y.TXT 31 3Z GLF 28 - chagas 202,477 Mar. 28, 2004 TABLE3Z.TXT 32 4 sequence listing 114,765 Mar. 11, 2004 TABLE4.TXT
BACKGROUND
[0003] The blood is a vital part of the human circulatory system for the human body. Numerous cell types make up the blood tissue including monocytes, leukocytes, lymphocytes and erythrocytes. Although many blood cell types have been described, there are likely many as yet undiscovered cell types in the human blood. Some of these undiscovered cells may exist transiently, such as those derived from tissues and organs that are constantly interacting with the circulating blood in health and disease. Thus, the blood can provide an immediate picture of what is happening in the human body at any given time.
[0004] The turnover of cells in the hematopoietic system is enormous. It was reported that over one trillion cells, including 200 billion erythrocytes and 70 billion neutrophilic leukocytes, turn over each day in the human body (Ogawa 1993). As a consequence of continuous interactions between the blood and the body, genetic changes that occur within the cells or tissues of the body will trigger specific changes in gene expression within blood. It is the goal of the present invention that these genetic alterations be harnessed for diagnostic and prognostic purposes, which may lead to the development of therapeutics for ameliorating disease.
[0005] For example, isoformic myosin heavy chain genes are known to be generally expressed in cardiac muscle tissue. In the rodent, the βMyHC gene is only highly expressed in the fetus and in diseased states such as overt cardiac hypertrophy, heart failure and diabetes; the αMyHC gene is highly expressed shortly after birth and continues to be expressed in the adult heart. In the human, however, βMyHC is highly expressed in the ventricles from the fetal stage through adulthood. This highly expressed βMyHC, which harbours several mutations, has been demonstrated to be involved in familial hypertrophic cardiomyopathy (Geisterfer-Lowrance et al. 1990). It was reported that mutations of βMyHC can be detected by PCR using blood lymphocyte DNA (Ferrie et al., 1992). Most recently, it was also demonstrated that mutations of the myosin-binding protein C in familial hypertrophic cardiomyopathy can be detected in the DNA extracted from lymphocytes (Niimura et al., 1998).
[0006] Similarly, APP and APC, which are known to be tissue specific and predominantly expressed in the brain and intestinal tract, are also detectable in the transcripts of blood. These cell- or tissue-specific transcripts are not detectable by Northern blot analysis. However, the low number of transcript copies can be detected by RT-PCR analysis. These findings strongly demonstrate that genes preferentially expressed in specific tissues can be detected by a highly sensitive RT-PCR assay. In recent years, evidence has been obtained to indicate that expression of cell or tissue-restricted genes can be detected in the certain peripheral nucleated blood cells of patients with metastatic transitional cell carcinoma (Yuasa et al. 1998) and patients with prostate cancer (Gala et al. 1998).
[0007] In the prior art, there is a need for large samples and/or costly and time-consuming separation of cell types within the blood (Kimoto (1998) and Chelly et al. (1989; 1988)). The prior art, however, is deficient in non-invasive methods of screening for tissue-specific diseases. The present invention fulfills this long-standing need and desire in the art.
SUMMARY OF THE INVENTION
[0008] The present invention relates generally to the molecular biology of human diseases. More specifically, the present invention relates to a process using the genetic information contained in human peripheral whole blood for the diagnosis, prognosis and monitoring of genetic and infectious disease in the human body.
[0009] This present invention discloses a process of using the genetic information contained in human peripheral whole blood in the diagnosis, prognosis and monitoring of genetic and infectious disease in the human body. The process described herein requires a simple blood sample and is, therefore, non-invasive compared to conventional practices used to detect tissue specific disease, such as biopsies.
[0010] The invention is based on the discovery that gene expression in the blood is reflective of body state and, as such, the resultant disruption of homeostasis under conditions of disease can be detected through analysis of transcripts differentially expressed in the blood alone. Thus, the identification of several key transcripts or genetic markers in blood will provide information about the genetic state of the cells, tissues, organ systems of the human body in health and disease.
[0011] The present invention demonstrates that a simple drop of blood may be used to determine the quantitative expression of various mRNAs that reflect the health/disease state of the subject through the use of RT-PCR analysis. This entire process takes about three hours or less. The single drop of blood may also be used for multiple RT-PCR analyses. It is believed that the present finding can potentially revolutionize the way that diseases are detected, diagnosed and monitored because it provides a non-invasive, simple, highly sensitive and quick screening for tissue-specific transcripts. The transcripts detected in whole blood have potential as prognostic or diagnostic markers of disease, as they reflect disturbances in homeostasis in the human body. Delineation of the sequences and/or quantitation of the expression levels of these marker genes by RT-PCR will allow for an immediate and accurate diagnostic/prognostic test for disease or to assess the efficacy and monitor a particular therapeutic.
[0012] One object of the present invention is to provide a non-invasive method for the diagnosis, prognosis and monitoring of genetic and infectious disease in humans and animals.
[0013] In one embodiment of the present invention, there is provided a method for detecting expression of a gene in blood from a subject, comprising the steps of: a) quantifying RNA from a subject blood sample; and b) detecting expression of the gene in the quantified RNA, wherein the expression of the gene in quantified RNA indicates the expression of the gene in the subject blood. An example of the quantifying method is by mass spectrometry.
[0014] In another embodiment of the present invention, there is provided a method for detecting expression of one or more genes in blood from a subject, comprising the steps of: a) obtaining a subject blood sample; b) extracting RNA from the blood sample; c) amplifying the RNA; d) generating expressed sequence tags (ESTs) from the amplified RNA product; and e) detecting expression of the genes in the ESTs, wherein the expression of the genes in the ESTs indicates the expression of the genes in the subject blood. Preferably, the subject is a fetus, an embryo, a child, an adult or a non-human animal. The genes are non-cancer-associated and tissue-specific genes. Still preferably, the amplification is performed by RT-PCR using random sequence primers or gene-specific primers.
[0015] In still another embodiment of the present invention, there is provided a method for detecting expression of one or more genes in blood from a subject, comprising the steps of: a) obtaining a subject blood sample; b) extracting DNA fragments from the blood sample; c) amplifying the DNA fragments; and d) detecting expression of the genes in the amplified DNA product, wherein the expression of the genes in the amplified DNA product indicates the expression of the genes in the subject blood.
[0016] In yet another embodiment of the present invention, there is provided a method for monitoring a course of a therapeutic treatment in an individual, comprising the steps of: a) obtaining a blood sample from the individual; b) extracting RNA from the blood sample; c) amplifying the RNA; d) generating expressed sequence tags (ESTs) from the amplified RNA product; e) detecting expression of genes in the ESTs, wherein the expression of the genes is associated with the effect of the therapeutic treatment; and f) repeating steps a)-e), wherein the course of the therapeutic treatment is monitored by detecting the change of expression of the genes in the ESTs. Such a method may also be used for monitoring the onset of overt symptoms of a disease, wherein the expression of the genes is associated with the onset of the symptoms. Preferably, the amplification is performed by RT-PCR, and the change of the expression of the genes in the ESTs is monitored by sequencing the ESTs and comparing the resulting sequences at various time points; or by performing single nucleotide polymorphism analysis and detecting the variation of a single nucleotide in the ESTs at various time points.
[0017] In still yet another embodiment of the present invention, there is provided a method for diagnosing a disease in a test subject, comprising the steps of: a) generating a cDNA library for the disease from a whole blood sample from a normal subject; b) generating expressed sequence tag (EST) profile from the normal subject cDNA library; c) generating a cDNA library for the disease from a whole blood sample from a test subject; d) generating EST profile from the test subject cDNA library; and e) comparing the test subject EST profile to the normal subject EST profile, wherein if the test subject EST profile differs from the normal subject EST profile, the test subject might be diagnosed with the disease.
[0018] In still yet another embodiment of the present invention, there is provided a kit for diagnosing, prognosing or predicting a disease, comprising: a) gene-specific primers; wherein the primers are designed in such a way that their sequences contain the opposing ends of two adjacent exons for the specific gene with the intron sequence excluded; and b) a carrier, wherein the carrier immobilizes the primer(s). Preferably, the gene-specific primers are selected from the group consisting of insulin-specific primers, atrial natriuretic factor-specific primers, zinc finger protein gene-specific primers, beta-myosin heavy chain gene-specific primers, amyloid precursor protein gene-specific primers, and adenomatous polyposis- coli protein gene-specific primers. Further preferably, the gene-specific primers are selected from the group consisting of SEQ ID Nos. 1 and 2; and SEQ ID Nos. 5 and 6. Such a kit may be applied to a test subject whole blood sample to diagnose, prognose or predict a disease by detecting the quantitative expression levels of specific genes associated with the disease in the test subject and then comparing to the levels of same genes expressed in a normal subject. Such a kit may also be used for monitoring a course of therapeutic treatment or monitoring the onset of overt symptoms of a disease.
[0019] In yet another embodiment of the present invention, there is provided a kit for diagnosing, prognosing or predicting a disease, comprising: a) probes derived from a whole blood sample for a specific disease; and b) a carrier, wherein the carrier immobilizes the probes. Such a kit may be applied to a test subject whole blood sample to diagnose, prognose or predict a disease by detecting the quantitative expression levels of specific genes associated with the disease in the test subject and then comparing to the levels of same genes expressed in a normal subject. Such a kit may also be used for monitoring a course of therapeutic treatment or monitoring the onset of overt symptoms of a disease.
[0020] Furthermore, the present invention provides a cDNA library specific for a disease, wherein the cDNA library is generated from whole blood samples.
[0021] In one embodiment of the present invention, there is a method of identifying one or more genetic markers for a disease, wherein each of said one or more genetic markers corresponds to a gene transcript, comprising the steps of: a) determining the level of one or more gene transcripts expressed in blood obtained from one or more individuals having a disease, wherein each of said one or more transcripts is expressed by a gene that is a candidate marker for disease; and b) comparing the level of each of said one or more gene transcripts from said step a) with the level of each of said one or more genes transcripts in blood obtained from one or more individuals not having a disease, wherein those compared transcripts which display differing levels in the comparison of step b) are identified as being genetic markers for a disease.
[0022] In another embodiment of the present invention, there is a method of identifying one or more genetic markers for a disease, wherein each of said one or more genetic markers corresponds to a gene transcript, comprising the steps of: a) determining the level of one or more gene transcripts expressed in blood obtained from one or more individuals having a disease, wherein each of said one or more transcripts is expressed by a gene that is a candidate marker for a disease; and b)comparing the level of each of said one or more gene transcripts from said step a) with the level of each of said one or more genes transcripts in blood obtained from one or more individuals having a disease, wherein those compared transcripts which display the same levels in the comparison of step b) are identified as being genetic markers for a disease.
[0023] In another embodiment of the present invention, there is a method of identifying one or more genetic markers of a stage of a disease progression or regression, wherein each of said one or more genetic markers corresponds to a gene transcript, comprising the steps of: a) determining the level of one or more gene transcripts expressed in blood obtained from one or more individuals having a stage of a disease, wherein said one or more individuals are at the same progressive or regressive stage of a disease, and wherein each of said one or more transcripts is expressed by a gene that is a candidate marker for determining the stage of progression or regression of a disease, and; b) comparing the level of each of said one or more gene transcripts from said step a) with the level of each of said one or more genes transcripts in blood obtained from one or more individuals who are at a progressive or regressive stage of a disease distinct from that of said one or more individuals of step a), wherein those compared transcripts which display differing levels in the comparison of step b) are identified as being genetic markers for the stage of progression or regression of a disease.
[0024] In another embodiment of the present invention, there is a method of identifying one or more genetic markers of a stage of a disease progression or regression, wherein each of said one or more genetic markers corresponds to a gene transcript, comprising the steps of: a) determining the level of one or more gene transcripts expressed in blood obtained from one or more individuals having a stage of a disease, wherein said one or more individuals are at the same progressive or regressive stage of a disease, and wherein each of said one or more transcripts is expressed by a gene that is a candidate marker for determining the stage of progression or regression of a disease, and b) comparing the level of each of said one or more gene transcripts from said step a) with the level of each of said one or more genes transcripts in blood obtained from one or more individuals who are at a progressive or regressive stage of a disease identical to that of said one or more individuals of step a), wherein those compared transcripts which display the same levels in the comparison of step b) are identified as being genetic markers for the stage of progression or regression of a disease.
[0025] Further embodiments of the methods described in the previous four paragraphs include the embodiments wherein each of said one or more markers identifies one or more transcripts of one or more non immune response genes, wherein each of said one or more markers identifies a transcript of a gene expressed by non-blood tissue, wherein each of said one or more markers identifies a transcript of a gene expressed by non-lymphoid tissue, wherein said one or more markers identifies a sequence selected from the sequences listed in any one of Table 3A-Z and Tables 3AA, 3AB, 3AC and 3AD, wherein said one or more markers identifies the sequence of one or more of the sequences selected from the group consisting of ANF, ZFP and βMyHC, wherein said blood comprises a blood sample obtained from said one or more individuals, wherein said blood sample consists of whole blood, wherein said blood sample consists of a drop of blood, and wherein said blood sample consists of blood that has been lysed.
[0026] In another embodiment of the present invention, there is a method of diagnosing or prognosing a disease in an individual, comprising the steps of: a) determining the level of one or more gene transcripts in blood obtained from said individual suspected of having a disease, and b) comparing the level of each of said one or more gene transcripts in said blood according to step a) with the level of each of said one or more gene transcripts in blood from one or more individuals not having a disease, wherein detecting a difference in the levels of each of said one or more gene transcripts in the comparison of step b) is indicative of a disease in the individual of step a).
[0027] In another embodiment of the present invention, there is a method of diagnosing or prognosing a disease in an individual, comprising the steps of: a) determining the level of one or more gene transcripts in blood obtained from said individual suspected of having a disease, and b) comparing the level of each of said one or more gene transcripts in said blood according to step a) with the level of each of said one or more gene transcripts in blood from one or more individuals having a disease, wherein detecting the same levels of each of said one or more gene transcripts in the comparison of step b) is indicative of a disease in the individual of step a).
[0028] In another embodiment of the present invention, there is a method of determining a stage of disease progression or regression in an individual having a disease, comprising the steps of: a) determining the level of one or more gene transcripts in blood obtained from said individual having a disease, and b) comparing the level of each if said one or more gene transcripts in said blood according to step a) with the level of each of said one or more gene transcripts in blood obtained from one or more individuals who each have been diagnosed as being at the same progressive or regressive stage of a disease, wherein the comparison from step b) allows the determination of the stage of a disease progression or regression in an individual.
[0029] In another embodiment of the present invention, there is a method of diagnosing or prognosing osteoarthritis in an individual, comprising the steps of: a) determining the level of one or more gene transcripts expressed in blood obtained from said individual, wherein said one or more gene transcripts correspond to said one or more markers of claim 1 and claim 2 , and b) comparing the level of each of said one or more gene transcripts in said blood according to step a) with the level of each of said one or more gene transcripts in blood from one or more individuals having osteoarthritis, c) comparing the level of each of said one or more gene transcripts in said blood according to step a) with the level of each of said one or more gene transcripts in blood from one or more individuals not having osteoarthritis, d) determining whether the level of said one or more gene transcripts of step a) classify with the levels of said transcripts in step b) as compared with the levels of said transcripts in step c) wherein said determination is indicative of said individual of step a) having osteoarthritis.
[0030] In another embodiment of the present invention, there is a method of determining a stage of disease progression or regression in an individual having osteoarthritis, comprising the steps of: a) determining the level of one or more gene transcripts expressed in blood obtained from said individual having said stage of osteoarthritis, wherein said one or more gene transcripts correspond to the markers of claim 3 and claim 4 , and b) comparing the level of each of said one or more gene transcripts in said blood according to step a) with the level of each of said one or more gene transcripts in blood from one or more individuals having said stage of osteoarthritis, c) comparing the level of each of said one or more gene transcripts in said blood according to step a) with the level of each of said one or more gene transcripts in blood from one or more individuals not having said stage of osteoarthritis, d) determining whether the level of said one or more gene transcripts of step a) classify with the levels of said transcripts in step b) as compared with levels of said transcripts in step c), wherein said determination is indicative of said individual of step a) having said stage of osteoarthritis.
[0031] Further embodiments of the methods described in the previous ten paragraphs include embodiments comprising a further step of isolating RNA from said blood samples, and embodiments comprising determining the level of each of said one or more gene transcripts comprising quantitative RT-PCR (QRT-PCR), wherein said one or more transcripts are from step a) and/or step b) of said methods. Further embodiments of these methods include embodiments wherein said QRT-PCR comprises primers which hybridize to one or more transcripts or the complement thereof, wherein said one or more transcripts are from step a) and/or step b) of said methods, embodiments wherein said primers are 15-25 nucleotides in length, and embodiments wherein said primers hybridize to one or more of the sequences of any one of Table 3A-Z and Tables 3AA, 3AB, 3AC and 3AD, or the complement thereof. Further embodiments of the methods described in the previous eight paragraphs include embodiments wherein the step of determining the level of each of said one or more gene transcripts comprises hybridizing a first plurality of isolated nucleic acid molecules that correspond to said one or more transcripts to an array comprising a second plurality of isolated nucleic acid molecules, wherein in one embodiment said first plurality of isolated nucleic acid molecules comprises RNA, DNA, cDNA, PCR products or ESTs, wherein in one embodiment said array comprises a plurality of isolated nucleic acid molecules comprising RNA, DNA, cDNA, PCR products or ESTs, wherein in one embodiment said array comprises two or more of the genetic markers of said methods, wherein in one embodiment said array comprises a plurality of nucleic acid molecules that correspond to genes of the human genome.
[0032] In another embodiment of the present invention, there is a plurality of nucleic acid molecules that correspond to two or more sequences from each of any one of Table 3A-Z and Tables 3AA, 3AB, 3AC and 3AD.
[0033] In another embodiment of the present invention, there is an array which comprises a plurality of nucleic acid molecules that correspond to two or more sequences from each of any one of Table 3A-Z and Tables 3AA, 3AB, 3AC and 3AD.
[0034] In another embodiment of the present invention, there is a kit for diagnosing or prognosing a disease comprising: a) two gene-specific priming means designed to produce double stranded DNA complementary to a gene selected from the group consisting of Table 3L; wherein said first priming means contains a sequence which can hybridize to RNA, cDNA or an EST complementary to said gene to create an extension product and said second priming means capable of hybridizing to said extension product; b) an enzyme with reverse transcriptase activity c) an enzyme with thermostable DNA polymerase activity and d) a labeling means; wherein said primers are used to detect the quantitative expression levels of said gene in a test subject
[0035] In another embodiment of the present invention, there is a kit for monitoring a course of therapeutic treatment of a disease, comprising a) two gene-specific priming means designed to produce double stranded DNA complementary to a gene selected group consisting of any one of Table 3A-Z and Tables 3AA, 3AB, 3AC and 3AD; wherein said first priming means contains a sequence which can hybridize to RNA, cDNA or an EST complementary to said gene to create an extension product and said second priming means capable of hybridizing to said extension product; b) an enzyme with reverse transcriptase activity c) an enzyme with thermostable DNA polymerase activity and d) a labeling means; wherein said primers are used to detect the quantitative expression levels of said gene in a test subject.
[0036] In another embodiment of the present invention, there is a kit for monitoring progression or regression of a disease, comprising: a) two gene-specific priming means designed to produce double stranded DNA complementary to a gene selected group consisting of any one of Table 3A-Z and Tables 3AA, 3AB, 3AC and 3AD; wherein said first priming means contains a sequence which can hybridize to RNA, cDNA or an EST complementary to said gene to create an extension product and said second priming means capable of hybridizing to said extension product; b) an enzyme with reverse transcriptase activity c) an enzyme with thermostable DNA polymerase activity and d) a labeling means; wherein said primers are used to detect the quantitative expression levels of said gene in a test subject.
[0037] In another embodiment of the present invention, there is a plurality of nucleic acid molecules that identify or correspond to two or more sequences from any one of Table 3A-Z and Tables 3AA, 3AB, 3AC and 3AD.
[0038] Other and further aspects, features, and advantages of the present invention will be apparent from the following description of the presently preferred embodiments of the invention. These embodiments are given for the purpose of disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] The above-recited features, advantages and objects of the invention, as well as others which will become clear, are attained and can be understood in detail, more particular descriptions of the invention briefly summarized above may be had by reference to certain embodiments thereof which are illustrated in the appended drawings. These drawings form a part of the specification. It is to be noted, however, that the appended drawings illustrate preferred embodiments of the invention and therefore are not to be considered limiting in their scope.
[0040] FIG. 1 shows the following RNA samples prepared from human blood; FIG. 1A : Lane 1, Molecular weight marker; Lane 2, RT-PCR on APP gene; Lane 3, PCR on APP gene; Lane 4, RT-PCR on APC gene; Lane 5, PCR on APC gene; FIG. 1B : Lanes 1 and 2, RT-PCR and PCR of βMyHC, respectively; Lanes 3 and 4, RT-PCR of βMyHC from RNA prepared from human fetal and human adult heart, respectively; Lane 5, Molecular weight marker.
[0041] FIG. 2 shows quantitative RT-PCR analysis performed on RNA samples extracted from a drop of blood. Forward primer (5′-GCCCTCTGGGGACCTGAC-3′, SEQ ID No. 1) of exon 1 and reverse primer (5′-CCCACCTGCAGGTCCTCT-3″, SEQ ID No. 2) of exons 1 and 2 of insulin gene. Blood samples of 4 normal subjects were assayed. Lanes 1, 3, 5 and 7 represent overnight “fasting” blood sample and lanes 2, 4, 6 and 8 represent “non-fasting” samples.
[0042] FIG. 3 shows quantitative RT-PCR analysis performed on RNA samples extracted from a drop of blood. Lanes 1 and 2 represent normal healthy person and lane 3 represents late-onset diabetes (Type II) and lane 4 represents asymptomatic diabetes.
[0043] FIG. 4 shows multiple RT-PCR assay in a drop of blood. Primers were derived from insulin gene (INS), zinc-finger protein gene (ZFP) and house-keeping gene (GADH). Lane 1 represents normal person. Lane 2 represents late-onset diabetes and lane 3 represents asymptomatic diabetes.
[0044] FIG. 5 shows standardized levels of insulin gene ( FIG. 5A ) and ZFP gene ( FIG. 5B ) expressed in a drop of blood. The first three subjects were normal, second two subjects showed normal glucose tolerance, and the last subject had late onset diabetes type II. FIG. 5C shows standardized levels of insulin gene expressed in each fractionated cell from whole blood.
[0045] FIG. 6 shows the differential screening of human blood cell cDNA library with different cDNA probes of heart and brain tissue. FIG. 6A shows blood cell cDNA probes vs. adult heart cDNA probes. FIG. 6B shows blood cell cDNA probes vs. human brain cDNA probes.
[0046] FIG. 7 graphically shows the 1,800 unique genes in human blood and in the human fetal heart grouped into seven cellular functions.
[0047] FIG. 8 shows a diagrammatic representation of gene expression profiles of blood samples from individuals having both osteoarthritis and hypertension as compared with gene expression profiles from normal individuals.
[0048] FIG. 9 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having both osteoarthritis and who were obese as described herein as compared with gene expression profiles from normal individuals
[0049] FIG. 10 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having both osteoarthritis and allergies as described herein as compared with gene expression profiles from normal individuals.
[0050] FIG. 11 shows a diagrammatic representation of gene expression profiles of blood samples from individuals having osteoarthritis and who were subject to systemic steroids as described herein as compared with gene expression profiles from normal individuals.
[0051] FIG. 12 shows a diagrammatic representation of gene expression profiles of blood samples from individuals having hypertension as compared with gene expression profiles from samples of both non-hypertensive and normal individuals.
[0052] FIG. 13 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as obese as described herein as compared with gene expression profiles from normal and non-obese individuals.
[0053] FIG. 14 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having type 2 diabetes as described herein as compared with gene expression profiles from normal and non-type 2 diabetes individuals.
[0054] FIG. 15 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having hyperlipidemia as described herein as compared with gene expression profiles from normal and non-hyperlipidemia patients.
[0055] FIG. 16 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having lung disease as described herein as compared with gene expression profiles from normal and non lung disease individuals.
[0056] FIG. 17 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having bladder cancer as described herein as compared with gene expression profiles from non bladder cancer individuals.
[0057] FIG. 18 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having advanced stage bladder cancer or early stage bladder cancer as described herein as compared with gene expression profiles from non bladder cancer individuals.
[0058] FIG. 19 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having coronary artery disease (CAD) as described herein as compared with gene expression profiles from non-coronary artery disease individuals.
[0059] FIG. 20 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having rheumatoid arthritis as described herein as compared with gene expression profiles from non-rheumatoid arthritis individuals.
[0060] FIG. 21 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having depression as described herein as compared with gene expression profiles from non-depression individuals.
[0061] FIG. 22 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having various stages of osteoarthritis as described herein as compared with gene expression profiles from normal individuals.
[0062] FIG. 23 shows RT-PCR of overexpressed genes in CAD peripheral blood cells identified using microarray experiments, including PBP, PF4 and F13A.
[0063] FIG. 24 shows the “Blood Chip”, a cDNA microarray slide with 10,368 PCR products derived from peripheral blood cell cDNA libraries. Colors represent hybridization to probes labelled with Cy3 (green) or Cy5 (red). Yellow spots indicate common hybridization between both probes. In slide A, normal blood cell RNA samples were labelled with Cy3 and CAD blood cell RNA samples were labelled with Cy5. In slide B, Cy3 and Cy5 were switched to label the RNA samples. (Cluster analysis revealed distinct gene expression profiles for normal and CAD samples.)
[0064] FIG. 25 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having liver cancer as described herein as compared with gene expression profiles from normal individuals.
[0065] FIG. 26 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having schizophrenia as described herein as compared with gene expression profiles from normal individuals.
[0066] FIG. 27 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having symptomatic or asymptomatic chagas disease as described herein as compared with gene expression profiles from normal individuals.
[0067] FIG. 28 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having asthma and OA as compared with individuals having just OA.
[0068] FIG. 29 shows a venn diagram illustrating a summary of the analysis comparing hypertension and OA patients vs. normal (Table 3A) hypertension and OA patients vs. OA patients (Table 3P) and the intersection between the two populations of genes (Table 3Q).
[0069] FIG. 30 shows a venn diagram illustrating a summary of the analysis comparing obesity and OA patients vs. normal (Table 3B) obesity and OA patients vs. OA patients (Table 3R) and the intersection between the two populations of genes (Table 3S).
[0070] FIG. 31 shows a venn diagram illustrating a summary of the analysis comparing allergy and OA patients vs. normal (Table 3C) allergy and OA patients vs. OA patients (Table 3T) and the intersection between the two populations of genes (Table 3U).
[0071] FIG. 32 shows a venn diagram illustrating a summary of the analysis comparing systemic steroids and OA patients vs. normal (Table 3D) systemic steroids and OA patients vs. OA patients (Table 3V) and the intersection between the two populations of genes (Table 3W).
[0072] FIG. 33 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having Manic Depression as compared with those individuals who have Schizophrenia.
[0073] FIG. 34 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having OA and being one form of systemic steroids.
DETAILED DESCRIPTION
[0074] In accordance with the present invention, there may be employed conventional molecular biology, microbiology, and recombinant DNA techniques within the skill of the art. Such techniques are explained fully in the literature. See, e.g., Sambrook, Fritsch & Maniatis, “Molecular Cloning: A Laboratory Manual (1982); “DNA Cloning: A Practical Approach,” Volumes I and II (D. N. Glover ed. 1985); “Oligonucleotide Synthesis” (M. J. Gait ed. 1984); “Nucleic Acid Hybridization” [B. D. Hames & S. J. Higgins eds. (1985)]; “Transcription and Translation” [B. D. Hames & S. J. Higgins eds. (1984)]; “Animal Cell Culture” [R. I. Freshney, ed. (1986)]; “Immobilized Cells And Enzymes” [IRL Press, (1986)]; B. Perbal, “A Practical Guide To Molecular Cloning” (1984). Therefore, if appearing herein, the following terms shall have the definitions set out below.
[0075] A “cDNA” is defined as copy-DNA or complementary-DNA, and is a product of a reverse transcription reaction from an mRNA transcript. “RT-PCR” refers to reverse transcription polymerase chain reaction and results in production of cDNAs that are complementary to the mRNA template(s).
[0076] In addition to RT-PCR, other methods of amplifying may also be used for the purpose of measuring/quantitating tissue-specific transcripts in human blood. For example, mass spectrometry may be used to quantify the transcripts (Koster et al., 1996; Fu et al., 1998). The application of presently disclosed method for detecting tissue-specific transcripts in blood does not restrict to subjects undergoing course of therapy or treatment, it may also be used for monitoring a patient for the onset of overt symptoms of a disease. Furthermore, the present method may be used for detecting any gene transcripts in blood. A kit for diagnosing, prognosing or even predicting a disease may be designed using gene-specific primers or probes derived from a whole blood sample for a specific disease and applied directly to a drop of blood. A cDNA library specific for a disease may be generated from whole blood samples and used for diagnosis, prognosis or even predicting a disease.
[0077] The term “oligonucleotide” is defined as a molecule comprised of two or more deoxyribonucleotides and/ or ribonucleotides, preferably more than three. Its exact size will depend upon many factors which, in turn, depend upon the ultimate function and use of the oligonucleotide. The upper limit may be 15, 20, 25, 30, 40 or 50 nucleotides in length. The term “primer” as used herein refers to an oligonucleotide, whether occurring naturally as in a purified restriction digest or produced synthetically, which is capable of acting as a point of initiation of synthesis when placed under conditions in which synthesis of a primer extension product, which is complementary to a nucleic acid strand, is induced, i.e., in the presence of nucleotides and an inducing agent such as a DNA polymerase and at a suitable temperature and pH. The primer may be either single-stranded or double-stranded and must be sufficiently long to prime the synthesis of the desired extension product in the presence of the inducing agent. The exact length of the primer will depend upon many factors, including temperature, source of primer and the method used. For example, for diagnostic applications, depending on the complexity of the target sequence, the oligonucleotide primer typically contains 15-25 or more nucleotides, although it may contain fewer nucleotides. The factors involved in determining the appropriate length of primer are readily known to one of ordinary skill in the art.
[0078] As used herein, random sequence primers refer to a composition of primers of random sequence, i.e. not directed towards a specific sequence. These sequences possess sufficient complementary to hybridize with a polynucleotide and the primer sequence need not reflect the exact sequence of the template.
[0079] “Restriction fragment length polymorphism” refers to variations in DNA sequence detected by variations in the length of DNA fragments generated by restriction endonuclease digestion.
[0080] A standard Northern blot assay can be used to ascertain the relative amounts of mRNA in a cell or tissue obtained from plant or other tissue, in accordance with conventional Northern hybridization techniques known to those persons of ordinary skill in the art. The Northern blot uses a hybridization probe, e.g. radiolabelled cDNA, either containing the full-length, single stranded DNA or a fragment of that DNA sequence at least 20 (preferably at least 30, more preferably at least 50, and most preferably at least 100 consecutive nucleotides in length). The DNA hybridization probe can be labelled by any of the many different methods known to those skilled in this art. The labels most commonly employed for these studies are radioactive elements, enzymes, chemicals which fluoresce when exposed to ultraviolet light, and others. A number of fluorescent materials are known and can be utilized as labels. These include, for example, fluorescein, rhodamine, auramine, Texas Red, AMCA blue and Lucifer Yellow. A particular detecting material is anti-rabbit antibody prepared in goats and conjugated with fluorescein through an isothiocyanate. Proteins can also be labelled with a radioactive element or with an enzyme. The radioactive label can be detected by any of the currently available counting procedures. The preferred isotope may be selected from 3 H, 14 C, 32 p, 35 S, 36 C 51 Cr, 57 Co, 58 Co, 59 Fe, 90 Y, 125 I , 131 I, and 186 Re. Enzyme labels are likewise useful, and can be detected by any of the presently utilized colorimetric, spectrophotometric, fluorospectrophotometric, amperometric or gasometric techniques. The enzyme is conjugated to the selected particle by reaction with bridging molecules such as carbodiimides, diisocyanates, glutaraldehyde and the like. Many enzymes which can be used in these procedures are known and can be utilized. The preferred are peroxidase, β-glucuronidase, β-D-glucosidase, β-D-galactosidase, urease, glucose oxidase plus peroxidase and alkaline phosphatase. U.S. Pat. Nos. 3,654,090, 3,850,752, and 4,016,043 are referred to by way of example for their disclosure of alternate labeling material and methods.
[0081] As used herein, “individual” refers to human subjects as well as non-human subjects. The examples herein are not meant to limit the methodology of the present invention to human subjects only, as the instant methodology is useful in the fields of veterinary medicine, animal sciences and such. The term “individual” refers to human subjects and non-human subjects who are disease or condition free and also includes human and non-human subjects diagnosed with one or more diseases or conditions, as defined herein. “Co-morbid individuals” or “comorbidity” or “individuals considered as co-morbid” are individuals who have more than one disease or condition as defined herein. For example a patient diagnosed with both osteoarthritis and hypertension is considered to present with comorbidities.
[0082] As used herein, “detecting” refers to determining the presence of a gene expression product, for example cDNA, RNA or EST, by any method known to those of skill in the art or taught in numerous texts and laboratory manuals (see for example, Ausubel et al. Short Protocols in Molecular Biology (1995) 3rd Ed. John Wiley & Sons, Inc.). For example, methods of detection include but are not limited to, RNA fingerprinting, Northern blotting, polymerase chain reaction, ligase chain reaction, Qbeta replicase, isothermal amplification method, strand displacement amplification, transcription based amplification systems, nuclease protection (SI nuclease or RNAse protection assays) as well as methods disclosed in WO 88/10315, WO89/06700, PCT/US87/00880, PCT/ US89/01025.
[0083] As used herein, a disease of the invention includes, but is not limited to, blood disorder, blood lipid disease, autoimmune disease, arthritis (including osteoarthritis, rheumatoid arthritis, lupus, allergies, juvenile rheumatoid arthritis and the like), bone or joint disorder, a cardiovascular disorder (including heart failure, congenital heart disease; rheumatic fever, valvular heart disease; corpulmonale, cardiomyopathy, myocarditis, pericardial disease; vascular diseases such as atherosclerosis, acute myocardial infarction, ischemic heart disease and the like), obesity, respiratory disease (including asthma, pneumonitis, pneumonia, pulmonary infections, lung disease, bronchiectasis, tuberculosis, cystic fibrosis, interstitial lung disease, chronic bronchitis emphysema, pulmonary hypertension, pulmonary thromboembolism, acute respiratory distress syndrome and the like), hyperlipidemias, endocrine disorder, immune disorder, infectious disease, muscle wasting and whole body wasting disorder, neurological disorders (including migraines, seizures, epilepsy, cerebrovascular diseases, alzheimers, dementia, Parkinson's, ataxic disorders, motor neuron diseases, cranial nerve disorders, spinal cord disorders, meningitis and the like) including neurodegenerative and/or neuropsychiatric diseases and mood disorders (including schizophrenia, anxiety, bipolar disorder; manic depression and the like, skin disorder, kidney disease, scleroderma, stroke, hereditary hemorrhage telangiectasia, diabetes, disorders associated with diabetes (e.g., PVD), hypertension, Gaucher's disease, cystic fibrosis, sickle cell anemia, liver disease, pancreatic disease, eye, ear, nose and/or throat disease, diseases affecting the reproductive organs, gastrointestinal diseases (including diseases of the colon, diseases of the spleen, appendix, gall bladder, and others) and the like. For further discussion of human diseases, see Mendelian Inheritance in Man: A Catalog of Human Genes and Genetic Disorders by Victor A. McKusick (12th Edition (3 volume set) June 1998, Johns Hopkins University Press, ISBN: 0801857422) and Harrison's Principles of Internal Medicine by Braunwald, Fauci, Kasper, Hauser, Longo, & Jameson (15th Edition, 2001), the entirety of which is incorporated herein.
[0084] In another embodiment of the invention, a disease refers to an immune disorder, such as those associated with overexpression of a gene or expression of a mutant gene (e.g., autoimmune diseases, such as diabetes mellitus, arthritis (including rheumatoid arthritis, juvenile rheumatoid arthritis, osteoarthritis, psoriatic arthritis), multiple sclerosis, encephalomyelitis, myasthenia gravis, systemic lupus erythematosis, automimmune thyroiditis, dermatitis (including atopic dermatitis and eczematous dermatitis), psoriasis, Sjogren's Syndrome, Crohn's disease, aphthous ulcer, iritis, conjunctivitis, keratoconjunctivitis, ulcerative colitis, asthma, allergic asthma, cutaneous lupus erythematosus, scleroderma, vaginitis, proctitis, drug eruptions, leprosy reversal reactions, erythema nodosum leprosum, autoimmune uveitis, allergic encephalomyelitis, acute necrotizing hemorrhagic encephalopathy, idiopathic bilateral progressive sensorineural hearing, loss, aplastic anemia, pure red cell anemia, idiopathic thrombocytopenia, polychondritis, Wegener's granulomatosis, chronic active hepatitis, Stevens-Johnson syndrome, idiopathic sprue, lichen planus, Graves' disease, sarcoidosis, primary biliary cirrhosis, uveitis posterior, and interstitial lung fibrosis), graft-versus-host disease, cases of transplantation, and allergy.
[0085] In another embodiment, a disease of the invention is a cellular proliferative and/or differentiative disorder that includes, but is not limited to, cancer e.g., carcinoma, sarcoma or other metastatic disorders and the like. As used herein, the term “cancer” refers to cells having the capacity for autonomous growth, i.e., an abnormal state of condition characterized by rapidly proliferating cell growth. “Cancer” is meant to include all types of cancerous growths or oncogenic processes, metastatic tissues or malignantly transformed cells, tissues, or organs, irrespective of histopathologic type or stage of invasiveness. Examples of cancers include but are nor limited to solid tumors and leukemias, including: apudoma, choristoma, branchioma, malignant carcinoid syndrome, carcinoid heart disease, carcinoma (e.g., Walker, basal cell, basosquamous, Brown-Pearce, ductal, Ehrlich tumour, in situ, Krebs 2, Merkel cell, mucinous, non-small cell lung, oat cell, papillary, scirrhous, bronchiolar, bronchogenic, squamous cell, and transitional cell), histiocytic disorders, leukaemia (e.g., B cell, mixed cell, null cell, T cell, T-cell chronic, HTLV-II-associated, lymphocytic acute, lymphocytic chronic, mast cell, and myeloid), histiocytosis malignant, Hodgkin disease, immunoproliferative small, non-Hodgkin lymphoma, plasmacytoma, reticuloendotheliosis, melanoma, chondroblastoma, chondroma, chondrosarcoma, fibroma, fibrosarcoma, giant cell tumors, histiocytoma, lipoma, liposarcoma, mesothelioma, myxoma, myxosarcoma, osteoma, osteosarcoma, Ewing sarcoma, synovioma, adenofibroma, adenolymphoma, carcinosarcoma, chordoma, craniopharyngioma, dysgerminoma, hamartoma, mesenchymoma, mesonephroma, myosarcoma, ameloblastoma, cementoma, odontoma, teratoma, thymoma, trophoblastic tumour, adeno-carcinoma, adenoma, cholangioma, cholesteatoma, cylindroma, cystadenocarcinoma, cystadenoma, granulosa cell tumour, gynandroblastoma, hepatoma, hidradenoma, islet cell tumour, Leydig cell tumour, papilloma, Sertoli cell tumour, theca cell tumour, leiomyoma, leiomyosarcoma, myoblastoma, mymoma, myosarcoma, rhabdomyoma, rhabdomyosarcoma, ependymoma, ganglioneuroma, glioma, medulloblastoma, meningioma, neurilemmoma, neuroblastoma, neuroepithelioma, neurofibroma, neuroma, paraganglioma, paraganglioma nonchromaffin, angiokeratoma, angiolymphoid hyperplasia with eosinophilia, angioma sclerosing, angiomatosis, glomangioma, hemangioendothelioma, hemangioma, hemangiopericytoma, hemangiosarcoma, lymphangioma, lymphangiomyoma, lymphangiosarcoma, pinealoma, carcinosarcoma, chondrosarcoma, cystosarcoma, phyllodes, fibrosarcoma, hemangiosarcoma, leimyosarcoma, leukosarcoma, liposarcoma, lymphangiosarcoma, myosarcoma, myxosarcoma, ovarian carcinoma, rhabdomyosarcoma, sarcoma (e.g., Ewing, experimental, Kaposi, and mast cell), neoplasms (e.g., bone, breast, digestive system, colorectal, liver, pancreatic, pituitary, testicular, orbital, head and neck, central nervous system, acoustic, pelvic respiratory tract, and urogenital), neurofibromatosis, and cervical dysplasia, and other conditions in which cells have become immortalized or transformed.
[0086] In another embodiment, a disease of the invention includes but is not limited to a condition wherein said condition is reflective of the state of a particular individual, whether said state is a physical, emotional or psychological state, said state resulting from the progression of time, treatment, environmental factors or genetic factors.
[0087] As used herein, a gene of the invention is a gene that is expressed in blood and is either upregulated, or downregulated and can be used, either solely or in conjunction with other genes, as a marker for disease as defined herein. By a gene that is expressed in blood or in a blood sample is meant a gene that is expressed in the cells which typically make up blood including monocytes, leukocytes, lymphocytes and erythrocytes, all other cells derived directly from haemopoietic or mesenchymal stem cells, or derived directly from a cell which typically makes up the blood.
[0088] The term “gene” includes a region that can be transcribed into RNA, as the invention contemplates detection of RNA or equivalents thereof, i.e., cDNA or EST. A gene of the invention includes but is not limited to genes specific for or involved in a particular biological process, such as apoptosis, differentiation, stress response, aging, proliferation, etc.; cellular mechanism genes, e.g. cell-cycle, signal transduction, metabolism of toxic compounds, and the like; disease associated genes, e.g. genes involved in cancer, schizophrenia, diabetes, high blood pressure, atherosclerosis, viral-host interaction and infection and the like.
[0089] For example, the gene of the invention can be an oncogene (Hanahan, D. and R. A. Weinberg, Cell (2000) 100:57; and Yokota, J., Carcinogenesis (2000) 21(3):497-503) whose expression within a cell induces that cell to become converted from a normal cell into a tumor cell. Further examples of genes of the invention include, but are not limited to, cytokine genes (Rubinstein, M., et al., Cytokine Growth Factor Rev. (1998) 9(2):175-81); idiotype (Id) protein genes (Benezra, R., et al., Oncogene (2001) 20(58):8334-41; Norton, J. D., J. Cell Sci. (2000) 113(22):3897-905); prion genes (Prusiner, S. B., et al., Cell (1998) 93(3):337-48; Safar, J. and S. B. Prusiner, Prog., Brain Res., (1998) 117:421-34); genes that express molecules that induce angiogenesis (Gould, V. E. and B. M. Wagner, Hum. Pathol. (2002) 33(11):1061-3); genes encoding adhesion molecules (Chothia, C. and E. Y. Jones, Annu. Rev. Biochem. (1997) 66:823-62; Parise, L. V., et al., Semin. Cancer Biol. (2000) 10(6):407-14); genes encoding cell surface receptors (Deller, M. C., and Y. E. Jones, Curr. Opin. Struct. Biol. (2000) 10(2):213-9); genes of proteins that are involved in metastasizing and/or invasive processes (Boyd, D., Cancer Metastasis Rev. (1996) 15(1):77-89; Yokota, J., Carcinogenesis (2000) 21(3):497-503); genes of proteases as well as of molecules that regulate apoptosis and the cell cycle (Matrisian, L. M., Curr. Biol. (1999) 9(20):R776-8; Krepela, E., Neoplasma (2001) 48(5):332-49; Basbaum and Werb, Curr. Opin. Cell Biol. (1996) 8:731-738; Birkedal-Hansen, et al., Crit. Rev. Oral Biol. Med. (1993) 4:197-250; Mignatti and Rifkin, Physiol. Rev. (1993) 73:161-195; Stetler-Stevenson, et al., Annu., Rev. Cell Biol., (1993) 9:541-573; Brinkerhoff, E., and L. M. Matrisan, Nature Reviews (2002) 3:207-214; Strasser, A., et al., Annu., Rev. Biochem., (2000), 69:217-45; Chao, D. T. and S. J. Korsmeyer, Annu. Rev. Immunol. (1998) 16:395-419; Mullauer, L., et al., Mutat. Res. (2001) 488(3):211-31; Fotedar, R., et al., Prog., Cell Cycle Res., (1996), 2:147-63; Reed, J. C., Am. J. Pathol., (2000) 157(5):1415-30; D'Ari, R., Bioassays (2001) 23(7):563-5); or multi-drug resistance genes, such as MDR1 gene (Childs, S., and V. Ling, Imp., Adv. Oncol., (1994) 21-36). In another embodiment, a gene of the invention contains a sequence found in Tables 2 or 3 or FIGS. 22-34 . In another embodiment, a gene of the invention can be an immune response gene or a non-immune response gene. By an immune response gene is meant a primary defense response gene located outside the major histocompatibility region (MHC) that is initially triggered in response to a foreign antigen to regulate immune responsiveness. All other genes expressed in blood are considered to be non-immune response gene. For example, an immune response gene would be understood by a person skilled in the art to include: cytokines including interleukins and interferons such as TNF-alpha, IL-10, IL-12, IL-2, IL-4, IL-10, IL-12, IL-13, TGF-Beta, IFN-gamma; immunoglobulins, complement and the like (see for example Bellardelli, F. Role of interferons and other cytokines in the regulation of the immune response APMIS., 1995, March; 103(3): 161-79;).
[heading-0090] Construction of a Microarray
[0091] A nucleic acid microarray (RNA, DNA, cDNA, PCR products or ESTs) according to the invention was constructed as follows:
[0092] Nucleic acids (RNA, DNA, cDNA, PCR products or ESTs) (˜40 μl) are precipitated with 4 μl ({fraction (1/10)} volume) of 3M sodium acetate (pH 5.2) and 100 μl (2.5 volumes) of ethanol and stored overnight at −20° C. They are then centrifuged at 3,300 rpm at 4° C for 1 hour. The obtained pellets were washed with 50 μl ice-cold 70% ethanol and centrifuged again for 30 minutes. The pellets are then air-dried and resuspended well in 50% dimethylsulfoxide (DMSO) or 20 μl 3×SSC overnight. The samples are then deposited either singly or in duplicate onto Gamma Amino Propyl Silane (Corning CMT-GAPS or CMT-GAP2, Catalog No. 40003, 40004) or polylysine-coated slides (Sigma Cat. No. P0425) using a robotic GMS 417 or 427 arrayer (Affymetrix, Calif.). The boundaries of the DNA spots on the microarray are marked with a diamond scriber. The invention provides for arrays where 10-20,000 different DNAs are spotted onto a solid support to prepare an array, and also may include duplicate or triplicate DNAs.
[0093] The arrays are rehydrated by suspending the slides over a dish of warm particle free ddH20 for approximately one minute (the spots will swell slightly but not run into each other) and snap-dried on a 70-80° C inverted heating block for 3 seconds. DNA is then UV crosslinked to the slide (Stratagene, Stratalinker, 65 mJ—set display to “650” which is 650×100 μJ, or baked at 80° C. for two to four hours. The arrays are placed in a slide rack. An empty slide chamber is prepared and filled with the following solution: 3.0 grams of succinic anhydride (Aldrich) is dissolved in 189 ml of 1-methyl-2-pyrrolidinone (rapid addition of reagent is crucial); immediately after the last flake of succinic anhydride dissolved, 21.0 ml of 0.2 M sodium borate is mixed in and the solution is poured into the slide chamber. The slide rack is plunged rapidly and evenly in the slide chamber and vigorously shaken up and down for a few seconds, making sure the slides never leave the solution, and then mixed on an orbital shaker for 15-20 minutes. The slide rack is then gently plunged in 95° C. ddH 2 0 for 2 minutes, followed by plunging five times in 95% ethanol. The slides are then air dried by allowing excess ethanol to drip onto paper towels. The arrays are then stored in the slide box at room temperature until use.
[0094] Nucleic Acid Microarrays
[0095] Any combination of the nucleic acid sequences generated from nucleotides complimentary to regions of DNA expressed in blood are used for the construction of a microarray. In one embodiment, the microarray is chondrocyte-specific and encompasses genes which are important in the osteoarthritis disease process. A microarray according to the invention preferably comprises between 10, 100, 500, 1000, 5000, 10,000 and 15,000 nucleic acid members, and more preferably comprises at least 5000 nucleic acid members. The nucleic acid members are known or novel nucleic acid sequences described herein, or any combination thereof. A microarray according to the invention is used to assay for differential gene expression profiles of genes in blood samples from healthy patients as compared to patients with a disease.
[heading-0096] Microarray Used According to the Invention
[0097] The Human Genome U133 (HG-U133) Set, consisting of two GeneChip® arrays, contains almost 45,000 probe sets representing more than 39,000 transcripts derived from approximately 33,000 well-substantiated human genes. This set design uses sequences selected from GenBank®, dbEST, and RefSeq.
[0098] The sequence clusters were created from the UniGene database (Build 133, Apr. 20, 2001). They were then refined by analysis and comparison with a number of other publicly available databases including the Washington University EST trace repository and the University of California, Santa Cruz Golden Path human genome database (April 2001 release).
[0099] The HG-U133A Array includes representation of the RefSeq database sequences and probe sets related to sequences previously represented on the Human Genome U95Av2 Array. The HG-U133B Array contains primarily probe sets representing EST clusters.
[heading-0100] 15 K ChondroChip™—The ChondroChip™ is chondrocyte-specific microarray chip comprising 15,000 novel and known EST sequences of the chondrocyte from human chondrocyte-specific cDNA libraries.
[heading-0101] Controls on the ChondroChip™—There are two types of controls used on microarrays. First, positive controls are genes whose expression level is invariant between different stages of investigation and are used to monitor:
[none]
a) target DNA binding to the slide,
b) quality of the spotting and binding processes of the target DNA onto the slide,
c) quality of the RNA samples, and
d) efficiency of the reverse transcription and fluorescent labelling of the probes.
[0106] Second, negative controls are external controls derived from an organism unrelated to and therefore unlikely to cross-hybridize with the sample of interest. These are used to monitor for:
a) variation in background fluorescence on the slide, and b) non-specific hybridization.
[0109] There are currently 63 control spots on the ChondroChip™ consisting of:
Type No. Positive Controls: 2 Alien DNA 12 A. thaliana DNA 10 Spotting Buffer 41
BloodChip™—The “BloodChip™” is a cDNA microarray slide with 10,368 PCR products derived from peripheral blood cell cDNA libraries as shown in FIG. 24 .
Target Nucleic acid Preparation and Hybridization
Preparation of Fluorescent DNA Probe from mRNA
[0113] Fluorescently labelled target nucleic acid samples are prepared for analysis with an array of the invention.
[0114] 2 μg Oligo-dT primers are annealed to 2 μg of mRNA isolated from a blood sample of a patient in a total volume of 15 μg, by heating to 70° C. for 10 min, and cooled on ice. The mRNA is reverse transcribed by incubating the sample at 42° C. for 1.5-2 hours in a 100 μg volume containing a final concentration of 50 mM Tris-HCl (pH 8.3), 75 mM KCl, 3 mM MgCl 2 , 25 mM DTT, 25 mM unlabelled dNTPs, 400 units of Superscript II (200 U/μL, Gibco BRL), and 15 mM of Cy3 or Cy5 (Amersham). RNA is then degraded by addition of 15 μl of 0.1N NaOH, and incubation at 70° C. for 10 min. The reaction mixture is neutralized by addition of 15 μl of 0.1N HCl, and the volume is brought to 500 μl with TE (10 MM Tris, 1 mM EDTA), and 20 μg of Cot1 human DNA (Gibco-BRL) is added.
[0115] The labelled target nucleic acid sample is purified by centrifugation in a Centricon-30 micro-concentrator (Amicon). If two different target nucleic acid samples (e.g., two samples derived from a healthy patient vs. patient with a disease) are being analyzed and compared by hybridization to the same array, each target nucleic acid sample is labelled with a different fluorescent label (e.g., Cy3 and Cy5) and separately concentrated. The separately concentrated target nucleic acid samples (Cy3 and Cy5 labelled) are combined into a fresh centricon, washed with 500 μl TE, and concentrated again to a volume of less than 7 μl. 1 μl of 10 μg/μl polyA RNA (Sigma, #P9403) and 1 μl of 10 μg/μl tRNA (Gibco-BRL, #15401-011) is added and the volume is adjusted to 9.5 μl with distilled water. For final target nucleic acid preparation 2.1 μl 20×SSC (1.5M NaCl, 150 mM NaCitrate (pH8.0)) and 0.35 μl 10% SDS is added.
[heading-0116] Hybridization
[0117] Labelled nucleic acid is denatured by heating for 2 min at 100° C., and incubated at 37° C. for 20-30 min before being placed on a nucleic acid array under a 22 mm×22 mm glass cover slip. Hybridization is carried out at 65° C. for 14 to 18 hours in a custom slide chamber with humidity maintained by a small reservoir of 3×SSC. The array is washed by submersion and agitation for 2-5 min in 2×SSC with 0.1% SDS, followed by 1×SSC, and 0.1×SSC. Finally, the array is dried by centrifugation for 2 min in a slide rack in a Beckman GS-6 tabletop centrifuge in Microplus carriers at 650 RPM for 2 min.
[heading-0118] Signal Detection and Data Generation
[0119] Following hybridization of an array with one or more labelled target nucleic acid samples, arrays are scanned immediately using a GMS Scanner 418 and Scanalyzer software (Michael Eisen, Stanford University), followed by GeneSpring™ software (Silicon Genetics, California) analysis. Alternatively, a GMS Scanner 428 and Jaguar software may be used followed by GeneSpring™ software analysis.
[0120] If one target nucleic acid sample is analyzed, the sample is labelled with one fluorescent dye (e.g., Cy3 or Cy5).
[0121] After hybridization to a microarray as described herein, fluorescence intensities at the associated nucleic acid members on the microarray are determined from images taken with a custom confocal microscope equipped with laser excitation sources and interference filters appropriate for the Cy3 or Cy5 fluorescence.
[0122] The presence of Cy3 or Cy5 fluorescent dye on the microarray indicates hybridization of a target nucleic acid and a specific nucleic acid member on the microarray. The intensity of Cy3 or Cy5 fluorescence represents the amount of target nucleic acid which is hybridized to the nucleic acid member on the microarray, and is indicative of the expression level of the specific nucleic acid member sequence in the target sample.
[0123] After hybridization, fluorescence intensities at the associated nucleic acid members on the microarray are determined from images taken with a custom confocal microscope equipped with laser excitation sources and interference filters appropriate for the Cy3 and Cy5 fluors. Separate scans are taken for each fluor at a resolution of 225 μm 2 per pixel and 65,536 gray levels. Normalization between the images is used to adjust for the different efficiencies in labeling and detection with the two different fluors. This is achieved by manual matching of the detection sensitivities to bring a set of internal control genes to nearly equal intensity followed by computational calculation of the residual scalar required for optimal intensity matching for this set of genes.
[0124] The presence of Cy3 or Cy5 fluorescent dye on the microarray indicates hybridization of a target nucleic acid and a specific nucleic acid member on the microarray. The intensities of Cy3 or Cy5 fluorescence represent the amount of target nucleic acid which is hybridized to the nucleic acid member on the microarray, and is indicative of the expression level of the specific nucleic acid member sequence in the target sample. If a nucleic acid member on the array shows no color, it indicates that the gene in that element is not expressed in either sample. If a nucleic acid member on the array shows a single color, it indicates that a labelled gene is expressed only in that cell sample. The appearance of both colors indicates that the gene is expressed in both tissue samples. The ratios of Cy3 and Cy5 fluorescence intensities, after normalization, are indicative of differences of expression levels of the associated nucleic acid member sequence in the two samples for comparison. A ratio of expression not equal to is used as an indication of differential gene expression.
[0125] The array is scanned in the Cy 3 and Cy5 channels and stored as separate 16-bit TIFF images. The images are incorporated and analyzed using Scanalyzer software which includes a gridding process to capture the hybridization intensity data from each spot on the array. The fluorescence intensity and background-subtracted hybridization intensity of each spot is collected and a ratio of measured mean intensities of Cy5 to Cy3 is calculated. A liner regression approach is used for normalization and assumes that a scatter plot of the measured CyS versus Cy3 intensities should have a scope of one. The average of the ratios is calculated and used to rescale the data and adjust the slope to one. A post-normalization cutoff of a ratio not equal to 1.0-is used to identify differentially expressed genes.
[0126] When comparing two or more samples for differences, results are reported as statistically significant when there is only a small probability that similar results Would have been observed if the tested hypothesis (i.e., the genes are not expressed at different levels) were true. A small probability can be defined as the accepted threshold level at which the results being compared are considered significantly different. The accepted lower threshold is set at, but not limited to, 0.05 (i.e., there is a 5% likelihood that the results would be observed between two or more identical populations) such that any values determined by statistical means at or below this threshold are considered significant.
[0127] When comparing two or more samples for similarities, results are reported as statistically significant when there is only a small probability that similar results would have been observed if the tested hypothesis (i.e., the genes are not expressed at different levels) were true. A small probability can be defined as the accepted threshold level at which the results being compared are considered significantly different. The accepted lower threshold is set at, but not limited to, 0.05 (i.e., there is a 5% likelihood that the results would be observed between two or more identical populations) such that any values determined by statistical means above this threshold are not considered significantly different and thus similar.
[0128] Identification of genes differentially expressed in blood samples from patients with disease as compared to healthy patients or as compared to patients without said disease is determined by statistical analysis of the gene expression profiles from healthy patients or patients without disease compared to patients with disease using the Wilcox Mann Whitney rank sum test. Other statistical tests can also be used, see for example (Sokal and Rohlf (1987) Introduction to Biostatistics 2 nd edition, WH Freeman, New York), which is incorporated herein in their entirety.
[0129] In order to facilitate ready access, e.g. for comparison, review, recovery and/or modification, the expression profiles of patients with disease and/or patients without disease or healthy patients can be recorded in a database, whether in a relational database accessible by a computational device or other format, or a manually accessible indexed file of profiles as photographs, analogue or digital imaging, readouts spreadsheets etc. Typically the database is compiled and maintained at a central facility, with access being available locally and/or remotely.
[0130] As would be understood by a person skilled in the art, comparison as between the expression profile of a test patient with expression profiles of patients with a disease, expression profiles of patients with a certain stage or degree of progression of said disease, without said disease, or a healthy patient so as to diagnose or prognose said test patient can occur via expression profiles generated concurrently or non concurrently. It would be understood that expression profiles can be stored in a database to allow said comparison.
[0131] As additional test samples from test patients are obtained, through clinical trials, further investigation, or the like, additional data can be determined in accordance with the methods disclosed herein and can likewise be added to a database to provide better reference data for comparison of healthy and/or non-disease patients and/or certain stage or degree of progression of a disease as compared with the test patient sample.
[heading-0132] Use of Expression Profiles for Diagnostic Purposes
[0133] As would be understood to a person skilled in the art, one can utilize sets of genes which have been identified as statistically significant as described above in order to characterize an unknown sample as having said disease or not having said disease. This is commonly termed “class prediction”.
[0134] Methods that can be used for class prediction analysis have been well described and generally involve a training phase using samples with known classification and a testing phase from which the algorithm generalizes from the training data so as to predict classification of unknown samples (see for Example Slonim, D. (2002), Nature Genetics Supp., Vol. 32 502-8, Raychaudhuri et al., (2001) Trends Biotechnol., 19: 189-193; Khan et al. (2001) Nature Med., 7 673-9.; Golub et al. (1999) Science 286: 531-7. Hastie et al., (2000) Genome Biol., 1(2) Research 0003.1-0003.21, all of which are incorporated herein by reference in their entirety).
[0135] As additional samples are obtained, for example during clinical trials, their expression profiles can be determined and correlated with the relevant subject data in the database and likewise be recorded in said database. Algorithms as described above can be used to query additional samples against the existing database to further refine the diagnostic and/or prognostic determination by allowing an even greater association between the disease and gene expression signature.
[0136] The diagnosing or prognosing may thus be performed by detecting the expression level of two or more genes, three or more genes, four or more genes, five or more genes, six or more genes, seven or more genes, eight or more genes, nine or more genes, ten or more genes, fifteen or more genes, twenty or more genes thirty or more genes, fifty or more genes, one hundred or more genes, two hundred or more genes, three hundred or more genes, five hundred or more genes or all of the genes disclosed for the specific disease in question.
[heading-0137] Data Acquisition and Analysis of differentially expressed EST Sequences
[0138] The differentially expressed EST sequences are then searched against available databases, including the “nt”, “nr”, “est”, “gss” and “htg” databases available through NCBI to determine putative identities for ESTs matching to known genes or other ESTs. Functional characterisation of ESTs with known gene matches are made according to any known method. Preferably, differentially expressed EST sequences are compared to the non-redundant Genbank/EMBL/DDBJ and dbEST databases using the BLAST algorithm (Altschul S F, Gish W, Miller W, Myers E W, Lipman D J., Basic local alignment search tool., J Mol Biol., 1990; 215:403-10). A minimum value of P=10 −10 and nucleotide sequence identity >95%, where the sequence identity is non-contiguous or scattered, are required for assignments of putative identities for ESTs matching to known genes or to other ESTs. Construction of a non-redundant list of genes represented in the EST set is done with the help of Unigene, Entrez and PubMed at the National Center for Biotechnology Information (NCBI) web site at www.ncbi.nlm.nih.gov.
[0139] Genes are identified from ESTs according to known methods. To identify novel genes from an EST sequence, the EST should preferably be at least 100 nucleotides in length, and more preferably 150 nucleotides in length, for annotation. Preferably, the EST exhibits open reading frame characteristics (i.e., can encode a putative polypeptide).
[0140] Because of the completion of the Human Genome Project, a specific EST which matches with a genomic sequence can be mapped onto a specific chromosome based on the chromosomal location of the genomic sequence. However, no function may be known for the protein encoded by the sequence and the EST would then be considered “novel” in a functional sense. In one aspect, the invention is used to identify a novel differentially expressed EST, which is part of a larger known sequence for which no function is known, is used to determine the function of a gene comprising the EST. Alternatively, or additionally, the EST can be used to identify an mRNA or polypeptide encoded by the larger sequence as a diagnostic or prognostic marker of a disease.
[0141] Having identified an EST corresponding to a larger sequence, other portions of the larger sequence which comprises the EST can be used in assays to elucidate gene function, e.g., to isolate polypeptides encoded by the gene, to generate antibodies specifically reactive with these polypeptides, to identify binding partners of the polypeptides (receptors, ligands, agonists, antagonists and the like) and/or to detect the expression of the gene (or lack thereof) in healthy or diseased individuals.
[0142] In another aspect, the invention provides for nucleic acid sequences that do not demonstrate a “significant match” to any of the publicly known sequences in sequence databases at the time a query is done. Longer genomic segments comprising these types of novel EST sequences can be identified by probing genomic libraries, while longer expressed sequences can be identified in cDNA libraries and/or by performing polymerase extension reactions (e.g., RACE) using EST sequences to derive primer sequences as is known in the art. Longer fragments can be mapped to particular chromosomes by FISH and other techniques and their sequences compared to known sequences in genomic and/or expressed sequence databases.
[0143] The amino acid sequences encoded by the ESTs can also be used to search databases, such as GenBank, SWISS-PROT, EMBL database, PIR protein database, Vecbase, or GenPept for the amino acid sequences of the corresponding full-length genes according to procedures well known in the art.
[0144] Identified genes can be catalogued according to their putative function. Functional characterization of ESTs with known gene matches is preferably made according to the categories described by Hwang et al Compendium of Cardiovascular Genes. Circulation 1997;96:4146-203. The distribution of genes in each of the subcellular categories will provide important insights into the disease process.
[0145] Alternative methods for analysing ESTs are also available. For example, the ESTs may be assembled into contigs with sequence alignment, editing, and assembly programs such as PHRED and PHRAP (Ewing, et al., 1998, Genome Res., 3:175, incorporated herein; and the web site at bozeman.genome.washington.edu). Contig redundancy is reduced by clustering nonoverlapping sequence contigs using the EST clone identification number, which is common for the nonoverlapping 5 and 3 sequence reads for a single EST cDNA clone. In one aspect, the consensus sequence from each cluster is compared to the non-redundant Genbank/EMBL/DDBJ and dbEST databases using the BLAST algorithm with the help of unigene, Entrez and PubMed at the NCBI site.
[heading-0146] Known Nucleic acid Sequences or ESTs and Novel Nucleic acid Sequences or ESTs
[0147] An EST that exhibits a significant match (>65%, and preferably 90% or greater, identity) to at least one existing sequence in an existing nucleic acid sequence database is characterised as a “known” sequence according to the invention. Within this category, some known ESTs match to existing sequences which encode polypeptides with known function(s) and are referred to as a “known sequence with a function”. Other “known” ESTs exhibit a significant match to existing sequences which encode polypeptides of unknown function(s) and are referred to as a “known sequence with no known function”.
[0148] EST sequences which have no significant match (less than 65% identity) to any existing sequence in the above cited available databases are categorised as novel ESTs. To identify a novel gene from an EST sequence, the EST is preferably at least 150 nucleotides in length. More preferably, the EST encodes at least part of an open reading frame, that is, a nucleic acid sequence between a translation initiation codon and a termination codon, which is potentially translated into a polypeptide sequence.
[0149] The following references were cited herein:
Claudio J O et al. (1998). Genomics 50:44-52. Chelly J et al. (1989). Proc. Nat. Acad. Sci. USA. 86:2617-2621. Chelly J et al. (1988). Nature 333:858-860. Drews J & Ryser S (1997). Nature Biotech. 15:1318-9. Ferrie R M et al. (1992). Am. J Hum. Genet. 51:251-62. Fu D-J et al. (1998). Nat. Biotech 16: 381-4. Gala J L et al. (1998). Clin. Chem. 44(3):472-81. Geisterfer-Lowrance A A T et al. (1990). Cell 62:999-1006. Groden J et al. (1991). Cell 66:589-600. Hwang D M et al. (1997). Circulation 96:4146-4203. Jandreski M A & Liew C C (1987). Hum. Genet. 76:47-53. Jin O et al. (1990). Circulation 82:8-16 Kimoto Y (1998). Mol. Gen. Genet 258:233-239. Koster M et al. (1996). Nat. Biotech 14: 1123-8. Liew & Jandreski (1986). Proc. Nat. Acad. Sci. USA. 83:3175-3179 Liew C C et al. (1990). Nucleic Acids Res. 18:3647-3651. Liew C C (1993). J Mol. Cell. Cardiol. 25:891-894 Liew C C et al. (1994). Proc. Natl. Acad. Sci. USA. 91:10645-10649. Liew et al. (1997). Mol. and Cell. Biochem. 172:81-87. Niimura H et al. (1998). New Eng. J. Med. 338:1248-1257. Ogawa M (1993). Blood 81:2844-2853. Santoro I M & Groden J (1997). Cancer Res. 57:488-494. Yuasa T et al. (1998). Japanese J Cancer Res. 89:879-882.
Description of Tables:
Table 1: Overlap of Genes Expressed in Blood
[0175] (Estimated from about 5,100 unique known genes from the over 25,000 ESTs obtained from human blood cDNA libraries).
[heading-0176] Table 2: Comparison of approximately 5,140 Unique Genes Identified in the Blood
[heading-0177] Cell cDNA Library to Genes Previously Identified in Specific Tissues
[0178] Column 1: List of unique genes derived from 25,000 known ESTs from blood cells.
[0179] Column 2: Number of genes found in randomly sequenced ESTs from blood cells.
[0180] Column 3: Accession number.
[0181] Column 4: “+” indicates the presence of the unique gene in publicly available cDNA libraries of blood (Bl), brain (Br), heart (H), kidney (K), liver (Li) and lung (Lu). **Comparison to previously identified tissue-specific genes was determined using the GenBank of the National Centre of Biotechnology Information (NCBI) Database.
[heading-0182] Table 3 shows genes that are differentially expressed in blood samples from patients with different diseases as compared to blood samples from healthy patients.
[heading-0183] Table 3A shows the identity of those genes that are differentially expressed in blood samples from patients with osteoarthritis and hypertension as compared with normal patients as depicted in FIG. 8
[heading-0184] Table 3B shows the identity of those genes that are differentially expressed in blood samples from patients with osteoarthritis and obesity as compared with normal patients as depicted in FIG. 9 .
[heading-0185] Table 3C shows the identity of those genes that are differentially expressed in blood samples from patients with osteoarthritis and allergies as compared with normal patients as depicted in FIG. 10 .
[heading-0186] Table 3D shows the identity of those genes that are differentially expressed in blood samples from patients with osteoarthritis and subject to systemic steroids as compared with normal patients as depicted in FIG. 11 .
[heading-0187] Table 3E shows the identity of those genes that are differentially expressed in blood samples from patients with hypertension as depicted in FIG. 12 .
[heading-0188] Table 3F shows the identity of those genes that are differentially expressed in blood samples from patients obesity as depicted in FIG. 13 .
[heading-0189] Table 3G shows the identity of those genes that are differentially expressed in blood samples from patients with type II diabetes as depicted in FIG. 14 .
[heading-0190] Table 3H shows the identity of those genes that are differentially expressed in blood samples from patients with hyperlipidemia as depicted in FIG. 15 .
[heading-0191] Table 3I shows the identity of those genes that are differentially expressed in blood samples from patients with lung disease as depicted in FIG. 16 .
[heading-0192] Table 3J shows the identity of those genes that are differentially expressed in blood samples from patients with bladder cancer as depicted in FIG. 17 .
[heading-0193] Table 3K shows the identity of those genes that are differentially expressed in blood samples from patients with bladder cancer as depicted in FIG. 18 .
[heading-0194] Table 3L shows the identity of those genes that are differentially expressed in blood samples from patients with coronary artery disease (CAD) as depicted in FIG. 19 .
[heading-0195] Table 3M shows the identity of those genes that are differentially expressed in blood samples from patients with rheumatoid arthritis as depicted in FIG. 20 .
[heading-0196] Table 3N shows the identity of those genes that are differentially expressed in blood samples from patients with depression as depicted in FIG. 21 .
[heading-0197] Table 3O shows the identity of those genes that are differentially expressed in blood samples from patients with various stages of osteoarthritis as depicted in FIG. 22 .
[0198] Table 3P shows the identity of those genes that are differentially expressed in blood samples from patients with hypertension and OA when compared with patients who have OA only wherein genes identified in Table 3A have been removed so as to identify genes which are unique to hypertension.
[heading-0199] Table 3Q shows the identity of those genes which were identified in Table 3A which are shared with those genes differentially expressed in blood samples from patients with hypertension and OA when compared with patients who have OA only.
[0200] Table 3R shows the identity of those genes that are differentially expressed in blood samples from patients who are obese and have OA when compared with patients who have OA only and wherein genes identified in Table 3B have been removed so as to identify genes which are unique to obesity.
[heading-0201] Table 3S shows the identify of those genes identified in Table 3B which are shared with those genes differentially expressed in blood samples from patients who are obese and have OA when compared with patients who have OA.
[0202] Table 3T shows the identity of those genes that are differentially expressed in blood samples from patients with allergies and OA when compared with patients who have OA only wherein genes identified in Table 3C have been removed so as to identify genes which are unique to allergies.
[heading-0203] Table 3U shows the identify of those genes identified in Table 3C which are shared with those genes differentially expressed in blood samples from patients with allergies and OA when compared with patients who have OA only.
[0204] Table 3V shows the identity of those genes that are differentially expressed in blood samples from patients who are on systemic steroids and have OA when compared with patients who have OA only wherein genes identified in Table 3D have been removed so as to identify genes which are unique to patients on systemic steroids.
[heading-0205] Table 3W shows the identify of those genes identified in Table 3D which are shared with those genes differentially expressed in blood samples from patients who are on systemic steroids and have OA when compared with patients who have OA only.
[heading-0206] Table 3X shows the identity of those genes that are differentially expressed in blood samples from patients with liver cancer as depicted in FIG. 25 .
[heading-0207] Table 3Y shows the identity of those genes that are differentially expressed in blood samples from patients with schizophrenia as depicted in FIG. 26 .
[heading-0208] Table 3Z shows the identity of those genes that are differentially expressed in blood samples from patients with Chagas disease as depicted in FIG. 27 .
[heading-0209] Table 3AA shows the identity of those genes that are differentially expressed in blood samples from patients with asthma as depicted in FIG. 28 .
[heading-0210] Table 3AB shows the identity of those genes that are differentially expressed in blood from patients with either mild or severe OA, but for which genes relevant to asthma, obesity, hypertension, systemic steroids and allergies have been removed.
[heading-0211] Table 3AC shows the identity of those genes that are differentially expressed in blood from patients with schizophrenia as compared with manic depression syndrome (MDS).
[heading-0212] Table 3AD shows the identity of those genes that are differentially expressed in blood from patients taking either birth control, prednisone or hormone replacement therapy and presenting with OA as depicted in FIG. 34 .
[heading-0213] Table 4 shows 102 EST sequences of Tables 3A-3AD with “no-significant match” to known gene sequences.
[heading-0214] Table 5 shows a list of genes showing greater than two fold differential expression in CAD peripheral blood cells vs. normal blood cells.
[0215] The following examples are given for the purpose of illustrating various embodiments of the invention and are not meant to limit the present invention in any fashion.
EXAMPLE 1
[heading-0216] Construction of a cDNA Library
[0217] RNA extracted from human tissues (including fetal heart, adult heart, liver, brain, prostate gland and whole blood) were used to construct unidirectional cDNA libraries. The first mammalian heart cDNA library was constructed as early as 1982. Since then, the methodology has been revised and optimal conditions have been developed for construction of human heart and hematopoietic progenitor cDNA libraries (Liew et al., 1984; Liew 1993, Claudio et al., 1998). Most of the novel genes which were identified by sequence annotation can now be obtained as full length transcripts.
EXAMPLE 2
[heading-0218] Catalogue of EST Database
[0219] Random partial sequencing of expressed sequence tags (ESTs) of CDNA clones from the blood cell library was carried out to establish an EST database of blood. The known genes as derived from the ESTs were categorized into seven major cellular functions (Hwang, Dempsey et al., 1997). The preparation of the chondrocyte-specific EST database is reported in WO 02/070737, which is hereby incorporated by reference in its entirety.
EXAMPLE 3
[heading-0220] Differential Screening of cDNA Library
[0221] cDNA probes generated from transcripts of each tissue were used to hybridize the blood cell cDNA clones or chondrocyte cDNA clones (Liew et al., 1997; WO 02/070737).
[0222] The “positive” signals which were hybridized with P-labelled cDNA probes were defined as genes which shared identity with blood and respective tissues. The “negative” spots which were not exposed to P-labelled cDNA probes were considered to be blood-cell-enriched or low frequency transcripts.
EXAMPLE 4
[heading-0223] Reverse Transcriptase-polymerase Chain Reaction (RT-PCR) Assay
[0224] RNA extracted from samples of human tissue was used for RT-PCR analysis (Jin et al. 1990). Three pairs of forward and reverse primers were designed for human cardiac beta-myosin heavy chain gene (βMyHC), amyloid precursor protein (APP) gene and adenomatous polyposis- coli protein (APC) gene. The PCR products were also subjected to automated DNA sequencing to verify the sequences as derived from the specific transcripts of blood.
EXAMPLE 5
[heading-0225] Detection of Tissue Specific Gene Expression in Human Blood Using RT-PCR
[0226] The beta-myosin heavy chain gene (βMyHC) transcript (mRNA) is known to be highly expressed in ventricles of the human heart. This sarcomeric protein is important for heart muscle contraction and its presence would not be expected in other non-muscle tissues and blood. In 1990, the gene for human cardiac βMyHC was completely sequenced (Liew et al. 1990) and was comprised of 41 exons and 42 introns.
[0227] The method of reverse transcription polymerase chain reaction (RT-PCR) was used to determine whether this cardiac specific mRNA is also present in human blood. A pair of primers was designed; the forward primer (SEQ ID No. 3) was on the boundary of exons 21 and 22, and the reverse primer (SEQ ID No. 4) was on the boundary of exons 24 and 25. This region of mRNA is only present in βMyHC and is not found in the alpha-myosin heavy chain gene (αMyHC).
[0228] A blood sample was first treated with lysing buffer and then undergone centrifuge. The resulting pellets were further processed with RT-PCR. RT-PCR was performed using the total blood cell RNA as a template. A nested PCR product was generated and used for sequencing. The sequencing results were subjected to BLAST and the identity of exons 21 to 25 was confirmed to be from βMyHC ( FIG. 1A ).
[0229] Using the same method just described, two other tissue specific genes—amyloid precursor protein (APP, forward primer, SEQ ID No. 7; reverse primer, SEQ ID No. 8) found in the brain and associated with Alzheimer's disease, and adenomatous polyposis coli protein (APC) found in the colon and rectum and associated with colorectal cancer (Groden et al. 1991; Santoro and Groden 1997)—were also detected in the RNA extracted from human blood ( FIG. 1B ).
EXAMPLE 6
[heading-0230] Multiple RT-PCR Analysis on a Drop of Blood From a Normal/Diseased Individual
[0231] A drop of blood was extracted to obtain RNA to carry out quantitative RT-PCR analysis. Specific primers for the insulin gene were designed: forward primer (5′-GCCCTCTGGGGACCTGAC-3′, SEQ ID NO 1) of exon 1 and reverse primer (5′-CCCACCTGCAGGTCCTCT-3″, SEQ ID NO 2) of exons 1 and 2 of insulin gene. Such reverse primer was obtained by deleting the intron between the exons 1 and 2. Blood samples of 4 normal subjects were assayed. It was found that the insulin gene is expressed in the blood and the quantitative expression of the insulin gene in a drop of blood is influenced by fasting and non-fasting states of normal healthy subjects ( FIG. 2 ). This very low level of expression of the insulin gene reflects the phenotypic status of a person and strongly suggests that there is a physiological and pathological role for its expression, contrary to the basal or illegitimate theory of transcription suggested by Chelly et al. (1989) and Kimoto (1998).
[0232] Same quantitative RT-PCR analysis was performed using insulin specific primers on RNA samples extracted from a drop of blood from a normal healthy person, a person having late-onset diabetes (Type II) and a person having asymptomatic diabetes. It was found that the insulin gene is expressed differentially amongst subjects that are healthy, diagnosed as type II diabetic, and also in an asymptomatic preclinical patient ( FIG. 3 ).
[0233] Similarly, specific primers for the atrial natriuretic factor (ANF) gene were designed (forward primer, SEQ ID No. 5; reverse primer, SEQ ID No. 6) and RT-PCR analysis was performed on a drop of blood. ANF is known to be highly expressed in heart tissue biopsies and in the plasma of heart failure patients. However, atrial natriuretic factor was observed to be expressed in the blood and the expression of the atrial natriuretic factor gene is significantly higher in the blood of patients with heart failure as compared to the blood of a normal control patient.
[0234] Specific primers for the zinc finger protein gene (ZFP, forward primer, SEQ ID No. 9; reverse primer, SEQ ID No. 10) were also designed and RT-PCR analysis was performed on a drop of blood. ZFP is known to be high in heart tissue biopsies of cardiac hypertrophy and heart failure patients. In the present study, the expression of ZFP was observed in the blood as well as differential expression levels of ZFP amongst the normal, diabetic and asymptomatic preclinical subjects ( FIG. 4 ); although neither of the non-normal subjects has been specifically diagnosed as suffering from cardiac hypertrophy and/or heart failure, the higher expression levels of the ZFP gene in their blood may indicate that these subjects are headed in that general direction.
[0235] It was hypothesized that a housekeeping gene such as glyceraldehyde dehydrogenase (GADH) which is required and highly expressed in all cells would not be differentially expressed in the blood of normal vs. disease subjects. This hypothesis was confirmed by RT-PCR using GADH specific primers ( FIG. 4 ). Thus, GADH is useful as an internal control.
[0236] Standardized levels of insulin gene or ZFP gene expressed in a drop of blood were estimated using a housekeeping gene as an internal control relative to insulin or ZFP expressed ( FIGS. 5A & 5B ). The levels of insulin gene expressed in each fractionated cell from whole blood were also standardized and shown in FIG. 5C .
EXAMPLE 7
[heading-0237] Human Blood Cell cDNA Library
[0238] In order to further substantiate the present invention, differential screening of the human blood cell cDNA library was conducted. cDNA probes derived from human blood, adult heart or brain were respectively hybridized to the human blood cDNA library clones. As shown in FIG. 7 , more than 95% of the “positively” identified clones are identical between the blood and other tissue samples.
[0239] DNA sequencing of randomly selected clones from the human whole blood cell cDNA library was also performed. This allowed information regarding the cellular function of blood to be obtained concurrently with gene identification. More than 20,000 expressed sequence tags (ESTs) have been generated and characterized to date, 17.6% of which did not result in a statistically significant match to entries in the GenBank databases and thus were designated as “Novel” ESTs. These results are summarized in FIG. 7 together with the seven cellular functions related to percent distribution of known genes in blood and in the fetal heart.
[0240] From 20,000 ESTs, 1,800 have been identified as known genes which may not all appear in the hemapoietic system. For example, the insulin gene and the atrial natriuretic factor gene have not been detected in these 20,000 ESTs but their transcripts were detected in a drop of blood, strongly suggesting that all transcripts of the human genome can be detected by performing RT-PCR analysis on a drop of blood.
[0241] In addition, approximately 400 novel genes have been identified from the 20,000 ESTs characterized to date, and these will be subjected to full length sequencing and open reading frame alignment to reduce the actual number of novel ESTs prior to screening for disease markers.
[0242] Analysis of the approximately 6,283 ESTs which have known matches in the GenBank databases revealed that this dataset represents over 1,800 unique genes. These genes have been catalogued into seven cellular functions. Comparisons of this set of unique genes with ESTs derived from human brain, heart, lung and kidney demonstrated a greater than 50% overlap in expression (Table 1).
TABLE 1 Overlap of Genes Expressed in Blood Tissue UniGene* Overlap Brain 19,158 70% Heart 17,021 67% Kidney 19,414 69% Liver 22,836 71% Lung 22,209 75% *Known gene cluster numbers found in a corresponding tissue in UniGene.
[0243] There are about 5,100 unique known genes from the over 25,000 ESTs obtained from human blood cDNA libraries. These genes were searched against human UniGene, Build #160 (with a total of 111,064 clusters).
EXAMPLE 8
[heading-0244] Blood Cell ESTs
[0245] The results from the differential screening clearly indicate that the transcripts expressed in the whole blood are reflective of genes expressed in all cells and tissues of the body. More than 95% of detectable spots were identical from two different tissues. The remaining 5% of spots may represent cell- or tissue-specific transcripts; however, results obtained from partial sequencing to generate ESTs of these clones revealed most of them not to be cell- or tissue-specific transcripts. Therefore, the negative spots are postulated to be reflective of low abundance transcripts in the tissue from which the cDNA probes were derived.
[0246] An alternative approach that was employed to identify transcripts expressed at low levels is the large-scale generation of expressed sequence tags (ESTs). There is substantial evidence regarding the efficiency of this technology to detect previously characterized (known) and uncharacterized (unknown or novel) genes expressed in the cardiovascular system (Hwang & Dempsey et al.. 1997). In the present invention, 20,000 ESTs have been produced from a human blood cell cDNA library and resulted in the identification of approximately 1,800 unique known genes (Table 2)
[0247] In the most recent GenBank release, analysis of more than 300,000 ESTs in the database (dbESTs) generated more than 48,000 gene clusters which are thought to represent approximately 50% of the genes in the human genome. Only 4,800 of the dbESTs are blood-derived. In the present invention, 20,000 ESTs have been obtained to date from a human blood cDNA library, which provides the world's most informative database with respect to blood cell transcripts. From the limited amount of information generated so far (i.e. 1,800 unique genes), it has already been determined that more than 50% of the transcripts are found in other cells or tissues of the human body (Table 2). Thus, it is expected that by increasing the number of ESTs generated, more genes will be identified that have an overlap in expression between the blood and other tissues. Furthermore, the transcripts for several genes which are known to have tissue-restricted patterns of expression (i.e. βMyHC, APP, APC, ANF, ZFP) have also been demonstrated to be present in blood.
[0248] Most recently, a cDNA library of human hematopoietic progenitor stem cells has also been constructed. From the limited set of 1,000 ESTs, there are at least 200 known genes that are shared with other tissue related genes (Claudio et al. 1998).
[0249] Table 2 demonstrates the expression of known genes of specific tissues in blood cells. Previously, only the presence of “housekeeping” genes would have been expected. Additionally, the presence of at least 25 of the currently known 500 genes corresponding to molecular drug targets was detected. These molecular drug targets are used in the treatment of a variety of diseases which involve inflammation, renal and cardiovascular function, neoplastic disease, immunomodulation and viral infection (Drews & Ryser, 1997). It is expected that additional novel ESTs will represent future molecular drug targets.
EXAMPLE 9
[0250] Blood cDNA chip Microarray Data Analysis of gene expression profiles of blood samples from individuals having coronary artery disease as compared with gene expression profiles from normal individuals.
[0251] A microarray was constructed using cDNA clones from a human peripheral blood cell cDNA library, as described herein. A total of 10,368 polymerase chain reaction (PCR) products of the clones from the human peripheral blood cell cDNA library described herein were arrayed using GNS 417 arrayer (Affymetrix). RNA for microarray analysis was isolated from whole blood samples obtained from three male and one female patients with coronary heart disease (80-90% stenosis) receiving vascular extension drugs and awaiting bypass surgery, and three healthy male controls.
[0252] A method of high-fidelity mRNA amplification from 1 pg of total RNA sample was used. Cy5- or Cy3-dUTP was incorporated into cDNA probes by reverse transcription of anti-sense RNA, primed by oligo-dT. Labelled probes were purified and concentrated to the desired volume. Pre- hybridization and hybridization were performed following Hegde's protocol (Hegde P et al., A concise guide to cDNA microarray analysis. Biotechniques, 2000; 29: 548-56). After overnight hybridization and washing, hybridization signals were detected with a GMS 418 scanner at 635-nm (Cy5) and 532-nm (Cy3) wave lengths (see FIG. 24 ). Two RNA pools were labelled alternatively with Cy5- and Cy3-dUTP, and each experiment was repeated twice. Cluster analysis using GeneSpring™ 4.1.5 (Silicon Genetics) revealed two distinct groups consisting of four CAD and three normal control samples. Two images scanned at different wavelengths were super-imposed. Individual spots were identified on a customized grid. Of 10,368 spots, 10,012 (96.6%) were selected after the removal of spots with irregular shapes. Data quality was assessed with values of Ch1GTB2 and Ch2GTB2 provided by ScanAlyze. Only spots with Ch1GTB2 and Ch2GTB2 over 0.50 were selected. After evaluation of signal intensities, 8750 (84.4%) spots were left. Signal intensities were normalized using a scatter-plot of the signal intensities of the two channels. After normalization, the expression ratios of β-actin were 1.00+0 21, 1.11+0.22, 1.14+0.20 and 1.30+0.18 (24 samples of β-actin were spotted on this slide as the positive control) in the four images. Gene differential expression was assessed as the ratio of two wave-length signal intensities. Spots showing a differential expression more than twofold in all four experiments were identified as peripheral blood cell, differentially expressed candidate genes in CAD. 108 genes are differentially expressed in CAD peripheral blood cells. 43 genes are downregulated in CAD blood cells and 65 are upregulated (see Table 5). Functional characterization of these genes shows that differential expression takes place in every gene functional category, indicating that profound changes occur in CAD blood cells.
[0253] The differential expression of three genes, pro-platelet basic protein (PBP), platelet factor 4 (PF4) and coagulation factor XIII Al (F13A), initially identified in the microarray data analysis, was further examined by reverse transcriptase-PCR (RT-PCR) using the Titan One-tube RT-PCR kit (Boehringer Mannheim). Reaction solution contains 0.2 mM each dNTP, 5 mM DTT, 1.5 mM MgCl 0.1 pg of total RNA from each sample and 20 pmol each of left and right primers of PBP (5′- GGTGCTGCTGCTTCTGTCAT-3′ and 5′-GGCAGATTTT CCTCCCATCC-3′), F13A (5′-AGTCCACCGTGCTAACCATC-3′ and 5′-AGGGAGTCACTGCTCATGCT-3′) and PF4 (5′ GTTGCTGCTCCTGCCACTT 3′ and 5′GTGGCTATCAGTTGGGCAGT-3′). RT-PCR steps are as follows: 1. reverse-transcription: 30 min at 60° C.; 2. PCR: 2 min at 94° C., followed by 30-35 cycles (as optimized for each gene) for 30 s at 94° C., 30 s at optimized annealing temperature and 2 min at 68° C.; 3. final extension: 7 min at 68° C. PCR products were electrophoresed on 1.5% agarose gels. Human (β-actin primers (5′-GCGAGAAGATGACCCAGATCAT-3′ and 5′-GCTCAGGAGGAGCAATGATCTT-3′) were used as the internal control. The RT-PCR analysis confirmed that the expression of the three secreted proteins: PBP, PF4 and F13A were all upregulated in CAD blood cells (see FIG. 23 ).
TABLE 5 Protein Accession Fold Functional Accession number (average) category Number Upregulated gene in CAD REV3-like, catalytic AF035537 2.3 Cell cycle NP_002903 subunit of DNA polymerase zeta TGFB1-induced anti- D86970 2.2 Cell cycle NP_510880 apoptotic factor 1 A disintegrin and AA044656 2.7 Cell signaling NP_001101 metalloproteinase domain 10 Centaurin, delta 2 AA351412 2 Cell signaling NP_631920 Chloride intracellular AA411940 2.2 Cell signaling NP_039234 channel 4 Endothelin receptor typeA D90348 2.1 Cell signaling NP_001948 Glutamate receptor, N33821 2.4 Cell signaling NP_777567 ionotropic Mitogen-activated protein L38486 3.7 Cell signaling NP_002395 kinase 7 Mitogen-activated protein AB009356 4.5 Cell signaling NP_663306 kinase kinase kinase 7 Myristoylated alanine-rich D10522 2.5 Cell signaling NP_002347 protein kinase C substrate NIMA-related kinase 7 AA093324 3.5 Cell signaling NP_598001 PAK2 AA262968 3.5 Cell signaling Q13177 Phospholipid scramblase 1 AA054476 3.3 Cell signaling NP_066928 Serum deprivation Z30112 4.5 Cell signaling NP_004648 response Adducin 3 AA029158 2.9 Cell structure NP_063968 Desmin AF167579 4.4 Cell structure NP_001918 Fibromodulin W23613 2.9 Cell structure NP_002014 Laminin, beta 2 S77512 2.2 Cell structure NP_002283 Laminin, beta 3 L25541 2.4 Cell structure NP_000219 Osteonectin Y00755 3.1 Cell structure NP_003109 CD59 antigen p18-20 W01111 2.4 Cell/organism NP_000602 defense Clusterin M64722 3.5 Cell/organism NP_001822 defense F13A M14539 2.1 Cell/organism NP_000120 defense Defensin, alpha 1 M26602 4.2 Cell/organism NP_004075 defense PF4 M25897 2.1 Cell/organism NP_002610 defense PBP M54995 5.5 Cell/organism NP_002695 defense E2F transcription factor 3 D38550 2.1 Gene NP_001940 expression Early growth response 1 M62829 2.7 Gene NP_001955 expression Eukaryotic translation N86030 2.3 Gene NP_001393 elongation factor 1 alpha 1 expression Eukaryotic translation M15353 2.1 Gene NP_001959 initiation factor 4E expression F-box and WD-40 domain AB014596 2.7 Gene NP_387449 protein 1B expression Makorin, ring finger AA331966 2.1 Gene NP_054879 protein, 2 expression Non-canonical ubiquitin- N92776 2.5 Gene NP_057420 conjugating enzyme 1 expression Nuclear receptor subfamily Z30425 4.7 Gene NP_005113 1, group I, member 3 expression Ring finger protein 11 T08927 3 Gene NP_055187 expression Transducin-like enhancer M99435 3.3 Gene NP_005068 of split 1 expression Alkaline phosphatase, AB011406 2.2 Metabolism NP_000469 liver/bone/kidney Annexin A3 M63310 3.4 Metabolism NP_005130 Branched chain AA336265 4.8 Metabolism NP_005495.1 aminotransferase 1, cytosolic Cytochrome b AF042500 2.5 Metabolism Glutaminase D30931 2.6 Metabolism NP_055720 Lysophospholipase I AF035293 2.8 Metabolism NP_006321 NADH dehydrogenase 1, AA056111 2.5 Metabolism NP_002485 subcomplex unknown 1, 6 kDa Phosphofructokinase M26066 2.2 Metabolism NP_000280 Ubiquinol-cytochrome c M22348 2.5 Metabolism NP_006285 reductase binding protein CGI-110 protein AA341061 2.4 Unclassified NP_057131 Dactylidin H95397 2.7 Unclassified NP_112225 Deleted in split-hand/split- T24503 2.4 Unclassified NP_006295 foot 1 region Follistatin-like 1 R14219 2.7 Unclassified NP_009016 FUS-interacting protein 1 W37945 2.8 Unclassified NP_473357 Hypothetical protein W47233 7 Unclassified NP_112201 FLJ12619 Hypothetical protein from N68247 2.7 Unclassified EUROIMAGE 588495 Hypothetical protein AA251423 2.2 Unclassified NP_057702 LOC51315 KIAA1705 protein T80569 2.7 Unclassified NP_009121.1 Mesoderm induction early AI650409 2.2 Unclassified NP_065999 response 1 Phosphodiesterase 4D- AA740661 2.5 Unclassified NP_055459 interacting protein Preimplantation protein 3 D59087 2.5 Unclassified NP_056202 Putative nuclear protein W33098 2.8 Unclassified NP_115788 ORF1-FL49 Similar to rat nuclear H09434 2.2 Unclassified Q9H1E3 ubiquitous casein kinase 2 Similar to RIKEN AA297412 2.5 Unclassified T02670 Spectrin, beta AI334431 2.5 Unclassified Q01082 Stromal cell-derived factor H71558 4.1 Unclassified NP_816929 receptor 1 Thioredoxin-related AA421549 2.8 Unclassified NP_110437 protein Transmembrane 4 D29808 2.4 Unclassified NP_004606 superfamily member 2 Tumor endothelial marker 8 D79964 2.5 Unclassified NP_444262 Downregulated gene in CAD CASP8 and FADD-like AF015450 0.45 Cell cycle NP_003870 apoptosis regulator CD81 antigen M33680 0.41 Cell cycle NP_004347 Cell division cycle 25B M81934 0.4 Cell cycle NP_068660 DEAD/H (Asp-Glu-Ala- AA985699 0.42 Cell cycle NP_694705 Asp/His) box polypeptide 27 F-box and leucine-rich R98291 0.27 Cell cycle NP_036440 repeat protein 11 Minichromosome H10286 0.43 Cell cycle NP_003897 maintenance deficient 3 associated protein Protein phosphatase 2, J02902 0.48 Cell cycle NP_055040 regulatory subunit A, alpha isoform Thyroid autoantigen 70 kDa J04607 0.25 Cell cycle NP_001460 A disintegrin and R32760 0.37 Cell signaling metalloproteinase domain 17 A kinase anchor protein 13 M90360 0.31 Cell signaling NP_658913 Calpastatin AF037194 0.39 Cell signaling NP_006471 Diacylglycerol kinase, AF064770 0.44 Cell signaling NP_001336 alpha 80 kDa gamma-aminobutyric acid AJ012187 0.42 Cell signaling NP_068705 B receptor, 1 Inositol polyphosphate-5- U84400 0.41 Cell signaling NP_005532 phosphatase, 145 kDa Lymphocyte-specific X05027 0.45 Cell signaling NP_005347 protein tyrosine kinase RAP1B, member of RAS P09526 0.4 Cell signaling P09526 oncogene family Ras association AF061836 0.43 Cell signaling NP_733835 (RaIGDS/AF-6) domain family 1 CDC42-effector protein 3 AF104857 0.28 Cell signaling NP_006440 Leupaxin AF062075 0.31 Cell signaling NP_004802 Annexin A6 D00510 0.45 Cell structure NP_004024 RAN-binding protein 9 AB008515 0.41 Cell structure NP_005484 Thymosin, beta 10 M20259 0.26 Cell structure NP_066926 GranzymeA M18737 0.17 Cell/organism NP_006135 defense ThromboxaneA synthase 1 M80646 0.44 Cell/organism NP_112246 defense Coatomer protein AA357332 0.39 Gene NP_057535 complex, subunit beta expression Cold-inducible RNA- H39820 0.27 Gene NP_001271 binding protein expression Leucine-rich repeat U69609 0.44 Gene NP_004726 interacting protein 1 expression Proteasome subunit, alpha D00762 0.31 Gene NP_687033 type, 3 expression Proteasome subunit, alpha AF022815 0.35 Gene NP_689468 type, 7 expression Protein phosphatase 1G, AI417405 0.5 Gene NP_817092 gamma isoform expression Ribonuclease/angiogenin M36717 0.44 Gene NP_002930 inhibitor expression RNA-binding protein- AF021819 0.3 Gene NP_009193 regulatory subunit expression Signal transducer and U16031 0.45 Gene NP_003144 activator of transcription 6 expression Transcription factor A, M62810 0.41 Gene NP_036383 mitochondrial expression Ubiquitin-specific protease 4 AF017306 0.31 Gene NP_003354 expression Dehydrogenase/reductase AA100046 0.46 Metabolism NP_612461 SDR family member 1 Solute carrier family 25, J03592 0.3 Metabolism NP_001627 member 6 Amplified in osteosarcoma U41635 0.45 Unclassified NP_006803 Expressed in activated C00577 0.45 Unclassified NP_009198 T/LAK lymphocytes Integral inner nuclear W00460 0.4 Unclassified NP_055134 membrane protein Phosphodiesterase 4D- T95969 0.45 Unclassified NP_055459 interacting protein Tumor endothelial marker N93789 0.45 Unclassified NP_065138 7 precursor Wiskott-Aldrich syndrome AF031588 0.22 Unclassified NP_003378 protein interacting protein
EXAMPLE 10
[0254] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from co-morbid individuals having osteoarthritis and hypertension as compared with gene expression profiles from normal individuals.
[0255] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with osteoarthritis and hypertension as compared to blood samples taken from healthy patients.
[0256] As used herein, the term “hypertension” is defined as high blood pressure or elevated arterial pressure. Patients identified with hypertension herein include persons who have an increased risk of developing a morbid cardiovascular event and/or persons who benefit from medical therapy designed to treat hypertension. Patients identified with hypertension also can include persons having systolic blood pressure of >130 mm Hg or a diastolic blood pressure of >90 mm Hg or a person takes antihypertensive medication.
[0257] Osteoarthritis (OA), as used herein also known as “degenerative joint disease”, represents failure of a diarthrodial (movable, synovial-lined) joint. It is a condition, which affects joint cartilage, and or subsequently underlying bone and supporting tissues leading to pain, stiffness, movement problems and activity limitations. It most often affects the hip, knee, foot, and hand, but can affect other joints as well.
[0258] OA severity can be graded according to the system described by Marshall (Marshall K W. J. Rheumatol, 1996:23(4) 582-85). Briefly, each of the six knee articular surfaces was assigned a cartilage grade with points based on the worst lesion seen on each particular surface. Grade 0 is normal (0 points), Grade I cartilage is soft or swollen but the articular surface is intact (1 point). In Grade II lesions, the cartilage surface is not intact but the lesion does not extend down to subchondral bone (2 points). Grade III damage extends to subchondral bone but the bone is neither eroded nor eburnated (3 points). In Grade IV lesions, there is eburnation of or erosion into bone (4 points). A global OA score is calculated by summing the points from all six cartilage surfaces. If there is any associated pathology, such as meniscus tear, an extra point will be added to the global score. Based on the total score, each patient is then categorized into one of four OA groups: mild (1-6), moderate (7-12), marked (13-18), and severe (>18). As used herein, patients identified with OA may be categorized in any of the four OA groupings as described above.
[0259] Blood samples were taken from patients who were diagnosed with osteoarthritis and hypertension as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of osteoarthritis and hypertension was corroborated by a skilled Board certified physician.
[0260] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with disease as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0261] FIG. 8 shows a diagrammatic representation of gene expression profiles of blood samples from individuals having hypertension and osteoarthritis as compared with gene expression profiles from normal individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. In this example, hypertensive patients also presented with OA, as described herein. Normal individuals have no known medical conditions and were not taking any known medication. Hybridizations to create said gene expression profiles were done using the ChondroChip™ A dendogram analysis is shown above. Samples are clustered and marked as representing patients who are hypertensive or normal. The “*” indicates those patients who abnormally clustered as either hypertensive, or normal despite presenting with the reverse. The number of hybridizations profiles determined for either hypertensive patients or normal individuals are shown. 861 differentially expressed genes were identified as being differentially expressed with a p value of <0.05 as between the hypertensive patients and normal individuals. The identity of the differentially expressed genes is shown in Table 3A.
[0262] Classification or class prediction of a test sample as either having hypertension and OA or being normal can be done using the differentially expressed genes as shown in Table 3A in combination with well known statistical algorithms for class prediction as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 10A
[0263] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from individuals having osteoarthritis and hypertension as compared with gene expression profiles from patients having osteoarthritis only.
[0264] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from co-morbid patients with osteoarthritis and hypertension as compared to blood samples taken from OA patients only.
[0265] Blood samples were taken from patients who were diagnosed with osteoarthritis and hypertension as defined herein. Gene expression profiles were then analysed and compared to profiles from patients having OA only. In each case, the diagnosis of osteoarthritis and/or hypertension was corroborated by a skilled Board certified physician.
[0266] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with disease as compared to OA patients only was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0267] Expression profiles were generated using GeneSpring™ software analysis as described herein (data not shown). The gene list generated from this analysis was identified and those genes previously identified in Table 3A removed so as to identify those genes which are unique to hypertension. 790 differentially expressed genes were identified as being differentially expressed with a p value of <0.05 as between the OA and hypertensive patients when compared with OA individuals. 577 genes were identified as unique to hypertension. The identity of these differentially expressed genes are shown in Table 3P. A gene list is also provided of the 213 genes which were found in common as between those genes identified in Table 3A and genes differentially expressed in blood samples taken from patients with osteoarthritis and hypertension as compared to blood samples taken from OA patients only. The identity of these intersecting differentially expressed genes is shown in Table 3Q and a venn diagram showing the relationship between the various groups of gene lists is found in FIG. 29 .
[0268] Classification or class prediction of a test sample as having hypertension or not having hypertension can be done using the differentially expressed genes as shown in Table 3P as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available. Classification of individuals as having both OA and hypertension using the genes in Table 3Q can also be performed.
EXAMPLE 11
[0269] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from co-morbid individuals having osteoarthritis and obesity as compared with gene expression profiles from normal individuals.
[0270] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with obesity and OA as compared to blood samples taken from healthy patients.
[0271] As used herein, “obesity” is defined as an excess of adipose tissue that imparts a health risk. Obesity is assessed in terms of height and weight in the relevance of age. Patients who are considered obese include, but are not limited to, patients having a body mass index or BMI ((defined as body weight in kg divided by (height in meters) 2 ) greater than or equal to 30.0.
[0272] Blood samples were taken from patients who were diagnosed with osteoarthritis and obesity as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of the disease was corroborated by a skilled Board certified physician. Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with disease as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0273] FIG. 9 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as obese as described herein as compared with gene expression profiles from normal individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. In this example, obese patients also presented with OA, as described herein. Normal individuals have no known medical conditions and were not taking any known medication. Hybridizations to create said gene expression profiles were done using the ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who are obese or normal. The “*” indicates those patients who abnormally clustered as either obese or normal despite presenting with the reverse. The number of hybridization profiles determined for obese patients with OA and normal individuals are shown. 913 genes were identified as being differentially expressed with a p value of <0.05 as between the obese patients with OA and normal individuals is noted. The identity of the differentially expressed genes is shown in Table 3B.
[0274] Classification or class prediction of a test sample as either having obesity and OA or being normal can be done using the differentially expressed genes as shown in Table 3B in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 11A
[0275] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from co-morbid individuals having osteoarthritis and obesity as compared with gene expression profiles from patients having osteoarthritis only.
[0276] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with obesity and OA as compared to blood samples taken from patients with OA only.
[0277] Blood samples were taken from patients who were diagnosed with osteoarthritis and obesity as defined herein. Gene expression profiles were then analysed and compared to profiles from patients affected by OA only.
[0278] In each case, the diagnosis of the disease was corroborated by a skilled Board certified physician. Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with obesity and OA as compared to OA patients only was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed. New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0279] Expression profiles were generated using GeneSpring™ software analysis as described herein (data not shown). 671 genes were identified as being differentially expressed with a p value of <0.05 as between the obese patients with OA and those patients with only OA. Those genes previously identified in Table 3B were removed so as to identify those genes which are unique to obesity. The identity of these 519 genes unique to obesity are shown in Table 3R. A gene list is also provided of those genes which were found in common as between those genes identified in Table 3B and genes differentially expressed in blood samples taken from patients with osteoarthritis and obesity as compared to blood samples taken from OA patients only. 152 genes are shown in Table 3S. A venn diagram showing the relationship between the various groups of gene lists is found in FIG. 30 .
[0280] Classification or class prediction of a test sample as having obesity or not having obesity can be done using the differentially expressed genes as shown in Table 3R as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available. Classification of individuals as having both OA and obesity using the genes in Table 3S can also be performed.
EXAMPLE 12
[0281] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from co-morbid individuals having osteoarthritis and allergies as compared with gene expression profiles from normal individuals.
[0282] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with allergies as compared to blood samples taken from healthy patients.
[0283] As used herein, “allergies” encompasses diseases and conditions wherein a patient demonstrates a hypersensitive or allergic reaction to one or more substances or stimuli such as drugs, food stuffs, plants, animals etc. and as a result has an increased immune response. Such immune responses can include anaphylaxis, allergic rhinitis, asthma, skin sensitivity such as urticaria, eczema, and allergic contact dermatitis and ocular allergies such as allergic conjunctivitis and contact allergy. Patients identified as having allergies includes patients having one or more of the above noted conditions.
[0284] Blood samples were taken from patients who were diagnosed with osteoarthritis and allergies as defined herein. These patients are classified as presenting with co-morbidity, or multiple disease states. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of osteoarthritis and allergies was corroborated by a skilled Board certified physician.
[0285] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with osteoarthritis and allergies as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0286] FIG. 10 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having allergies as described herein as compared with gene expression profiles from normal individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. In this example, patients with allergies also presented with OA, as described herein. Normal individuals had no known medical conditions and were not taking any known medication. Hybridizations to create said gene expression profiles were done using the ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who are obese or normal. The “*” indicates those patients who abnormally clustered as either having allergies or being normal despite presenting with the reverse. The number of hybridizations profiles determined for patients with allergies and normal individuals are shown. 633 genes were identified as being differentially expressed with a p value of <0.05 as between patients with allergies and normal individuals is noted. The identity of the differentially expressed genes is shown in Table 3C.
[0287] Classification or class prediction of a test sample as either having allergies and OA or being normal can be done using the differentially expressed genes as shown in Table 3C in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 12A
[0288] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from individuals having osteoarthritis (OA) and allergies as compared with gene expression profiles from individuals with OA only.
[0289] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with allergies and OA as compared to blood samples taken from OA patients.
[0290] Blood samples were taken from patients who were diagnosed with osteoarthritis and allergies as defined herein. Gene expression profiles were then analysed and compared to profiles from patients affected by OA only. In each case, the diagnosis of osteoarthritis and allergies was corroborated by a skilled Board certified physician.
[0291] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with osteoarthritis and allergies as compared to OA patients only was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0292] Expression profiles were generated using GeneSpring™ software analysis as described herein (data not shown). 498 genes were identified as being differentially expressed with a p value of <0.05 as between patients with allergies and OA as compared with patients with OA only. Of the 498 genes identified, those genes previously identified in Table 3C were removed so as to identify those genes which are unique to allergies. 257 differentially expressed genes were identified as being as unique to allergies. The identity of these differentially expressed genes is shown in Table 3T. A gene list is also provided of the 241 genes which were found in common as between those genes identified in Table 3C and genes differentially expressed in blood samples taken from patients with osteoarthritis and allergies as compared to blood samples taken from OA patients only. The identity of these intersecting differentially expressed genes is shown in Table 3U and a venn diagram showing the relationship between the various groups of gene lists is found in FIG. 31 .
[0293] Classification or class prediction of a test sample as having allergies or not having allergies can be done using the differentially expressed genes as shown in Table 3T as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available. Classification of individuals as having both OA and allergies using the genes in Table 3U can also be performed.
EXAMPLE 13
[0294] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from co-morbid individuals having osteoarthritis and subject to systemic steroids as compared with gene expression profiles from normal individuals
[0295] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients subject to systemic steroids as compared to blood samples taken from healthy patients.
[0296] As used herein, “systemic steroids” indicates a person subjected to artificial levels of steroids as a result of medical intervention. Such systemic steroids include birth control pills, prednisone, and hormones as a result of hormone replacement treatment. A person identified as having systemic steroids is one who is on one or more of the following of the above treatment regimes.
[0297] Blood samples were taken from patients who were diagnosed with osteoarthritis and subject to systemic steroids as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of osteoarthritis and systemic steroids was corroborated by a skilled Board certified physician.
[0298] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to the 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with osteoarthritis and subject to systemic steroids as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0299] FIG. 11 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were subject to systemic steroids as described herein as compared with gene expression profiles from normal individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. In this example, patients taking systemic steroids also presented with OA, as described herein. Normal individuals have no known medical conditions and were not taking any known medication. Hybridizations to create said gene expression profiles were done using the ChondroChip™. (A dendogram analysis is shown above. Samples are clustered and marked as representing patients who are taking systemic steroids or normal. The “*” indicates those patients who abnormally clustered as either systemic steroids or normal despite presenting with the reverse. The number of hybridizations profiles determined for patients with systemic steroids and normal individuals are shown. 605 genes were identified as being differentially expressed with a p value of <0.05 as between patients with systemic steroids and normal individuals is noted. The identity of the differentially expressed genes is shown in Table 3D.
[0300] Classification or class prediction of a test sample from a patient as indicating said patient takes systemic steroids and has OA or as being normal can be done using the differentially expressed genes as shown in Table 3A in combination with well known statistical algorithms for class prediction as would be understood by a person skilled in the art and is described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 13A
[0301] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from co-morbid individuals having osteoarthritis and subject to systemic steroids as compared with gene expression profiles from with osteoarthritis only.
[0302] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients subject to systemic steroids and having OA as compared to blood samples taken from OA patients only.
[0303] Blood samples were taken from patients who were diagnosed with osteoarthritis and subject to systemic steroids as defined herein. Gene expression profiles were then analysed and compared to profiles from patients having OA only. In each case, the diagnosis of osteoarthritis and systemic steroids was corroborated by a skilled Board certified physician.
[0304] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to the 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with osteoarthritis and subject to systemic steroids as compared patients with OA only was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0305] Expression profiles were generated using GeneSpring™ software analysis as described herein (data not shown). 553 genes were identified as being differentially expressed with a p value of <0.05 as between patients taking systemic steroids and OA as compared with patients with OA only. Of the 553 genes identified, those genes previously identified in Table 3D were removed so as to identify those genes which are unique to systemic steroids. 362 differentially expressed genes were identified as being as unique to systemic steroids. The identity of these differentially expressed genes are shown in Table 3V. A gene list is also provided of the 191 genes which were found in common as between those genes identified in Table 3D and genes differentially expressed in blood samples taken from patients with osteoarthritis and systemic steroids as compared to blood samples taken from OA patients only. The identity of these intersecting differentially expressed genes is shown in Table 3W and a venn diagram showing the relationship between the various groups of gene lists is found in FIG. 32 .
[0306] Classification or class prediction of a test sample of an individual as either taking systemic steroids or not taking systemic steroids can be done using the differentially expressed genes as shown in Table 3V as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available. Classification of individuals as having both OA and taking systemic steroids using the genes in Table 3W can also be performed.
EXAMPLE 13B
[0307] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from co-morbid individuals having osteoarthritis and subject to systemic steroids as compared with gene expression profiles from normal individuals.
[0308] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients subject to various specific systemic steroids as compared to blood samples taken from healthy patients, and the ability to categorize and differentiate as between the systemic steroid being taken.
[0309] As used herein, “systemic steroids” indicates a person subjected to artificial levels of steroids as a result of medical intervention. Such systemic steroids include birth control pills, prednisone, and hormones as a result of hormone replacement treatment. A person identified as having systemic steroids is one who is on one or more of the following of the above treatment regimes.
[0310] Blood samples were taken from patients who were diagnosed with osteoarthritis and subject to systemic steroids as defined herein. Gene expression profiles were then analysed and compared as between the systemic steroids as compared to profiles from patients unaffected by any disease. In each case, the diagnosis of osteoarthritis and systemic steroids was corroborated by a skilled Board certified physician.
[0311] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to the 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with osteoarthritis and subject to systemic steroids as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0312] FIG. 34 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were subject to either birth control, prednisone, or hormone replacement therapy as described herein as compared with gene expression profiles from normal individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. In this example, patients taking with each of the systemic steroids also presented with OA, as described herein. Normal individuals have no known medical conditions and were not taking any known medication. Hybridizations to create said gene expression profiles were done using the ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who are taking birth control, prednisone, hormone replacement therapy or normal. The “*” indicates those patients who abnormally clustered. The number of hybridizations profiles determined for patients with birth control, prednisone, hormone replacement therapy or normal individuals are shown. 396 genes were identified as being differentially expressed with a p value of <0.05 as between patients with systemic steroids and normal individuals is noted. The identity of the differentially expressed genes is shown in Table 3AD.
[0313] Classification or class prediction of a test sample from a patient as indicating said patient takes systemic steroids and has OA or as being normal can be done using the differentially expressed genes as shown in Table 3AD in combination with well known statistical algorithms for class prediction as would be understood by a person skilled in the art and is described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 14
[0314] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from individuals having hypertension as compared with gene expression profiles from normal individuals.
[0315] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with hypertension but without osteoarthritis as compared to blood samples taken from healthy patients.
[0316] As used herein, the term “hypertension” is defined as high blood pressure or elevated arterial pressure. Patients identified with hypertension herein include persons who have an increased risk of developing a morbid cardiovascular event and/or persons who benefit from medical therapy designed to treat hypertension. Patients identified with hypertension also can include persons having systolic blood pressure of >130 mm Hg or a diastolic blood pressure of >90 mm Hg or a person takes antihypertensive medication.
[0317] Blood samples were taken from patients who were diagnosed with hypertension as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of hypertension was corroborated by a skilled Board certified physician.
[0318] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with hypertension as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0319] FIG. 12 shows a diagrammatic representation of gene expression profiles of blood samples from individuals having hypertension as compared with gene expression profiles from samples of both non-hypertensive and normal individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Non-hypertensive individuals presented without hypertension, but may have presented with other medical conditions and may be under various treatment regimes. Normal individuals have no known medical conditions and were not taking any known medication. Hybridizations to create said gene expression profiles were done using the ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who are hypertensive, normal or non-hypertensive. The “*” indicates those patients who abnormally clustered as either hypertensive, non-hypertensive or normal despite actual presentation. The number of hybridizations profiles determined for hypertensive patients, non-hypertensive patients and normal individuals are shown. 1, 993 genes identified as being differentially expressed with a p value of <0.05 as between the hypertensive patients and the combined normal and non-hypertensive individuals is noted. The identity of the differentially expressed genes are shown in Table 3E.
[0320] Classification or class prediction of a test sample of an individual so as to determine whether said individual has or does not have hypertension can be done using the differentially expressed genes as shown in Table 3E as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 15
[0321] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from individuals having obesity as compared with gene expression profiles from normal individuals.
[0322] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with obesity but without osteoarthritis as compared to blood samples taken from healthy patients.
[0323] As used herein, “obesity” is defined as an excess of adipose tissue that imparts a health risk. Obesity is assessed in terms of height and weight in the relevance of age. Patients who are considered obese include, but are not limited to, patients having a body mass index or BMI ((defined as body weight in kg divided by (height in meters) 2 ) greater than or equal to 30.0.
[0324] Blood samples were taken from patients who were diagnosed with hypertension as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of obesity was corroborated by a skilled Board certified physician.
[0325] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with obesity as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0326] FIG. 13 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as obese as described herein as compared with gene expression profiles from normal and non-obese individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Normal individuals have no known medical conditions and were not taking any known medication. Non-obese individuals presented without obesity, but may have presented with other medical conditions and may be under various treatment regimes. Hybridizations to create said gene expression profiles were done using the ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who are obese, normal or non-obese. The “*” indicates those patients who abnormally clustered as either obese, normal or non-obese despite actual presentation. The number of hybridizations profiles determined for obese patients, non-obese patients and normal individuals are shown. 1,147 genes were identified as being differentially expressed with a p value of <0.05 as between the obese patients and the combination of normal and non-obese individuals is noted. The identity of the differentially expressed genes is shown in Table 3F.
[0327] Classification or class prediction of a test sample as being obese or not being obese can be done using the differentially expressed genes as shown in Table 3F as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 16
[0328] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from individuals having type 2 diabetes as compared with gene expression profiles from normal individuals.
[0329] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with type 2 diabetes but without osteoarthritis as compared to blood samples taken from healthy patients.
[0330] As used herein, “diabetes”, or “diabetes mellitus” includes both “type 1 diabetes” (insulin-dependent diabetes (IDDM)) and “type 2 diabetes” (insulin-independent diabetes (NIDDM). Both type 1 and type 2 diabetes characterized in accordance with Harrison's Principles of Internal Medicine 14th edition, as a person having a venous plasma glucose concentration ≧140 mg/dL on at least two separate occasions after overnight fasting and venous plasma glucose concentration ≧200 mg/dL at 2 h and on at least one other occasion during the 2-h test following ingestion of 75 g of glucose. Patients identified as having type 2 diabetes as described herein are those demonstrating insulin-independent diabetes as determined by the methods described above.
[0331] Blood samples were taken from patients who were diagnosed with type II diabetes as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of type II diabetes was corroborated by a skilled Board certified physician.
[0332] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with type 2 diabetes as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0333] FIG. 14 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having type 2 diabetes as described herein as compared with gene expression profiles from normal and non-type 2 diabetes individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Normal individuals have no known medical conditions and were not taking any known medication. Non-type 2 diabetes individuals presented without type 2 diabetes, but may have presented with other medical conditions and may be under various treatment regimes. Hybridizations to create said gene expression profiles were done using the ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have type 2 diabetes, are normal or do not have type 2 diabetes. The “*” indicates those patients who abnormally clustered despite actual presentation. The number of hybridizations profiles determined for type 2 diabetes, non-type 2 diabetes and normal individuals are shown. 915 were identified as being differentially expressed with a p value of <0.05 as between the type 2 diabetes patients and the combination of normal and non type 2 diabetes individuals is noted. The identity of the differentially expressed genes is shown in Table 3G.
[0334] Classification or class prediction of a test sample of an individual so as to determine whether said individual has type 2 diabetes or does not have type 2 diabetes can be done using the differentially expressed genes as shown in Table 3G as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 17
[0335] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from individuals having hyperlipidemia as compared with gene expression profiles from normal individuals.
[0336] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with hyperlipidemia but without osteoarthritis as compared to blood samples taken from healthy patients.
[0337] As used herein, “hyperlipidemia” is defined as an elevation of lipid protein profiles and includes the elevation of chylomicrons, very low-density lipoproteins (VLDL), intermediate-density lipoproteins (IDL), low-density lipoproteins (LDL), and/or high-density lipoproteins (HDL) as compared with the general population. Hyperlipidemia includes hypercholesterolemia and/or hypertriglyceridemia. By hypercholesterolemia, it is meant elevated fasting plasma total cholesterol level of>200 mg/dL, and/or LDL-cholesterol levels of >130 mg/dL. A desirable level of HDL-cholesterol is>60 mg/dL. By hypertriglyceridemia it is meant plasma triglyceride (TG) concentrations of greater than the 90 th or 95 th percentile for age and sex and can include, for example, TG >160 mg/dL as determined after an overnight fast.
[0338] Blood samples were taken from patients who were diagnosed with hyperlipidemia as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of hyperlipidemia was corroborated by a skilled Board certified physician.
[0339] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with hyperlipidemia as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0340] FIG. 15 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having hyperlipidemia as described herein as compared with gene expression profiles from normal and non-hyperlipidemia patients. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Normal individuals have no known medical conditions and were not taking any known medication. Non hyperlipidemia individuals presented without elevated cholesterol or elevated triglycerides but may have presented with other medical conditions and may be under various treatment regimes. Hybridizations to create said gene expression profiles were done using the ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have elevated lipids and/or cholesterol, are normal or do not have elevated lipids or cholesterol. The “*” indicates those patients who abnormally clustered as having either hyperlipidemia, normal or non-hyperlipidemia despite actual presentation. The number of hybridizations profiles determined for hyperlipidemia patients, non-hyperlipidemia patients and normal individuals are shown. 1,022 genes were identified as being differentially expressed with a p value of <0.05 as between the patients with hyperlipidemia and the combination of normal and non hyperlipidemia individuals. The identity of the differentially expressed genes is shown in Table 3H.
[0341] Classification or class prediction of a test sample of an individual as having hyperlipidemia or not having hyperlipidemia can be done using the differentially expressed genes as shown in Table 3H as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics for Class Predication (e.g. GeneSpring™) are also available.
EXAMPLE 18
[0342] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from individuals having lung disease as compared with gene expression profiles from normal individuals.
[0343] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with lung disease but without osteoarthritis as compared to blood samples taken from healthy patients.
[0344] As used herein, “lung disease” encompasses any disease that affects the respiratory system and includes bronchitis, chronic obstructive lung disease, emphysema, asthma, and lung cancer. Patients identified as having lung disease includes patients having one or more of the above noted conditions.
[0345] Blood samples were taken from patients who were diagnosed with lung disease as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of lung disease was corroborated by a skilled Board certified physician.
[0346] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRizol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with lung disease as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0347] FIG. 16 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having lung disease as described herein as compared with gene expression profiles from normal and non lung disease individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Normal individuals have no known medical conditions and were not taking any known medication. Non-lung disease individuals presented without lung disease, but may have presented with other medical conditions and may be under various treatment regimes. Hybridizations to create said gene expression profiles were done using the ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have lung disease, are normal or do not have lung disease. The “*” indicates those patients who abnormally clustered despite actual presentation. The number of hybridizations profiles determined for either the lung disease patients, non-lung disease patients and normal individuals are show. 596 genes were identified as being differentially expressed with a p value of <0.05 as between the lung disease patients and the combination of normal and non lung disease individuals is noted. The identity of the differentially expressed genes is shown in Table 3I.
[0348] Classification or class prediction of a test sample of an individual to determine whether said individual has lung disease or does not having lung disease can be done using the differentially expressed genes as shown in Table 3I as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 19
[0349] Affymetrix U133A Chip Microarray Data Analysis of gene expression profiles of blood samples from individuals having bladder cancer as compared with gene expression profiles from normal individuals.
[0350] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with bladder cancer but without osteoarthritis as compared to blood samples taken from healthy patients.
[0351] As used herein, the term “cancer” or “carcinoma” is defined as a disease in which cells behave abnormally and includes; (i) cancers which originate from a single cell proliferating to form a clone of malignant cells, (ii) cancers wherein the growth of the cell is not regulated by normal biological and physical influences of the environment, (iii) anaplasic cancer, wherein the cells lack normal coordinated cell differentiation and (iv) metastasis cancer, wherein the cells have the capacity for discontinuous growth and dissemination to other parts of the body. The diagnosis of cancer can include careful clinical assessment and/or diagnostic investigations including endoscopy, imaging, histopathology, cytology and laboratory studies.
[0352] As used herein, “bladder cancer” includes carcinomas that occur in the transitional epithelium lining the urinary tract, starting at the renal pelvis and extending through the ureter, the urinary bladder, and the proximal two-thirds of the urethra. As used herein, patients diagnosed with bladder cancer include patients diagnosed utilizing any of the following methods or a combination thereof: urinary cytologic evaluation, endoscopic evaluation for the presence of malignant cells, CT (computed tomography), MRI (magnetic resonance imaging) for metastasis status.
[0353] Blood samples were taken from patients who were diagnosed with bladder cancer as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of bladder cancer was corroborated by a skilled Board certified physician.
[0354] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to an Affymetrix U133A Chip as described herein. Identification of genes differentially expressed in blood samples from patients with bladder cancer as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0355] FIG. 17 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having bladder cancer as described herein as compared with gene expression profiles from non bladder cancer individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Non bladder cancer individuals presented without bladder cancer, but may have presented with other medical conditions and may be under various treatment regimes. Hybridizations to create said gene expression profiles were done using the Affymetrix U133A chip. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have bladder cancer, or do not have bladder cancer. The “*” indicates those patients who abnormally clustered as either bladder cancer, or non bladder cancer despite actual presentation. The number of hybridizations profiles determined for patients with bladder cancer and without bladder cancer are shown. 4,228 genes were identified as being differentially expressed with a p value of <0.05 as between the bladder cancer patients and the non bladder cancer individuals is noted. The identity of the differentially expressed genes is shown in Table 3J.
[0356] Classification or class prediction of a test sample of an individual to determine whether said individual has bladder cancer or does not having bladder cancer can be done using the differentially expressed genes as shown in Table 3J as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 20
[0357] Affymetrix U133A Chip Microarray Data Analysis of gene expression profiles of blood samples from individuals having early or advanced bladder cancer as compared with gene expression profiles from normal individuals.
[0358] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with early or advanced late stage bladder cancer but without osteoarthritis as compared to blood samples taken from healthy patients.
[0359] As used herein, “early stage bladder cancer” includes bladder cancer wherein the detection of the anatomic extent of the tumour, both in its primary location and in metastatic sites, as defined by the TNM staging system in accordance with Harrison's Principles of Internal Medicine 14th edition can be considered early stage. More specifically, early stage bladder cancer can include those instances wherein the carcinoma is mainly superficial.
[0360] As used herein, “advanced stage bladder cancer” is defined as bladder cancer wherein the detection of the anatomic extent of the tumour, both in its primary location and in metastatic sites, as defined by the TNM staging system in accordance with Harrison's Principles of Internal Medicine 14th edition, can be considered as advanced stage. More specifically, advanced stage carcinomas can involve instances wherein the cancer has infiltrated the muscle and wherein metastasis has occurred.
[0361] Blood samples were taken from patients who were diagnosed with early or advanced late stage bladder cancer as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of early or advanced late stage bladder cancer was corroborated by a skilled Board certified physician.
[0362] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to an Affymetrix U133A Chip as described herein. Identification of genes differentially expressed in blood samples from patients with early or advanced late stage bladder cancer as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0363] FIG. 18 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having advanced stage bladder cancer or early stage bladder cancer as described herein as compared with gene expression profiles from non bladder cancer individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Non bladder cancer individuals presented without bladder cancer, but may have presented with other medical conditions and may be under various treatment regimes. Hybridizations to create said gene expression profiles were done using the Affymetrix U1338 chip. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have early stage bladder cancer, advanced stage bladder cancer, or do not have bladder cancer. The “*” indicates those patients who abnormally clustered despite actual presentation. The number of hybridizations profiles determined for either early stage bladder cancer, advanced bladder cancer or non-bladder cancer are shown. 3,518 genes were identified as being differentially expressed with a p value of <0.05 as between the bladder cancer patients and the non bladder cancer individuals is noted. The identity of the differentially expressed genes is shown in Table 3K.
[0364] Classification or class prediction of a test sample of an individual to determine whether said individual has advanced bladder cancer, early stage bladder cancer or does not have bladder cancer can be done using the differentially expressed genes as shown in Table 3K as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 21
[0365] Affymetrix U133A Chip Microarray Data Analysis of gene expression profiles of blood samples from individuals having coronary artery disease as compared with gene expression profiles from normal individuals.
[0366] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with coronary artery disease but without osteoarthritis as compared to blood samples taken from healthy patients As used herein, “Coronary artery disease” (CAD) is defined as a condition wherein at least one coronary artery has >50% luminal diameter stenosis, as diagnosed by coronary angiography and includes conditions in which there is atheromatous narrowing and subsequent occlusion of the vessel. CAD includes those conditions which manifest as angina, silent ischaemia, unstable angina, myocardial infarction, arrhythmias, heart failure, and sudden death. Patients identified as having CAD herein Coronary artery disease is defined
[0367] Blood samples were taken from patients who were diagnosed with Coronary artery disease as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of Coronary artery disease was corroborated by a skilled Board certified physician.
[0368] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to an Affymetrix U133A Chip as described herein. Identification of genes differentially expressed in blood samples from patients with Coronary artery disease as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics, 5th ed., New York, USA, McGraw-Hill Medical Publishing Division, 2002).
[0369] FIG. 19 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having coronary artery disease (CAD) as described herein as compared with gene expression profiles from non-coronary artery disease individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Non coronary artery disease individuals presented without coronary artery disease, but may have presented with other medical conditions and may be under various treatment regimes. Hybridizations to create said gene expression profiles were done using the Affymetrix™ U133A chip. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have coronary artery disease or do not have coronary artery disease. The “*” indicates those patients who abnormally clustered despite actual presentation. The number of hybridizations profiles determined for patients with CAD or without CAD are shown. 967 genes were identified as being differentially expressed with a p value of <0.05 as between the coronary artery disease patients and those individuals without coronary artery disease is noted. The identity of the differentially expressed genes is shown in Table 3L.
[0370] Classification or class prediction of a test sample of an individual to determine whether said individual has CAD or does not have CAD can be done using the differentially expressed genes as shown in Table 3L as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics for Class Predication (e.g. GeneSpring™) are also available.
EXAMPLE 22
[0371] Affymetrix U133A Chip Microarray Data Analysis of gene expression profiles of blood samples from individuals having Rheumatoid arthritis as compared with gene expression profiles from normal individuals.
[0372] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with Rheumatoid arthritis but without osteoarthritis as compared to blood samples taken from healthy patients.
[0373] Rheumatoid arthritis (RA) is defined as a chronic, multisystem disease of unknown etiology with the characteristic feature of persistent inflammatory synovitis. Said inflammatory synovitis usually involves peripheral joints in a systemic distribution. Patients having RA as defined herein were identified as having one or more of the following; (i) cartilage destruction, (ii) bone erosions, and/or (iii) joint deformities.
[0374] Blood samples were taken from patients who were diagnosed Rheumatoid arthritis as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of Rheumatoid arthritis was corroborated by a skilled Board certified physician.
[0375] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to an Affymetrix U133A Chip as described herein. Identification of genes differentially expressed in blood samples from patients with Rheumatoid arthritis as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0376] FIG. 20 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having rheumatoid arthritis as described herein as compared with gene expression profiles from non-rheumatoid arthritis individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Normal individuals have no known medical conditions and were not taking any known medication. Non rheumatoid arthritis individuals presented without rheumatoid arthritis, but may have presented with other medical conditions and may be under various treatment regimes. Hybridizations to create said gene expression profiles were done using ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have rheumatoid arthritis or do not have rheumatoid arthritis. The “*” indicates those patients who abnormally clustered despite actual presentation. The number of hybridizations profiles determined for patients with rheumatoid arthritis and without rheumatoid arthritis are shown. 2,068 genes were identified as being differentially expressed with a p value of <0.05 as between the rheumatoid arthritis patients and a combination of those individuals without rheumatoid arthritis and normal is noted. The identity of the differentially expressed genes is shown in Table 3M.
[0377] Classification or class prediction of a test sample of an individual as having rheumatoid arthritis or not having rheumatoid arthritis can be done using the differentially expressed genes as shown in Table 3M as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics for Class Predication (e.g. GeneSpring™) are also available.
EXAMPLE 23
[0378] Affymetrix U133A Chip Microarray Data Analysis of gene expression profiles of blood samples from individuals having depression as compared with gene expression profiles from normal individuals.
[0379] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with depression but without osteoarthritis as compared to blood samples taken from healthy patients
[0380] As used herein “mood disorders” are conditions characterized by a disturbance in the regulation of mood, behavior, and affect. “Mood disorders” can include depression, anxiety, schizophrenia, bipolar disorder, manic depression and the like.
[0381] As used herein “depression” includes depressive disorders or depression in association with medical illness or substance abuse in addition to depression as a result of sociological situations. Patients defined as having depression were diagnosed mainly on the basis of clinical symptoms including a depressed mood episode wherein a person displays a depressed mood on a daily basis for a period of greater than 2 weeks. A depressed mood episode may be characterized by sadness, indifference, apathy, or irritability and is usually associated with changes in a number of neurovegetative functions, including sleep patterns, appetite and weight, fatigue, impairment in concentration and decision making.
[0382] Blood samples were taken from patients who were diagnosed with depression as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of depression was corroborated by a skilled Board certified physician.
[0383] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to an Affymetrix U133A Chip as described herein. Identification of genes differentially expressed in blood samples from patients with depression as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0384] FIG. 21 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having depression as described herein as compared with gene expression profiles from non-depression individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Normal individuals have no known medical conditions and were not taking any known medication. Non depression individuals presented without depression, but may have presented with other medical conditions and may be under various treatment regimes. Hybridizations to create said gene expression profiles were done using ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have depression, having non-depression or normal. The “*” indicates those patients who abnormally clustered despite actual presentation. The number of hybridizations profiles determined for patients with depression, non-depression and normal are shown. 941 genes were identified as being differentially expressed with a p value of <0.05 as between the patients with depression and a combination of those individuals without depression and normal is noted. The identity of the differentially expressed genes is shown in Table 3N.
[0385] Classification or class prediction of a test sample of an individual to determine whether said individuals has depression or does not having depression can be done using the differentially expressed genes as shown in Table 3N as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 24
[0386] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from individuals having osteoarthritis as compared with gene expression profiles from normal individuals.
[0387] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients who were identified as having various stages of osteoarthritis as compared to blood samples taken from healthy patients.
[0388] Osteoarthritis (OA), as used herein also known as “degenerative joint disease”, represents failure of a diarthrodial (movable, synovial-lined) joint. It is a condition, which affects joint cartilage, and or subsequently underlying bone and supporting tissues leading to pain, stiffness, movement problems and activity limitations. It most often affects the hip, knee, foot, and hand, but can affect other joints as well.
[0389] OA severity can be graded according to the system described by Marshall (Marshall, K. W., J. Rheumatol., 1996, 23(4):582-85). Briefly, each of the six knee articular surfaces was assigned a cartilage grade with points based on the worst lesion seen on each particular surface. Grade 0 is normal (0 points), Grade I cartilage is soft or swollen but the articular surface is intact (1 point). In Grade II lesions, the cartilage surface is not intact but the lesion does not extend down to subchondral bone (2 points). Grade III damage extends to subchondral bone but the bone is neither eroded nor eburnated (3 points). In Grade IV lesions, there is eburnation of or erosion into bone (4 points). A global OA score is calculated by summing the points from all six cartilage surfaces. If there is any associated pathology, such as meniscus tear, an extra point will be added to the global score. Based on the total score, each patient is then categorized into one of four OA groups: mild (1-6), moderate (7-12), marked (13-18), and severe (>18). As used herein, patients identified with OA may be categorized in any of the four OA groupings as described above.
[0390] Blood samples were taken from patients who were diagnosed with osteoarthritis and a specific stage of osteoarthritis as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of osteoarthritis and the stage of osteoarthritis was corroborated by a skilled Board certified physician.
[0391] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with disease as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0392] FIG. 22 shows a diagrammatic representation of gene expression profiles of blood samples from individuals having osteoarthritis as compared with gene expression profiles from normal individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Normal individuals have no known medical conditions and were not taking any known medication. Hybridizations to create said gene expression profiles were done using the ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who presented with different stages of osteoarthritis or normal. The “*” indicates those patients who abnormally clustered despite actual presentation. The number of hybridizations profiles determined for either osteoarthritis patients or normal individuals are shown. 300 differentially expressed genes were identified as being differentially expressed with a p value of <0.05 as between the osteoarthritis patients and normal individuals. The identity of the differentially expressed genes is shown in Table 3I.
[0393] Classification or class prediction of a test sample of an individual as having OA, having mild OA, having marked OA, having moderate OA, having severe OA or not having OA can be done using the differentially expressed genes as shown in Table 30 as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 25
[0394] Microarray Data Analysis of gene expression profiles of blood samples from individuals having a condition as compared with gene expression profiles from individuals not having said condition, and wherein said individual is undergoing therapeutic treatment in light of said condition.
[0395] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from individuals undergoing therapeutic treatment of a condition as compared with gene expression profiles from individuals not undergoing treatment.
[0396] Blood samples are taken from patients who are undergoing therapeutic treatment. Gene expression profiles are then analysed and compared to profiles from patients not undergoing treatment.
[0397] Total mRNA from a drop of peripheral whole blood taken from each patient is isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample are generated as described above. Each probe is denatured and hybridized to a microarray for example the 15K Chondrogene Microarray Chip (ChondroChip™), Affymetrix Genechip or Blood chip as described herein. Identification of genes differentially expressed in blood samples from patients undergoing therapeutic treatment as compared to patients not undergoing treatment is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics. 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002). Expression profiles are generated using GeneSpring™ software analysis as described herein. The number of differentially expressed genes are then identified as being differentially expressed with a p value of <0.05.
EXAMPLE 26
[0398] Affymetrix U133A Chip Microarray Data Analysis of gene expression profiles of blood samples from individuals having liver cancer as compared with gene expression profiles from normal individuals.
[0399] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with liver cancer as compared to blood samples taken from healthy patients.
[0400] As used herein, “liver cancer” means primary liver cancer wherein the cancer initiates in the liver. Primary liver cancer includes both hepatomas or hepatocellular carcinomas (HCC) which start in the liver and chonalgiomas where cancers develop in the bile ducts of the liver.
[0401] Blood samples were taken from patients who were diagnosed with liver cancer as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of liver cancer was corroborated by a skilled Board certified physician.
[0402] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to an Affymetrix U133A Chip as described herein. Identification of genes differentially expressed in blood samples from patients with liver cancer as compared to healthy patients was determined by statistical analysis using the Weltch t-Test.
[0403] FIG. 25 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having liver cancer as described herein as compared with gene expression profiles from non-liver cancer disease individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Control samples presented without liver cancer but may have presented with other medical conditions and may be under various treatment regimes.
[0404] Hybridizations to create said gene expression profiles were done using the Affymetrix™ U133A chip. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have liver cancer or control. The number of hybridizations profiles determined for patients with liver cancer or who are controls are shown. 1,475 genes were identified as being differentially expressed with a p value of <0.05 as between the liver cancer patients and those control individuals. The identity of the differentially expressed genes is shown in Table 3X.
[0405] Classification or class prediction of a test sample of an individual to determine whether said individual has liver cancer or does not have liver cancer can be done using the differentially expressed genes as shown in Table 3X as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 27
[0406] Affymetrix U133A Chip Microarray Data Analysis of gene expression profiles of blood samples from individuals having schizophrenia as compared with gene expression profiles from normal individuals.
[0407] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with schizophrenia as compared to blood samples taken from healthy patients.
[0408] As used herein, “schizophrenia” is defined as a psychotic disorders characterized by distortions of reality and disturbances of thought and language and withdrawal from social contact. Patients diagnosed with “schizophrenia” can include patients having any of the following diagnosis: an acute schizophrenic episode, borderline schizophrenia, catatonia, catatonic schizophrenia, catatonic type schizophrenia, disorganized schizophrenia, disorganized type schizophrenia, hebephrenia, hebephrenic schizophrenia, latent schizophrenia, paranoic type schizophrenia, paranoid schizophrenia, paraphrenia, paraphrenic schizophrenia, psychosis, reactive schizophrenia or the like.
[0409] Blood samples were taken from patients who were diagnosed with schizophrenia as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of schizophrenia was corroborated by a skilled Board certified physician.
[0410] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to an Affymetrix U133A Chip as described herein. Identification of genes differentially expressed in blood samples from patients with schizophrenia as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division).
[0411] FIG. 26 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having schizophrenia as described herein as compared with gene expression profiles from non schizophrenic individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Control samples presented without schizophrenia but may have presented with other medical conditions and may be under various treatment regimes. Hybridizations to create said gene expression profiles were done using the Affymetrix™ U133A chip. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have schizophrenia or control individuals. The number of hybridizations profiles determined for patients with liver cancer or who are controls are shown. 1,952 genes were identified as being differentially expressed with a p value of <0.05 as between the schizophrenic patients and those control individuals. The identity of the differentially expressed genes is shown in Table 3Y.
[0412] Classification or class prediction of a test sample of an individual to determine whether said individual has schizophrenia or does not having schizophrenia can be done using the differentially expressed genes as shown in Table 3Y as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 28
[0413] Affymetrix U133A Chip Microarray Data Analysis of gene expression profiles of blood samples from individuals having Chagas disease as compared with gene expression profiles from normal individuals.
[0414] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with symptomatic Chagas disease, asymptomatic Chagas disease or control individuals wherein said control individuals were confirmed as not having Chagas disease.
[0415] As used herein, “Chagas disease” is defined as a condition wherein an individual is infected with the protozoan parasite Trypanosoma cruzi and includes both acute and chronic infection. Acute infection with T. cruzi can be diagnosed by detection of parasites by either microscopic examination of fresh anticoagulated blood or the buffy coat, giemsa-stained thin and thick blood smears and/or mouse inoculation and culturing of the blood of a potentially infected individual. Even in the absence of a positive result from the above, an accurate determination of infection can be made by xenodiagnosis wherein reduviid bugs are allowed to feed on the patient's blood and subsequently the bugs are examined for infection. Chronic infection can be determined by detection of antibodies specific to the T. cruzi antigens and/or immunoprecipitation and electrophoresis of the T. cruzi antigens.
[0416] As used herein “Symptomatic Chagas disease” includes symptomatic acute chagas and symptomatic chronic chagas disease. Acute symptomatic chagas disease can be characterized by one or more of the following: area of erythema and swelling (a chagoma); local lymphadenopathy; generalized lymphadenopathy; mild hepatosplenomegaly; unilateral painless edema of the palpebrae and periocular tissues; malaise; fever; anorexia and/or edema of the face and lower extremities. Symptomatic chronic Chagas' disease includes one or more of the following symptoms: heart rhythm disturbances, cardiomyopathy, thromboembolism, electrocardiographic abnormalities including right bundle-branch blockage; atrioventricular block; premature ventricular contractions and tachy- and bradyarrhythmias; dysphagia; odynophagia, chest pain; regurgitation; weight loss, cachexia and pulmonary infections.
[0417] As used herein “Asymptomatic Chagas disease” is meant to refer to individuals who are infected with T. cruzi but who do not show either acute or chronic symptoms of the disease.
[0418] Blood samples were taken from patients who were diagnosed symptomatic or asymptomatic Chagas disease as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of Chagas disease was corroborated by a qualified physician.
[0419] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to an Affymetrix U133A Chip as described herein. Identification of genes differentially expressed in blood samples from patients with Chagas disease as compared to healthy patients was determined by statistical analysis using the Weltch ANOVA test (Michelson and Schofield, 1996).
[0420] FIG. 27 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having symptomatic Chagas disease; asymptomatic Chagas disease or who were control individuals as described herein as compared with gene expression profiles from non-schizophrenic individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Control samples presented without Chagas disease but may have presented with other medical conditions and may be under various treatment regimes.
[0421] Hybridizations to create said gene expression profiles were done using the Affymetrix™ U133A chip. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have symptomatic chagas disease; asymptomatic chagas disease or control. The number of hybridizations profiles determined for patients with chagas disease; asymptomatic chagas disease or who are controls are shown. 668 genes were identified as being differentially expressed with a p value of <0.05 as between the symptomatic, asymptomatic Chagas patients and those control individuals. The identity of the differentially expressed genes is shown in Table 3Y.
[0422] Classification or class prediction of a test sample of an individual to determine whether said individual has symptomatic Chagas disease, asymptomatic Chagas disease or does not have Chagas disease can be done using the differentially expressed genes as shown in Table 3Y as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 29
[0423] Identification of Genes Specific for OA Only by Removing Genes Relevant to Co-Morbidities and Other Disease States.
[0424] This example demonstrates the use of the claimed invention to detect differential gene expression in blood unique to Osteoarthritis as compared with other disease states.
[0425] Blood samples were taken from patients who were diagnosed with mild OA or severe OA and compared with individuals who were identified as normal individuals as defined herein. Gene expression profiles were then analysed to identify genes which are differentially expressed in OA as compared with normal. In each case, the diagnosis of OA was corroborated by a qualified physician.
[0426] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with mild or severe OA as compared to healthy patients was determined by statistical analysis using the Weltch ANOVA test (Michelson and Schofield, 1996). (Dendogram analysis not shown).
[0427] In order to identify genes differentially expressed in blood unique to OA but not differentially expressed as a result of possible co-morbidities including hypertension, obesity, asthma, taking systemic steroids, or allergies, genes identified as differentially expressed in both OA and any of the genes identified as differentially expressed as a result of co-morbidity, e.g., Table 3A (co-morbidity of OA and hypertension v. normal), Table 3B (co-morbidity of OA and obesity v. normal), Table 3C (co-morbidity of OA and allergy v. normal), Table 3D (co-morbidity of OA and taking systemic steroids v. normal), and genes in common with people identified as having asthma and OA (Table 3AA) were removed. Similarly any genes and unique to obesity (Table 3R), hypertension (Table 3P), allergies (Table 3T), systemic steroids (Table 3V) were also removed. As a result of these comparisons, a list of genes unique to individuals with OA was identified. The identity of the differentially expressed genes is shown in Table 3AB.
[0428] It would be clear to a person skilled in the art that rather than simply remove those genes which are relevant to other disease states, one could use a more refined analysis and remove those genes which show the same trend in gene expression, e.g. remove those genes which show up regulation in a co-morbid state and also show up-regulation in the single disease state, but retain those genes which show a different trend in gene expression e.g. retain those genes which show up regulation in a co-morbid state as compared to down regulation in a single disease state.
[0429] Classification or class prediction of a test sample of an individual to determine whether said individual has OA or does not have OA can be done using the differentially expressed genes as shown in Table 3AB, irrespective of whether the individual presents with co-morbidity using well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 30
[0430] Analysis of gene expression profiles of blood samples from individuals having brain cancer as compared with gene expression profiles from normal individuals.
[0431] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with brain cancer as compared to blood samples taken from healthy patients.
[0432] As used herein “brain cancer” refers to all forms of primary brain tumours, both intracranial and extracranial and includes one or more of the following: Glioblastoma, Ependymoma, Gliomas, Astrocytoma, Medulloblastoma, Neuroglioma, Oligodendroglioma, Meningioma, Retinoblastoma, and Craniopharyngioma.
[0433] Blood samples are taken from patients diagnosed with brain cancer as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of brain cancer is corroborated by a skilled Board certified physician.
[0434] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample are generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with brain cancer as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0435] Classification or class prediction of a test sample of an individual to determine whether said individuals has brain cancer or does not having brain cancer can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 31
[0436] Analysis of gene expression profiles of blood samples from individuals having ankylosing spondylitis as compared with gene expression profiles from normal individuals.
[0437] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with ankylosing spondylitis as compared to blood samples taken from healthy patients.
[0438] As used herein “ankylosing spondylitis” refers to a chronic inflammatory disease that affects the joints between the vertebrae of the spine, and/or the joints between the spine and the pelvis and can eventually cause the affected vertebrae to fuse or grow together.
[0439] Blood samples are taken from patients diagnosed with ankylosing spondylitis as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of ankylosing spondylitis is corroborated by a skilled Board certified physician.
[0440] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with ankylosing spondylitis as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0441] Classification or class prediction of a test sample of an individual to determine whether said individuals has ankylosing spondylitis or does not having ankylosing spondylitis can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 32
[0442] Analysis of gene expression profiles of blood samples from individuals having prostate cancer as compared with gene expression profiles from normal individuals.
[0443] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with prostate cancer as compared to blood samples taken from healthy patients
[0444] As used herein “prostate cancer” refers to a malignant cancer originating within the prostate gland. Patients identified as having prostate cancer can have any stage of prostate cancer, as determined clinically (by digital rectal exam or PSA testing) and or pathologically. Staging of prostate cancer can done in accordance with TNM or the Staging System of the American Joint Committee on Cancer (AJCC). In addition to the TNM system, other systems may be used to stage prostate cancer, for example, the Whitmore-Jewett system.
[0445] Blood samples are taken from patients diagnosed with prostate cancer as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease to identify genes which differentiate as between the two groups. Similarly gene expression profiles can be analysed so as to differentiate as between the severity of the prostate cancer. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease or with a specific stage of said disease. In each case, the diagnosis of prostate cancer is corroborated by a skilled Board certified physician.
[0446] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with prostate cancer as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0447] Classification or class prediction of a test sample of an individual to determine whether said individuals has prostate cancer, has a specific stage of prostate cancer, or does not having prostate cancer can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 33
[0448] Analysis of gene expression profiles of blood samples from individuals having ovarian cancer as compared with gene expression profiles from normal individuals.
[0449] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with ovarian cancer as compared to blood samples taken from healthy patients.
[0450] As used herein “ovarian cancer” refers to a malignant cancerous growth originating within the ovaries. Patients identified as having ovarian cancer can have any stage of ovarian cancer. Staging is done by combining information from imaging tests with the results of a surgical examination done during a laprotomy. Numbered stages I to IV are used to describe the extent of the cancer and whether it has spread (metastasized) to more distant organs.
[0451] Blood samples are taken from patients diagnosed with ovarian cancer, or with a specific stage of ovarian cancer as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease or with a specific stage of said disease. In each case, the diagnosis of ovarian cancer is corroborated by a skilled Board certified physician.
[0452] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with ovarian cancer and or a specific stage of ovarian cancer as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0453] Classification or class prediction of a test sample of an individual to determine whether said individuals has ovarian cancer, has a specific stage of ovarian cancer or does not having ovarian cancer can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 34
[0454] Analysis of gene expression profiles of blood samples from individuals having kidney cancer as compared with gene expression profiles from normal individuals.
[0455] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with kidney cancer as compared to blood samples taken from healthy patients.
[0456] As used herein “kidney cancer” refers to a malignant cancerous growth originating within the kidneys. Kidney cancer includes renal cell carcinoma, transitional cell carcinoma, and Wilms' tumor. Patients identified as having renal cell carcinoma can also be categorized by stage of said cancer as determined by the System of the American Joint Committee on Cancer (AJCC). Numbered stages I to IV are used to describe the extent of the carcinoma and whether it has spread (metastased) to more distant organs.
[0457] Blood samples are taken from patients diagnosed with kidney cancer, or with a specific stage of renal cell carcinoma as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease or with a specific stage of said disease. In each case, the diagnosis of kidney cancer is corroborated by a skilled Board certified physician.
[0458] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with kidney cancer and or a specific stage of kidney cancer as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0459] Classification or class prediction of a test sample of an individual to determine whether said individuals has kidney cancer, has a specific stage of kidney cancer or does not having kidney cancer can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 35
[0460] Analysis of gene expression profiles of blood samples from individuals having gastric cancer as compared with gene expression profiles from normal individuals.
[0461] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with gastric cancer as compared to blood samples taken from healthy patients.
[0462] As used herein “gastric or stomach cancer” refers to a cancerous growth originating within the stomach and includes gastric adenocarcinoma, primary gastric lymphoma and gastric nonlymphoid sarcoma. Patients identified as having stomac can also be categorized by stage of said cancer as determined by the System of the American Joint Committee on Cancer (AJCC).
[0463] Blood samples are taken from patients diagnosed with stomach cancer, or with a specific stage of stomach cancer as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease or with a specific stage of said disease. In each case, the diagnosis of stomach cancer is corroborated by a skilled Board certified physician.
[0464] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with stomach cancer and or a specific stage of stomach cancer as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0465] Classification or class prediction of a test sample of an individual to determine whether said individuals has stomach cancer, has a specific stage of stomach cancer or does not having stomach cancer can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 36
[0466] Analysis of gene expression profiles of blood samples from individuals having lung cancer as compared with gene expression profiles from normal individuals.
[0467] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with lung cancer as compared to blood samples taken from healthy patients.
[0468] As used herein “lung cancer” refers to a cancerous growth originating within the lung and includes adenocarcinoma, alveolar cell carcinoma, squamous cell carcinoma, large cell and small cell carcinomas. Patients identified as having lung cancer can also be categorized by stage of said cancer as determined by the System of the American Joint Committee on Cancer (AJCC).
[0469] Blood samples are taken from patients diagnosed with lung cancer, or with a specific stage of lung cancer as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease or with a specific stage of said disease. In each case, the diagnosis of lung cancer is corroborated by a skilled Board certified physician.
[0470] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with lung cancer and or a specific stage of lung cancer as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0471] Classification or class prediction of a test sample of an individual to determine whether said individuals has lung cancer, has a specific stage of lung cancer or does not having lung cancer can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 37
[0472] Analysis of gene expression profiles of blood samples from individuals having breast cancer as compared with gene expression profiles from normal individuals.
[0473] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with breast cancer as compared to blood samples taken from healthy patients.
[0474] As used herein “breast cancer” refers to a cancerous growth originating within the breast and includes invasive and non invasive breast cancer such as ductal carcinoma in situ (DCIS), lobular carcinoma in situ (LCIS), infiltrating ductal carcinoma, and infiltrating lobular carcinoma. Patients identified as having breast cancer can also be categorized by stage of said cancer as determined by the System of the American Joint Committee on Cancer (AJCC) or TNM classification.
[0475] Blood samples are taken from patients diagnosed with breast cancer, or with a specific stage of breast cancer as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease or with a specific stage of said disease. In each case, the diagnosis of breast cancer is corroborated by a skilled Board certified physician.
[0476] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with breast cancer and or a specific stage of breast cancer as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0477] Classification or class prediction of a test sample of an individual to determine whether said individuals has breast cancer, has a specific stage of breast cancer or does not have breast cancer can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 38
[0478] Analysis of gene expression profiles of blood samples from individuals having nasopharyngeal cancer as compared with gene expression profiles from normal individuals.
[0479] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with nasopharyngeal cancer as compared to blood samples taken from healthy patients.
[0480] As used herein “nasopharyngeal cancer” refers to a cancerous growth arising from the epithelial cells that cover the surface and line the nasopharynx. Patients identified as having nasopharyngeal cancer can also be categorized by stage of said cancer as determined by the System of the American Joint Committee on Cancer (AJCC) or TNM classification.
[0481] Blood samples are taken from patients diagnosed with nasopharyngeal cancer, or with a specific stage of nasopharyngeal cancer as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease or with a specific stage of said disease. In each case, the diagnosis of nasopharyngeal cancer is corroborated by a skilled Board certified physician.
[0482] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to a Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with nasopharyngeal cancer and or a specific stage of breast cancer as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0483] Classification or class prediction of a test sample of an individual to determine whether said individuals has nasopharyngeal cancer, has a specific stage of nasopharyngeal cancer or does not have nasopharyngeal cancer can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 39
[0484] Analysis of gene expression profiles of blood samples from individuals having Guillain Barre syndrome as compared with gene expression profiles from normal individuals.
[0485] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with Guillain Barre syndrome as compared to blood samples taken from healthy patients.
[0486] As used herein “Guillain Barre syndrome” refers to an acute, usually rapidly progressive form of inflammatory polyneuropathy characterized by muscular weakness and mild distal sensory loss.
[0487] Blood samples are taken from patients diagnosed with Guillain Barre syndrome as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of Guillain Barre syndrome is corroborated by a skilled Board certified physician.
[0488] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with Guillain Barre syndrome as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0489] Classification or class prediction of a test sample of an individual to determine whether said individuals has Guillain Barre syndrome, or does not have Guillain Barre syndrome can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 40
[0490] Analysis of gene expression profiles of blood samples from individuals having Fibromyalgia as compared with gene expression profiles from normal individuals.
[0491] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with Fibromyalgia as compared to blood samples taken from healthy patients.
[0492] As used herein “Fibromyalgia” refers to widespread chronic musculoskeletal pain and fatigue. The pain comes from the connective tissues, such as the muscles, tendons, and ligaments and does not involve the joints. Blood samples are taken from patients diagnosed with Fibromyalgia as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of Fibromyalgia is corroborated by a skilled Board certified physician.
[0493] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with Fibromyalgia as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0494] Classification or class prediction of a test sample of an individual to determine whether said individuals has Fibromyalgia, or does not have Fibromyalgia can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 41
[0495] Analysis of gene expression profiles of blood samples from individuals having Multiple Sclerosis as compared with gene expression profiles from normal individuals.
[0496] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with Multiple Sclerosis as compared to blood samples taken from healthy patients.
[0497] As used herein “Multiple Sclerosis” refers to chronic progressive nervous disorder involving the loss of myelin sheath surrounding certain nerve fibres. Blood samples are taken from patients diagnosed with Multiple Sclerosis as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of Multiple Sclerosis is corroborated by a skilled Board certified physician.
[0498] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with Multiple Sclerosis as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0499] Classification or class prediction of a test sample of an individual to determine whether said individuals has Multiple Sclerosis, or does not have Multiple Sclerosis can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 42
[0500] Analysis of gene expression profiles of blood samples from individuals having Muscular Dystrophy as compared with gene expression profiles from normal individuals.
[0501] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with Muscular Dystrophy as compared to blood samples taken from healthy patients.
[0502] As used herein “Muscular Dystrophy” refers to a hereditary disease of the muscular system characterized by weakness and wasting of the skeletal muscles. Muscular Dystrophy includes Duchennes' Muscular Dystrophy, limb-girdle muscular dystrophy, myotonia atrophica, myotonic muscular dystrophy, pseudohypertrophic muscular dystrophy, and Steinhardt's disease.
[0503] Blood samples are taken from patients diagnosed with Muscular Dystrophy as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of Muscular Dystrophy is corroborated by a skilled Board certified physician.
[0504] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with Muscular Dystrophy as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0505] Classification or class prediction of a test sample of an individual to determine whether said individuals has Muscular Dystrophy, or does not have Muscular Dystrophy can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 43
[0506] Analysis of gene expression profiles of blood samples from individuals having septic joint arthroplasty as compared with gene expression profiles from normal individuals.
[0507] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with septic joint arthroplasty as compared to blood samples taken from healthy patients.
[0508] As used herein “septic joint arthroplasty” refers to an inflammation of the joint caused by a bacterial infection.
[0509] Blood samples are taken from patients diagnosed with septic joint arthroplasty as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of septic joint arthroplasty is corroborated by a skilled Board certified physician.
[0510] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with septic joint arthroplasty as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0511] Classification or class prediction of a test sample of an individual to determine whether said individuals has septic joint arthroplasty, or does not have septic joint arthroplasty can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 44
[0512] Analysis of gene expression profiles of blood samples from individuals having Alzheimers Disease as compared with gene expression profiles from normal individuals.
[0513] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with Alzheimers as compared to blood samples taken from healthy patients.
[0514] As used herein “Alzheimers” refers to a degenerative disease of the central nervous system characterized especially by premature senile mental deterioration.
[0515] Blood samples are taken from patients diagnosed with Alzheimers as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of Alzheimers is corroborated by a skilled Board certified physician.
[0516] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with Alzheimers as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0517] Classification or class prediction of a test sample of an individual to determine whether said individuals has Alzheimers, or does not have Alzheimers can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 45
[0518] Analysis of gene expression profiles of blood samples from individuals having hepatitis as compared with gene expression profiles from normal individuals.
[0519] This example demonstrates the use of the claimed invention to detect gene expression in blood samples taken from patients diagnosed with hepatitis as compared to blood samples taken from healthy patients.
[0520] As used herein “hepatitis” refers to an inflammation of the liver caused by a virus or toxin and can include hepatitis A, hepatitis B, hepatitis C, hepatitis D, hepatitis E, and hepatitis F.
[0521] Blood samples are taken from patients diagnosed with hepatitis as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of hepatitis is corroborated by a skilled Board certified physician.
[0522] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with hepatitis as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0523] Classification or class prediction of a test sample of an individual to determine whether said individuals has hepatitis, or does not have hepatitis can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 46
[0524] Analysis of gene expression profiles of blood samples from individuals having Manic Depression Syndrome (MDS) as compared with gene expression profiles from normal individuals.
[0525] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with MDS as compared to blood samples taken from healthy patients.
[0526] As used herein “Manic Depression Syndrome (MDS)” refers to a mood disorder characterized by alternating mania and depression.
[0527] Blood samples are taken from patients diagnosed with MDS as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of MDS is corroborated by a skilled Board certified physician.
[0528] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with MDS as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0529] Classification or class prediction of a test sample of an individual to determine whether said individuals has MDS, or does not have MDS can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 47
[0530] Analysis of gene expression profiles of blood samples from individuals having Crohn's Disease and/or Colitis as compared with gene expression profiles from normal individuals.
[0531] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with Crohn's Disease and/or Colitis as compared to blood samples taken from healthy patients.
[0532] As used herein “Crohn's Disease” refers to a chronic inflammation of the ileum which is often progressive. As used herein “Colitis” or “Inflammatory Bowel Disease” refers to inflammation of the colon.
[0533] Blood samples are taken from patients diagnosed with Crohn's and or Colitis as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of Crohn's and or Colitis is corroborated by a skilled Board certified physician.
[0534] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with Crohn's and or Colitis as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0535] Classification or class prediction of a test sample of an individual to determine whether said individuals has Crohn's and or Colitis, or does not have Crohn's and or Colitis can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 48
[0536] Analysis of gene expression profiles of blood samples from individuals having Malignant Hyperthermia Susceptibility as compared with gene expression profiles from normal individuals.
[0537] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with Malignant Hyperthermia Susceptibility as compared to blood samples taken from healthy patients.
[0538] As used herein “Malignant Hyperthermia Susceptibility” refers to a pharmacogenetic disorder of skeletal muscle calcium regulation often developing during or after a general anaesthesia.
[0539] Blood samples are taken from patients diagnosed with Malignant Hyperthermia Susceptibility as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of Malignant Hyperthermia Susceptibility is corroborated by a skilled Board certified physician.
[0540] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with Malignant Hyperthermia Susceptibility as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0541] Classification or class prediction of a test sample of an individual to determine whether said individuals has Malignant Hyperthermia Susceptibility, or does not have Malignant Hyperthermia Susceptibility can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 49
[0542] Analysis of gene expression profiles of blood samples from horses having osteoarthritis as compared with gene expression profiles from normal or non-osteoarthritic horses.
[0543] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from horses so as to diagnose equine arthritis as compared to blood samples taken from healthy horses.
[0544] As used herein “arthritis” in reference to horses refers to a degenerative joint disease that affects horses by causing lameness. Although it can appear in any joint, most common areas are the upper knee joint, front fetlocks, hocks, or coffin joints in the front feet. The condition can be caused by trauma, mineral or dietary deficiency, old age, poor conformation, over exertion or infection. The different structures that can be damaged in arthritis are the cartilage inside joints, the bone in the joints, the joint capsule, the synovial membranes, the ligaments around the joints and lastly the fluid that lubricates the insides of ‘synovial joints’. In severe cases all of these structures are affected. In for example osteochondrosis only the cartilage may be affected.
[0545] Regardless of the cause, the disease begins when the synovial fluid that lubricates healthy joints begins to thin. The decrease in lubrication causes the cartilage cushion to break down, and eventually the bones begin to grind painfully against each other. Diagnostic tests used to confirm arthritis include X-rays, joint fluid analysis, and ultrasound.
[0546] Blood samples are taken from horses diagnosed with arthritis as defined herein. Gene expression profiles are then analysed and compared to profiles from horses unaffected by any disease. Preferably healthy horses are chosen who are age and sex matched to said horses diagnosed with disease. In each case, the diagnosis of arthritis is corroborated by a certified veterinarian.
[0547] Total mRNA from a drop of peripheral whole blood is taken from each horse and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. An equine specific microarray representing the equine genome can also be used. Identification of genes differentially expressed in blood samples from horses with arthritis as compared to healthy horses is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0548] Classification or class prediction of a test sample of a horse to determine whether said horse has arthritis or does not have arthritis can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 50
[0549] Analysis of gene expression profiles of blood samples from dogs having osteoarthritis as compared with gene expression profiles from normal or non-osteoarthritic dogs.
[0550] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from dogs so as to diagnose equine arthritis as compared to blood samples taken from healthy horses.
[0551] As used herein “osteoarthritis” in reference to dogs is a form of degenerative joint disease which involves the deterioration of and changes to the cartilage and bone. In response to inflammation in and about the joint, the body responds with bony remodelling around the joint structure. This process can be slow and gradual with minimal outward symptoms, or more rapidly progressive with significant pain and discomfort. Osteoarthritic changes can occur in response to infection and injury of the joint as well.
[0552] Blood samples are taken from dogs diagnosed with osteoarthritis as defined herein. Gene expression profiles are then analysed and compared to profiles from dogs unaffected by any disease. Preferably healthy dogs are chosen who are age, sex and breed matched to said dogs diagnosed with disease. In each case, the diagnosis of osteoarthritis is corroborated by a certified veterinarian.
[0553] Total mRNA from a drop of peripheral whole blood is taken from each dog and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. A canine specific microarray representing the canine genome can also be used. Identification of genes differentially expressed in blood samples from dogs with osteoarthritis as compared to healthy horses is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0554] Classification or class prediction of a test sample of a dog to determine whether said dog has osteoarthritis or does not have osteoarthritis can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 51
[0555] Analysis of gene expression profiles of blood samples from individuals having Manic Depression Syndrome (MDS) as compared with gene expression profiles from individuals having Schizophrenia.
[0556] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with MDS as compared to blood samples taken from schizophrenic patients.
[0557] As used herein “Manic Depression Syndrome (MDS)” refers to a mood disorder characterized by alternating mania and depression. As used herein, “schizophrenia” is defined as a psychotic disorders characterized by distortions of reality and disturbances of thought and language and withdrawal from social contact. Patients diagnosed with “schizophrenia” can include patients having any of the following diagnosis: an acute schizophrenic episode, borderline schizophrenia, catatonia, catatonic schizophrenia, catatonic type schizophrenia, disorganized schizophrenia, disorganized type schizophrenia, hebephrenia, hebephrenic schizophrenia, latent schizophrenia, paranoic type schizophrenia, paranoid schizophrenia, paraphrenia, paraphrenic schizophrenia, psychosis, reactive schizophrenia or the like.
[0558] Blood samples are taken from patients diagnosed with MDS or Schizophrenia as defined herein. Gene expression profiles are then analyzed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of MDS and Schizophrenia is corroborated by a skilled Board certified physician. Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above.
[0559] Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip(™) as described herein. Identification of genes differentially expressed in blood samples from patients with MDS as compared to Schizophrenic patients as compared to normal individuals is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002) (data not shown). 294 genes were identified as being differentially expressed with a p value of <0.05 as between the schizophrenic patients, the MDS patients and those control individuals. The identity of the differentially expressed genes is shown in Table 3AC.
[0560] Classification or class prediction of a test sample of an individual to determine whether said individuals has MDS, has Schizophrenia or is normal can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring (™) ) for Class Predication are also available.
EXAMPLE 52
[0561] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from co-morbid individuals having osteoarthritis and asthma as compared with gene expression profiles from normal individuals
[0562] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with asthma and osteoarthritis as compared to blood samples taken from patients with just osteoarthritis.
[0563] As used herein, “asthma” indicates a chronic disease of the airways in the lungs characterized by constriction (the tightening of the muscles surrounding the airways) and inflammation (the swelling and irritation of the airways). Together constriction and inflammation cause narrowing of the airways, which results in symptoms such as wheezing, coughing, chest tightness, and shortness of breath.
[0564] Blood samples were taken from patients who were diagnosed with osteoarthritis and having asthma as defined herein. Gene expression profiles were then analyzed and compared to profiles from patients with just osteoarthritis so as to identify genes unique to the condition of asthma. In each case, the diagnosis of osteoarthritis and asthma was corroborated by a skilled Board certified physician.
[0565] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labeled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to the 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with osteoarthritis and asthma as compared to osteoarthritis patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0566] FIG. 28 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who had asthma and osteoarthritis as described herein as compared with gene expression profiles from osteoarthritic individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Hybridizations to create said gene expression profiles were done using the ChondroChip™. (A dendogram analysis is shown above). Samples are clustered and marked as representing patients who are taking systemic steroids or normal. The number of hybridizations profiles determined for patients with asthma and patients without asthma are shown. 219 genes were identified as being differentially expressed with a p value of <0.05 as between patients with asthma and OA and patients with just OA. The identity of the differentially expressed genes is shown in Table 3AA.
[0567] Classification or class prediction of a test sample from a patient as indicating said patient has asthma or does not have asthma can be done using the differentially expressed genes as shown in Table 3AA in combination with well known statistical algorithms for class prediction as would be understood by a person skilled in the art and is described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
[0568] One skilled in the art will appreciate readily that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those objects, ends and advantages inherent herein. The present examples, along with the methods, procedures, treatments, molecules, and specific compounds described herein are presently representative of preferred embodiments, are exemplary, and are not intended as limitations on the scope of the invention. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention as defined by the scope of the claims.
[0569] All patents, patent applications, and published references cited herein are hereby incorporated by reference in their entirety. While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.
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The present invention is directed to detection and measurement of gene transcripts and their equivalent nucleic acid products in blood. Specifically provided is analysis performed on a drop of blood for detecting, diagnosing and monitoring diseases using gene-specific and/or tissue-specific primers. The present invention also describes methods by which delineation of the sequence and/or quantitation of the expression levels of disease-specific genes allows for an immediate and accurate diagnostic/prognostic test for disease or to assess the effect of a particular treatment regimen.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to satellite communications, and more particularly to satellite-based network routers.
2. Background of the Invention
For several decades, satellites have been an integral part of communication systems. Inherent to such communication systems is the need for routing signals and/or messages to their appropriate destinations. Until recently, routing functions have always been accomplished using ground-based routers, with a satellite acting only as a “mirror”, reflecting uplink traffic back to a ground-based central station. It is this central station which performs the routing of messages to their appropriate destinations. Using ground-based routing, however, requires traffic to go through land lines, such as fiber-optic cables. As a result, the rate of transfer of information is significantly decreased.
Recently, a new generation of satellites have been introduced which act not only as uplink traffic “mirrors” but perform the routing functions themselves, thus becoming, space based routers. Space-based routers must support a large number of ports. Ports are analogous to doorways into and out of a router system. Port types comprise input, output and bi-directional ports. The communications system interacts via radio waves, which fall within an allocated spectrum of frequencies. It is the nature of these systems to reuse an allocated spectrum as many times as possible. Multi-beam, phased array antennas are implemented to reuse an allocated spectrum many times over. Spectral reuse is achieved by forming as many uplink and downlink beams as size, weight and power, of a particular satellite, permit. As such, beams themselves become ports to and from the router. There can be hundreds and even thousands of ports resulting from the spectral reuse design. Additional ports for the router are formed from crosslinks between satellites within a constellation of satellites.
Earlier generations of these satellite based routers implemented hardware switches to perform the routing function. Hardware switches, however, are limited in bandwidth and centralize the routing process. This makes the routing process more susceptible to failures. Also, in order for such a system to grow or change its routing scheme, the hardware switches require redesign. This would require the satellite to be brought back to earth for modification or replacement by a completely new satellite.
It is therefore desirable to provide a routing architecture, for space-based routers, which overcomes the limitations of reduced bandwidth and decentralizes the routing process. It is also desirable to implement a routing architecture whose components do not require redesign to allow for scaleable growth or routing scheme changes.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become fully understood from the detailed description and the accompanying drawings, wherein:
FIG. 1 is a schematic view of a satellite communications system according to the principles of the present invention;
FIG. 2 is a block diagram of an internal satellite structure according to the principles of the present invention;
FIG. 3 is a schematic view of an array of processors architecture according to the principles of the present invention; and
FIG. 4 is a flow diagram of the node interface chip logic according to the principles of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides a matrix of processors architecture for use in space-based routers, which overcomes the deficiencies inherent when using hardware switches to perform the routing functions. The hardware necessary to accomplish a matrix of processors architecture comprises a processor at each of a plurality of nodes and a corresponding bus interface chip, which connects each processor into the bus system. If the system grows, more of these “basic building blocks” are required. However, redesigning of the devices themselves (processor and bus interface chip) is not required. Earlier generations, using hardware switch schemes, require redesign of the hardware as systems grow or routing schemes change. Another advantage of having these “basic building blocks”, is that the processor, memory and bus interface chip become a module that can be located wherever it is mechanically advantageous rather than having the bus structure define the mechanical layout.
In this manner, the present invention provides a distributed routing architecture for space-based routers that is scalable to meet a routing need. As the size of the router increases, the bandwidth increases correspondingly to meet the growing data transport needs. The distributed processing nature of the present invention yields significantly increased processing power to handle link layer processing right at the link termination. Increased satellite lifetime and reduced system costs are achieved through a reduced number of part types and a reduced number of interconnects between nodes. Additionally, an array of processors architecture results in a distributed, parallel processing/multiprocessing router, which is scalable, highly fault tolerant, flexible and requires fewer chip types than the centralized switch router approach. While the below described embodiment is a preferred embodiment, it will be appreciated that this embodiment is merely exemplary and does not limit the applicability of the invention.
Referencing FIG. 1, an exemplary satellite communications system 10 is shown, comprising individual subscriber units 12 and a constellation of satellites 14 . The satellites 14 receive uplink and downlink information from the individual subscriber units 12 which may include wireless telephones and wireless data terminals. Additionally, the satellites 14 can be in cross-communication with one another.
FIG. 2 is a block diagram of various components associated with satellite 14 , including an antenna array 16 , a link signal detection component or transceiver 18 , a resource controller 19 and an array of processors 20 . The transceiver 18 sends and receives signals between the satellite 14 and the individual subscriber units 12 , as well as between other satellites 14 in the constellation. The resource controller 19 functions to manage bidirectional communications between the transceiver 18 and the array of processors 20 .
Referencing FIG. 3, an array-of-processors architecture for a space-based network router, will now be described in detail. The two-dimensional array 20 , employs horizontal communication components or horizontally oriented rings 22 that alternately run left and right. Similarly, vertical communication components or vertically oriented rings 24 run alternately up and down. The communication rings 22 , 24 are interconnected by at least one node interface chip 26 for forming the two-dimensional array. As shown, the architecture formed by the communication rings 22 , 24 create a communication bus between adjacent nodes 26 . Preferably, the communication rings 22 , 24 are scalable coherent interface (SCI) rings. However, one skilled in the art will appreciate that other suitable bus architectures can be used for interconnecting nodes 26 . In the spirit of simplifying the figure, the completed rings are not shown for every ring 22 , 24 , although it should be understood that each ring 22 connects from A to A and each ring 24 connects from B to B. The advantage of a two dimensional array 20 , is that it scales well and the routing decisions between communication rings 22 , 24 are straightforward. Node interface chips (nodes) 26 form a mesh 21 and a processor 28 is associated with each node interface chip 26 .
FIG. 4 details the function of each node interface chip 26 . Signals enter node 26 through an input link 40 to an elastic buffer 42 . The elastic buffer 42 re-times the signal to the local node time. A signal entering each node 26 can be of three kinds: a signal not destined for the particular node 26 , a signal generated by other processors 28 and destined for the particular node 26 or a signal generated by other processors 28 in response to requests sent out by the particular processor 28 of the particular node 26 , which are destined for the particular node 26 .
The elastic buffer 42 passes the re-timed signal to an address decoder 44 . The address decoder 44 analyzes the address associated with the signal and determines if the signal is destined for the particular node 26 . If address decoder 44 determines that the signal is not destined for that particular node 26 , the signal is sent to a bypass first-in-first-out (FIFO) gate 46 for transmission to the downstream node. However, if address decoder 44 determines that the signal is destined for the particular node 26 the signal is sent to a first signal alignment gate or input FIFO gate 52 for delivery to the particular processor 28 associated with the particular node 26 . The input FIFO gate 52 aligns the signal with node queues associated with the latter two types of the messages (described above) that can be addressed to that particular node 26 . The input FIFO gate 52 is further connected to a first input queue or input request queue 54 and a second input queue or input response queue 56 . Each node interface chip 26 also includes a second signal alignment gate or output FIFO gate 62 connected to and receiving signals from a first output queue or output request queue 58 and a second output queue or output response queue 60 .
Requests from other processors 28 for services of the particular processor 28 associated with the particular node 26 are placed in the input request queue 54 . Responses from other processors 28 to requests made by the particular processor 28 of the particular node 26 are placed in the input response queue 56 . After being serviced by processor 28 , requests for services from other processors 28 are placed in the output request queue 58 of the particular node 26 . Likewise, responses to requests received from other processors 28 , generated by the processor 28 associated with the particular node 26 , are placed in the output response queue 60 . Messages from both the output request queue 58 and the output response queue 60 are gathered by the output FIFO gate 62 for delivery to another node 26 . An output multiplexer 48 selects from the bypass FIFO gate 46 or the output FIFO gate 62 for delivering the processed signals to other nodes 26 . The selected signal is then transferred out through an output link 50 .
It should be noted that node interface chip 26 , shown in FIG. 4, is of a single dimension, as it has a single input link 40 and a single output link 50 . It is foreseen, however, that node interface chip 26 can have multiple input and output links for establishing multiple dimensions. For example, each node interface chip 26 could have two input links 40 and two output links 50 , resulting in a two-dimensional chip, for a two-dimensional mesh 21 , or three input links 40 and three output links 50 , resulting in a three-dimensional chip, for a three dimensional mesh 21 .
Node interface chip 26 can itself automatically generate an acknowledge message. The output response queue 60 generates the acknowledge message upon successful receipt of a request for service from another processor 28 and placement of hat request in input FIFO gate 52 by the address decoder 44 . The acknowledge message is sent to the originating node 26 informing the particular processor 28 , of the originating node 26 , of receipt of the request.
Referring back to FIGS. 2 and 3, each processor 28 is coupled with either a demodulator 30 or modulator 32 . Processors 28 associated with a demodulator 30 handle Demand Assignment, Multiple Access (DAMA) and other link requests as well as routing of traffic packets. Processors 28 associated with a modulator 32 handle queuing of DAMA and other link responses, as well as traffic packets for the modulator 32 . The communication link between the transceiver and either a demodulator 30 or a modulator 32 is managed by the resource controller 19 .
As will be appreciated by one skilled in the art, mesh 21 can comprise varying numbers of node interface chips 26 , processors 28 , demodulators 30 and modulators 32 . For example, mesh 21 could be a 10×10 matrix of components or could be a 1000×1000 matrix of components. The size of mesh 21 will be dependent upon the particular routing needs of the communications system.
Crosslink collection points 34 and crosslink injection points 36 are dispersed throughout mesh 21 . Each crosslink collection point 34 comprises a node interface chip 26 and a processor 28 . By way of non-limiting example, each crosslink might have eight (8) crosslink collection points 34 , two in each quadrant of the mesh 21 . Any processor 28 , associated with a demodulator 30 , which identifies a packet destined for a particular crosslink, sends the packet to the nearest crosslink collection point 34 in mesh 21 . Similarly, each crosslink might have eight (8) crosslink injection points 36 , two in each quadrant of mesh 21 . If a message received over a crosslink is to be sent to a particular processor 28 and modulator 32 , the crosslink sends the message to the crosslink injection point 36 , nearest that particular node 26 in the mesh 21 .
As previously described, processors 28 , associated with demodulators 30 , handle all of the DAMA requests and other link signaling, as well as performing all packet routing for traffic packets that flow from the particular demodulator 30 . The resource controller 19 allocates the uplink and downlink information amongst the various demodulators 30 and modulators 32 in the mesh 21 . Each processor 28 must know which beam a packet is coming from in order to properly process the maintenance and DAMA packets received from the resource controller. To achieve this, each demodulated DAMA and maintenance request contains an origination beam and channel identification. In this manner, a processor 28 is provided with all of the information necessary for getting the link signaling or DAMA response to an appropriate modulator 32 .
Scalability is achieved by designing the mesh 21 for the number of beams it has to support. By way of non-limiting example, a system with 1000 ports might be based on a 32×32 mesh 21 of processors 28 . A system of 100 ports might be based on a 10×10 mesh 21 architecture. In scaling the system from 100 to 1000 processors 28 , additional serial bus segments 22 , 24 are added. The addition of more bus segments 22 , 24 increases the bandwidth of the system proportionally so that a 1000 processor 28 design achieves 10 times the transport bandwidth of a 100 processor 28 mesh 21 .
Fault tolerance is inherent to the mesh 21 itself. A processor 28 or bus segment failure is easily detected by other processors 28 in the mesh 21 , around a failed node 26 or link. Rerouting algorithms can excise the failed node 26 or link from the mesh 21 and restore data transport through the mesh 21 with only slight degradation in performance. Accordingly, each node interface chip 26 within the mesh 21 can be programmed by another processor 28 for routing signals around a failed node 26 or a failed segment of the router mesh 21 .
Flexibility results from the programmable nature of the processors 28 which make up the nodes 26 of the mesh 21 . As part of the present invention, each processor 28 may be remotely updated with one or more new software programs for changing a protocol forming part of the satellite communication system 10 . New software downloaded to each processor 28 in the mesh 21 can increase the efficiency of the distributed router or program new link-layer protocols into certain ports as required by the changing communications system.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention. Such variations or modifications, as would be obvious to one skilled in the art, are intended to be included within the scope of the following claims.
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A space-based network router architecture ( 20 ) is disclosed. The router includes an array-of-processors architecture ( 20 ) for routing uplink and downlink traffic of a communications system ( 10 ). The architecture comprises multiple node interface chips ( 26 ) linked to one another via horizontal and vertical rings ( 22, 24 ), thus forming a mesh ( 21 ). Associated with each node interface chip ( 26 ) is a processor ( 28 ) and either a demodulator ( 30 ) or modulator ( 32 ). Each node interface chip ( 26 ) selectively transfers a signal depending upon the particular signal's destination and processing requirements. The router architecture ( 20 ) provides scalabitly, fault-tolerance and flexibility, as well as structural advantages over present router systems.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
BACKGROUND OF THE INVENTION
This invention relates to gangways used for example with docks, piers, and the like, and in particular, to a gangway which is molded from plastic.
Gangways have long been used to provide access between shore and docks, or between docks and boats. Gangways that are currently used are often one piece units that are assembled on-site. These gangways are time consuming and difficult to assemble. Additionally, the gangways are difficult to secure, for example, to the dock, a shore abutment, etc. Further, once assembled, the gangways are difficult to remove, for example, for storage in winter or for repair.
BRIEF SUMMARY OF THE INVENTION
Briefly stated, a molded gangway section of the present invention comprises an upper surface, side surfaces, and a lower surface, which, in combination define a volume. Preferably, the volume is hollow (i.e., empty), but could be filled, for example, with foam or other buoyant materials. The gangway sides extend above the top surface and define rails. The top surface includes spaced apart, generally parallel grooves, which extend across the top surface from one side to the other. Additionally, a groove extends along the junction between the upper surface and at least one of the side walls.
The lower surface comprises a plurality of recesses which are defined by a side wall extending from the lower surface towards the upper surface and a recess ceiling. A plurality of grooves, which extend generally parallel to the upper surface grooves, are formed in the recess ceiling. Preferably, the recesses are formed in at least three columns—there being two side columns and one center column. There can also be two or more center columns. Preferably, the columns are made of rows of recesses, such that the recesses define an array or recesses, such as a 3×3 or 4×3 array of recesses.
A trough is formed in the lower surface between the outer and center columns of recesses. Additional surface grooves are formed in the bottom surface between the rows of recesses. A surface groove is also formed in the gangway bottom surface between the outer columns of recesses and the sides of the gangway. The lower surface also includes a connecting surface at opposite ends of the gangway. Preferably, the connecting surface is divided into three areas which are aligned with the columns of recesses.
The recess ceiling grooves are adjacent, and preferably, in contact with, the lower side of the upper surface. The recess ceiling grooves preferably include two types of grooves—the first grooves are positioned to be under the upper surface grooves and the second grooves are positioned between the upper surface grooves. The first grooves are formed by a wall of substantially constant width. The second grooves, of at least the outer column of recesses, have a first portion of a first thickness and a second portion of a second thickness, thicker than the first portion.
Two or more gangway sections can be connected together to form a gangway. Gangway sections can be connected using a reinforcing member or truss which is received in the gangway bottom surface trough. The truss is sized to extend across the junction between adjacent gangway sections. The truss is secured to the gangway sections by fasteners which extend through the gangway section upper surface and into the truss. The gangway sections can also be connected by use of connector plates which span the junction between two adjacent gangways. The connecting plates, which are sized to span the junction between adjacent gangway sections, are secured to the connecting surface on the gangway section bottom surface. Preferably, two connecting plates are used—one on each of the outer connecting surface areas. The gangway sections can be connected using either of the two methods independently, but, are preferably connected together using the trusses and the connecting plates in combination.
The gangway connecting surface is also used to connect the gangway to shore abutments, piers, docks, etc. The gangway section includes a hinge member mountable to the connection surface. Preferably, hinge members are mounted in all three areas of the connection surface. The hinge members includes pin sleeves which, when the hinge member is mounted to the gangway section, extend outwardly from the end of the gangway section.
The gangway section can be mounted to a shore abutment or dock using a bracket. The bracket includes pin sleeves positioned to be aligned with the pin sleeves of the hinge member. A hinge pin extends through the pin sleeves of the hinge member and the bracket to hingedly connect the gangway to the shore abutment bracket, and hence, the shore abutment.
The gangway section can also be provided with a roller assembly and/or a ramp. The ramp includes a sloped upper surface, a back surface, and ears extending from the back surface. The ears include openings therein which are aligned with the hinge member pin sleeves when the ramp is adjacent the gangway section. A hinge pin which extends through the hinge member pin sleeve and the ramp ears to hingedly connect the ramp to the gangway. The roller assembly includes opposed mounting members mountable to lower surfaces of the sides of the gangway and a roller extending between the mounting members. The roller is vertically spaced from the connecting surface and the mounting brackets are horizontally spaced from the connecting surface. Thus, the roller assembly can be mounted to the gangway along with the ramp.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a top perspective view of a gangway section of the present invention;
FIG. 2 is a bottom perspective view of the gangway section;
FIG. 3 is a bottom perspective view of two gangway sections connected together;
FIG. 4 is a bottom exploded perspective view showing connection plates used to connect the two sections together;
FIG. 5 is a top perspective view showing the connection of trusses to the two sections;
FIG. 6 is a bottom plan view of the gangway section;
FIG. 7 is a cross-sectional view of the gangway taken along line 7 — 7 of FIG. 6 ;
FIG. 8 is a cross-sectional view of the gangway taken along line 8 — 8 of FIG. 6 ;
FIG. 9 is a cross-sectional view of the gangway taken along line 9 — 9 of FIG. 6 ;
FIG. 10 is a cross-sectional view of the gangway taken along line 10 — 10 of FIG. 6 ;
FIG. 11 is a cross-sectional view of the gangway taken along line 11 — 11 of FIG. 6 ;
FIG. 12 is a cross-sectional view of the gangway taken along line 12 — 12 of FIG. 6 ;
FIG. 13 is a cross-sectional view of the gangway taken along line 13 — 13 of FIG. 6 ;
FIG. 14 is an exploded view showing the connection of hinge members to the gangway section;
FIG. 15 is an exploded view showing the connection of the gangway section to a shore abutment;
FIG. 16 is an exploded view showing the connection of the gangway section to a dock section;
FIG. 17 is an exploded view showing the connection of a ramp or transition plate to the gangway section;
FIG. 18 is an exploded view showing the connection of a roller to the gangway section.
Corresponding reference numerals will be used throughout the several figures of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
The following detailed description illustrates the invention by way of example and not by way of limitation. This description will clearly enable one skilled in the art to make and use the invention, and describes several embodiments, adaptations, variations, alternatives and uses of the invention, including what I presently believe is the best mode of carrying out the invention. Additionally, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
An illustrative embodiment of a gangway section 10 of the present invention is seen generally in FIGS. 1 and 2 . A complete gangway can be formed from a single gangway section 10 , or two or more of the gangway sections 10 can be connected together, as will be described below, to form a gangway of a desired length.
The gangway section 10 is quadrilateral in shape having two opposed and generally parallel ends 12 and two opposed and generally parallel sides 14 . In a preferred embodiment, the gangway section is about 6′ long and about 4′ wide. These dimension, of course, can be changed if desired.
The gangway section 10 includes an upper surface 16 having a top side 18 upon which a person walks and a bottom side 20 ; a bottom surface 22 spaced from the upper surface; and opposed sides 24 extending between the upper surface 16 and the bottom surface 22 . The sides 24 are generally rectangular in cross-section, as seen best in FIGS. 7 and 10 . The sides 24 include an outer wall 26 , an inner wall 28 , a top wall 30 and a bottom wall 32 . The side bottom wall 32 is approximately level with the gangway section bottom surface 22 . The side top wall 30 , however, is spaced above the gangway section upper surface 16 . Thus, the sides 24 define rails which extend the length of the gangway section. As seen in FIGS. 2 and 5 , the sides 24 are generally pentagonal in side elevation. They include generally flat and parallel top and bottom surfaces defined by the top and bottom walls 30 and 32 , end surfaces 31 at opposite ends of the side walls, and sloped surfaces 33 extending between the bottoms of the end surfaces 31 and the opposed ends of the bottom walls 32 (which are not as long as the top walls 30 ). As best seen in FIG. 1 , the sides 24 include grooves 34 on the side top wall 30 which extend between the outer and inner walls 26 and 28 , respectively, and grooves 36 on the outer side walls 26 which extend between the side top and bottom walls 30 and 32 , respectively. As seen in FIG. 1 , the sides 24 can be divided into end sections which have the side wall grooves 36 and a central section which does not have the grooves 36 . In the end sections, with the grooves 36 , there are side wall grooves 36 which intersect with the top wall grooves 34 and side wall grooves 36 between the position of the top wall grooves 34 .
Returning to the gangway upper surface, the upper surface is provided with channels 38 at the junction of the side inner wall 28 and the gangway upper surface 16 . Transverse channels 40 extend across the width of the gangway upper surface 16 between the channels 38 , and intersect with the channels 38 . Preferably, the channels 40 are co-linear with the side top wall channels 34 . The channels 38 are deeper than the channels 40 . Hence, the channels 40 empty into the channels 38 . As can be appreciated, the channels 40 define a waterway to direct water off the upper surface of the gangway. The channels 40 facilitate movement of any water on the gangway upper surface to the channels 38 .
Turning now to the bottom of the gangway section 10 , the bottom surface is provided with a plurality of recesses 50 L, 50 R, 52 L, 52 R, 54 L, 54 R, 56 and 58 . The recesses 50 L and 50 R are mirror images of each other, as are recesses 52 L and 52 R and recesses 54 L and 54 R. The recesses 50 L, 50 R, 52 L, 52 R, 54 L, and 54 R are side recesses and are substantially similar to each other, hence, only one of the recesses will be described below. The recesses 56 and 58 are inner recesses and differ from the side recesses in only one respect, which will be pointed out below. As can be seen in FIG. 2 , the recesses are all generally quadrilateral in plan and are arranged in 3×4 array. The end recesses 50 L,R, 54 L,R, and 56 are shorter than the center recesses 52 R,L and 58 . The side recesses are separated from the inner recesses by troughs 60 defined by trough side walls 62 and a trough upper wall 64 which is spaced from the bottom side 20 of the gangway upper surface 16 . A plurality of spaced apart grooves 66 extend across the troughs 60 . The troughs 60 are sized and shaped to receive trusses 68 ( FIG. 3 ) to connect to gangway sections 10 together, as will be described below. A plurality of screw holes 70 extend through the gangway upper surface 16 and into the channel 60 to accept fasteners 72 (such as bolts or screws) to secure the trusses 68 in the channels 60 .
Grooves 74 are formed in the gangway bottom surface 22 between the inner end recesses 56 and the inner central recesses by grooves 74 . Additionally, a groove 76 is formed in the bottom surface 22 between the two rows of inner recesses. Similarly, grooves 78 are formed in the gangway bottom surface 22 between the side end recesses 50 R,L and 54 R,L. Lastly, an elongate groove 80 extends alongside of the side recesses in the gangway bottom surface 16 (which at that point also forms the bottom wall 32 of the sides 24 ).
Turning to FIGS. 7-13 , the recesses are all generally similar in configuration. The recesses include end walls 82 which are generally parallel to the ends 12 of the gangway section 10 , side walls 84 which are generally parallel to the sides 24 of the gangway, and ceilings 86 which span between the opposed end walls 82 and opposed side walls 84 . For the side recesses 50 R,L, 52 R,L, and 54 R,L, the outer side wall of the recesses is also the inner side wall 28 of the gangway side 24 . As can be seen, the recesses all have a generally quadrilateral shape. However, the shape of the recesses could be changed, and the recesses could be circular, triangular, trapezoidal, or any other desired shape in plan view. The recess ceiling 86 includes a ceiling surface 88 with a series of spaced apart, generally perpendicular grooves 90 extending between the recess sidewalls 84 . The grooves 90 give the recess ceiling 86 a generally crenellated appearance in cross-section, as seen in FIGS. 8 and 11 - 13 . The ceiling surface 88 is spaced from the bottom side 20 of the gangway upper surface 18 , and the grooves 90 have a peak which is adjacent the bottom side 20 of the gangway upper surface 18 . Preferably, the groove peaks contact, or are spaced only slightly from, the gangway upper surface bottom side 20 . Actually, there are two sets or types of grooves 90 . Grooves 90 a are beneath the gangway upper surface grooves 40 and grooves 90 b are spaced between the gangway upper surface grooves 40 . The contact between the grooves 90 b and the bottom 20 of the upper surface is shown in FIG. 10 , where, the top of the groove 90 a is essentially merged into the bottom of the gangway upper section. The bottom (or exposed) surface of the grooves 90 a and 90 b are substantially identical. However, the inner or upper surface of the walls which form the grooves 90 a and 90 b are varied slightly. While these inner surfaces are both generally trapezoidal in shape, the grooves 90 a generally come to a point at their peaks where they are closest to the gangway upper surface. The grooves 90 b , on the other hand, have a generally flat peak area where the grooves 90 b are closest to the upper surface grooves 40 . As can be appreciated, because the grooves 90 a extend upwardly to contact (or nearly contact) the bottom of the gangway upper surface and the grooves 90 b extend upwardly to contact (or nearly contact) the bottom of the upper surface grooves 40 , the grooves 90 a are deeper than the grooves 90 b . The grooves 90 a and 90 b are formed by a groove wall that has a generally constant thickness.
In the side recesses 50 R,L, 52 R,L, and 54 R,L, the grooves 90 a , are formed in two parts or portions. The grooves 90 a include an inner portion having a wall thickness substantially similar to the wall thickness of the groove 90 b . The grooves 90 a also include an outer portion which, as seen in FIG. 12 , has an increased wall thickness, especially along the top of the groove. This second outer portion of the groove 90 a extends from the recess outer side wall 84 a distance equal to about ¼ to about ⅓ the length of the groove. In the second portion, where the grooves 90 a are thickened, the grooves are less deep. Preferably, the depth of the grooves 90 a in the second portion is about as deep as the grooves 90 b . Stated differently, the groove 90 a is thickened in the second portion such that its depth in this second portion is approximately equal to the depth of the grooves 90 b . The grooves 90 a of the inner recesses 56 and 58 do not include any such thickened area.
The recesses, in combination, do not extend the full length of the gangway section 10 . The gangway section 10 is provided with attachment areas 100 a,b at opposite ends of the gangway section in the bottom surface 22 of the gangway section 10 . The gangway sections 100 a,b are all recessed relative to the gangway bottom surface 22 and have connection surfaces 102 a,b which are substantially parallel with the cavity ceiling surfaces 88 . The attachment areas 100 a are co-linear with the side recesses 50 R,L, 52 R,L and 54 R,L and have a width substantially equal to the width of the side recesses. The attachment areas 100 b are at the ends of the inner recesses 56 and 58 and have a width substantially equal to the combined width of the two rows of inner recesses. The attachment areas 100 a,b each include a groove 104 a,b which extends generally perpendicular to the gangway sides 24 across the approximate center of the attachment surfaces 102 a,b . A circumferential groove 106 extends around three sides of the attachment surfaces 102 a,b , such that the grooves 106 have a generally U-shaped appearance in plan view. Additionally, the attachment surfaces 102 b each include grooves 108 which extend generally perpendicularly to the grooves 104 b and effectively divide the attachment surfaces 102 b into thirds. Each third of the attachment surface 102 b is approximately equal in width to the attachment surfaces 102 a . Lastly, the attachment surfaces 102 a,b are provided with screw holes 110 . Preferably, each attachment surface is provided with three screw holes 110 formed in a generally triangular pattern. Two screw holes are provided between the end of the gangway section and the groove 104 a,b and one hole is provided between the groove 104 a,b and the U-shaped groove 106 .
The surfaces which define the gangway section, as described above, in combination, define a chamber C 1 . Additionally, the surfaces which define the sides 24 define a second chamber C 2 which, preferably, is separate and distinct from the chamber C 1 . The chambers C 1 and C 2 are preferably hollow. Hence, the gangway section is buoyant. One or all of the chambers could be filled with a buoyant material, such as foam, to increase buoyancy of the gangway section, if necessary.
As mentioned above, two or more gangway sections 10 can be connected together to form a longer gangway. To connect the two gangway sections together, a connection plate 120 is provided for the outer attachment areas 100 a . The plates 120 have a length approximately equal to the combined length of the attachment surfaces 102 a when two gangway sections are in abutting relationship, as seen in FIG. 3 . Hence, the plates 120 will span across the two gangway sections 10 . The plates 120 are provided with screw holes 122 which are arranged in a pattern such that the screw holes 122 will be aligned with the screw holes 110 of the attachment surfaces 102 a . Screws 124 (preferably with washers 126 ) are passed through the connection plate screw holes 122 and into the attachment surface screw holes 110 in order to connect two gangway sections together. The connection plates are made from a material, such as aluminum, which will not rust upon prolonged exposure to water. The plates could also be made of other materials. As can be appreciated, because the connection plates 120 are relatively short, trusses 68 ( FIGS. 3 and 5 ) are provided. The trusses 68 are received in the bottom surface troughs 60 . Fasteners 72 are passed through the holes 70 in the gangway upper surface and through the trusses 68 to secure the trusses 68 to the gangway section. Preferably, the fasteners are bolts, which are passed through the gangway section and trusses and receive nuts to hold the trusses to the gangway section. The trusses can be provided with bolt holes, or bolt holes can be drilled through the trusses on site. Preferably, two trusses are provided, which, as described above, are positioned between the three rows of recesses. However, the gangway bottom section could be modified to use a single truss extending, for example, along the center of the gangway section.
The trusses 68 are provided to increase stability of the gangway. Hence, trusses 68 extend the full length of the gangway. Thus, if the gangway comprise three sections, the trusses will extend for three sections (or 18′ for three 6′ long sections). If the gangway comprises only two section, then the trusses will have an overall length of 12′. The trusses can each be comprised of a single long truss, or can be made of truss sections which are secured to the gangway sections. If truss sections are used, the junctions between adjacent truss sections is positioned away from the junction between adjacent gangway sections, and is preferably positioned near the center of the gangway sections.
Turning to FIG. 14 , hinges 130 and 132 can be mounted to the attachment surfaces 102 a and 102 b , respectively, to enable the gangway section 10 to be mounted to shore abutments, decks, etc. The hinges 130 each include a mounting plate 134 and pin sleeves 136 . The hinge mounting plates 134 have a width substantially equal to the width of the respective attachment surface 102 a,b and holes 138 positioned to be aligned at least with the two end holes 110 on the gangway attachment surface. Screws 140 are used to secure the hinge plates to the attachment surfaces 102 a,b . As best seen in FIG. 3 , the hinges 130 are generally L-shaped and include a leg 142 at the end of the mounting plate 134 to which the hinge pin sleeves 136 are mounted. The hinge leg 142 overlies the end surface of the gangway section 10 . Hence, the hinge pin sleeves 136 extend outwardly from the gangway end surface.
Connection of the gangway section 10 to a shore abutment 150 As seen in FIG. 15 , a mating hinge plate 152 is mounted to the shore abutment 150 . The hinge plate 152 is shown to be generally a right angle member which overlies a corner of the shore abutment 150 and is connected to the shore abutment by screws, bolts, or other fasteners which extend through both legs of the angle member. Pin sleeves 154 are positioned on the generally vertical leg of the hinge plate 152 and are positioned to be offset from the pin sleeves 136 of the hinge plates 130 mounted to the gangway attachment surface. A hinge pin 156 passes through the pin sleeves of the opposing hinge plates to hingedly connect the gangway section 10 to the shore abutment 150 .
In FIG. 16 , the gangway 10 is shown connected to a floating dock section 160 . The dock section 160 is preferably one such as U.S. Pat. No. 5,280,155, which is incorporated herein by reference. The dock section 160 is provided with hardware connectors 162 having threaded shafts 164 extending outwardly therefrom. A hinge plate or bracket 166 is mounted to a side surface of the dock section 160 using the hardware connectors 162 . As seen, the bracket 166 is generally U-shaped in configuration, and includes holes 168 in its legs and top cross member. The holes 168 are positioned to be aligned with the connector shafts 164 , and the shafts 164 extend through the bracket holes 168 to receive nuts 170 to secure the bracket 166 to the dock section 160 . The bracket additionally includes pin sleeves 172 positioned along the cross-member of the bracket 166 . The pin sleeves are positioned to be offset from the pin sleeves of the gangway hinge. A hinge pin 174 is passed through the respective pin sleeves to hingedly connect the gangway section 10 to the dock section 160 . The bracket 166 is sized and positioned on the dock section 160 such that the upper surface of the gangway and the upper surface of the dock 160 will be substantially co-planar when the gangway is connected to the dock section.
FIG. 17 shows the connection of a ramp or transition plate 180 to the gangway 10 . The ramp 180 is generally triangular in side elevation and has a top surface 182 , side surfaces 184 , and a back surface 186 . A plurality of ears 188 extend from the back surface 186 and have openings 190 through which a hinge pin 192 can extend. As can be appreciate, the hinge pin 192 extends through the pin sleeves of the gangway hinges and through the ears of the ramp. Preferable, the ramp ears 188 are arranged in pairs, the ears of each pair being spaced apart a distance slightly greater than the length of the gangway hinge pin sleeves. Hence, the ramp ears sandwich the gangway hinge pin sleeves. Additionally, the number of pairs of ears corresponds to the number of pin sleeves on the gangway hinge.
As can be appreciated, because the connection between the gangway and the shore abutment, ramp, and/or dock is hinged, the gangway can pivot about the hinge pin as the dock, pier, etc. to which the gangway is connected is raised and lowered by water, or simply as the water level in the lake, pond, etc. changes. Additionally, the hinged connection at the opposite ends of the gangway allow for the gangway to move slightly relative to the shore and dock, pier, etc. when someone steps on the gangway.
Lastly, FIG. 18 shows a roller assembly 200 which is mounted to the gangway section 10 . The roller assembly includes a roller bracket 202 having a base which is connected to the sloped surface 33 of the gangway wall 24 . An axle 204 extends inwardly from the bracket 202 and receives a bearing 206 . A roller 208 is mounted on the bearings 206 . The roller assembly 200 protects the gangway 10 by allowing it to roll due to vertical movement when the opposite end of the gangway is connected to a floating dock or pier. As can be appreciated, because the roller assembly is mounted to the gangway side walls 24 , rather than to the attachment surfaces 102 a,b , the roller assembly 200 and the ramp 180 can both be mounted to the gangway.
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. For example, the inner recesses 56 and 58 could be formed as a single column of recesses, rather than as two columns of recesses. Alternatively, the recesses could be formed in a pattern other than a 4×3 array. The cross-sectional profile of the recess ceiling grooves could be changed—they could all be arched or triangular, for example. Some (or all) of the grooves of the inner recesses 56 and 58 could be formed similarly to the grooves 90 b to include portions of greater wall thickness. Conversely, all the recess ceiling grooves could be formed like the grooves 90 a , wherein the groove wall is of a substantially constant thickness across the length of the groove. These examples are merely illustrative.
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A molded gangway section is provided to form a gangway between a shore and a dock, pier, and the like. The gangway includes an upper tread surface and a bottom surface having recesses formed therein. The ceilings or upper surfaces of the recesses are formed with grooves. Two or more of the gangway sections can be connected together to form gangways of incrementally increasing lengths. Hinge connections are provided to connect the gangway to piers, docks, shore abutments, ramps, etc. Additionally, a roller can be mounted to a shore end of the gangway.
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BACKGROUND OF THE INVENTION
The invention is concerned with a marine structure. In particular it is concerned with installing, particularly with suction force e.g. generated by a so called suction pile, and the design of an anchoring body in the subsea bottom. The invention is both relative to the anchoring body and the installing device and the combination of both and is also relative to the method of installing.
With this anchoring body horizontal and/or vertical loads can be taken up from an object to be anchored in or above the subsea bottom, such as an oil production platform floating in or on the water or a vessel or a mooring buoy for a vessel or a subsea pipe line. The anchoring body can be part of a plurality of horizontal spaced anchoring bodies provided within the soil and from each of which an anchoring line extends upward to a floating object, such as an oil production platform (a so called tension-leg platform; viz. e.g. WO96/40548, incorporated here by reference). The anchoring body can be integrated with the installing device, or be coupled therewith in a easily disengageable manner.
The design and installation of an anchoring body with the aid of a suction pile is e.g. described in WO98/52819 and in GB-A-2317153 (corresponding to the British patent application, filing number 19960001894, titled “A Subsea Mooring”, in the name of Karel Karal), both incorporated here by reference. Both describe coupling of the anchor and the suction pile on a ship deck above seal level, lowering the combination onto the subsea bottom, sucking in of the upright suction pile into the subsea bottom such that the upright anchor completely disappears into the subsea bottom and therewith is completely embedded by the subsea bottom, disengaging the anchor from the suction pile and pressing the suction pile upward from the subsea bottom by internal over pressure to relocate it onto the ship deck. The anchor is coupled to a flexible anchor line extending therefrom until above the subsea bottom. This anchor line follows such a path through the subsea bottom and the water there above, that this is exclusively adapted to transmit a horizontal load onto the anchor. Since the anchor is separate from the suction pile it is possible to install the suction pile completely below the subsea bottom.
Suction piles and their way of installing are o.a. known from GB-B2300661 and EP-B-0011894, which disclosures are incorporated here by reference. Briefly, a suction pile is a thin walled steel cylinder, closed at at least one longitudinal end, that is located on the subsea bottom with the opposite end and penetrates the subsea bottom with the aid of a suction created within the cylinder. The creation of the suction can be with the aid of a suction source, such as a pump, being on, or close to or at a distance (e.g. above the water surface, e.g. at a vessel) from the suction pile. The applied level of the suction can be e.g. at least substantially constant, smoothly increase or decrease or else pulsate; for which there are convenient means; for an e.g. pulsating level a possibly in the suction pile integrated pressure accumulator that is After use, the suction pile can easily be removed by creating an overpressure within the cylinder, e.g. by pumping in (sea) water.
SUMMARY OF THE INVENTION
According to one aspect installing is concerned of an in embedding-direction profiled anchoring body, i.e. a body that is preferably not flat sheet like as viewed in embedding direction, but shows more of e.g. a wave or bulge, or is preferably assembled from mutually angularly connected parts, or has an in itself closed shape, such as a ring shape, wherein said shape is preferably adapted such that said body gets support from the inner wall of the suction pile and/or the lower side of the suction pile or the suction pile requires no additional implements to at least tilting free holding said anchoring body. In this manner it is e.g. not necessary that the anchoring body penetrates the sideway boundaries of the suction space substantially, which e.g. results in an at its lower side diametrically oppositely over about half the height of the anchor notched suction pile with a notch width about equal to the anchor plate thickness. It is also e.g. not necessary in that sense that the suction pile penetrates the anchoring body with e.g. a boundary from above.
In one aspect the concern is the installing of the anchoring body in the subsea bottom wherein the body remains at least substantially fixed in position, this contrary to the known installing wherein after bringing to a convenient depth into the subsea bottom, the body experiences tilting, e.g. by pulling thereon via a so called bridle, to become active.
In one aspect the concern is to give the anchoring body the desired configuration within the subsea bottom by means of a tension or compression force provided by e.g. the suction pile during its pressing out the subsea bottom. E.g. a wedge is activated or an extendable part is extended by it, from which the anchoring body gets its anchoring power at least partly, preferably at least substantially.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is characterised by the attached claim 1.
The invention is further illustrated with the aid of at the moment advantageous, non-limiting embodiments. The drawings show in:
FIG. 1 a perspective view of a first embodiment of the anchor;
FIG. 2 the exploded view of FIG. 1;
FIG. 3 a and b, a detail in side view and sectional view, respectively;
FIGS. 4 a-d several subsequent steps during installing the anchor of FIG. 1; FIG. 4 a and b in side view. FIG. 4 c end d in perspective;
FIG. 5 a perspective view of a second embodiment of the anchor;
FIGS. 6 a-e a prespective view of several subsequent steps during installing the anchor of FIG. 5;
FIGS. 7 a-c a detail view of three subsequent positions of the anchor of FIG. 5;
FIG. 8 a detail view of the anchor of FIG. 5; and
FIG. 9 a top view of the anchor of FIG. 5 in its final position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 show a cylindrical anchor 1 of steel, open at the top and bottom side. It has a diameter of 6 m and a height of 2 m. It consists of two shell halves pivotably connected mutually at the lower side by a diametrically extending pin 5 connecting the pivot lips 3 and 4 . The longitudinal edges of each shell half are bridged by a pulling member 2 , in this case a steel section.
FIG. 3 shows the pivotal connection more in detail. Below the pivot lip 4 there is the filling plate 6 . The pivot lip 4 overlaps the pivot lip 3 .
In FIG. 4 a the anchor 1 is suspended under a suction pile 8 below the water surface 12 . The suction pile 8 is suspended from vessel (not shown) by a hoisting cable 7 . Above the suction pile 8 there is the pump unit 10 to generate suction and over pressure, respectively, within the suction pile during installing within the subsea bottom 13 . The connection of the anchor 1 to the suction pile 8 is air and water tight by the coupling 9 . At both sides of the anchor 1 a flexible pulling member 11 , extending upward outside the anchor 1 and the suction pile, is fixed (FIG. 4 b ) to the pivot pin 5 . The suction pile 8 is subsequently lifted, while the anchor 1 is left behind. By vertically pulling on the members 11 (FIG. 4 c ) the shell halves pivot towards the open position around the pin 5 . The anchor 1 remains completely below the subsea bottom during this. The capacity of the anchor to resist vertical loads is substantially increased now.
The shell halves of the anchor 1 of FIG. 1 can be provided with stiffeners for increased shape stability. For automatic extension a shell half can be fixed to pivot around a pivot axis that is provided such that when pulling at the anchoring body in the direction opposite the direction in which it is inserted in the subsea bottom, the shell half tries to further pivot open. The pivot axis is e.g. provided at a low level at the anchoring body, based on the retracted position of the shell half. The shell half can have a shape that differs from the cylindrical shape. The anchor 1 can be e.g. provided by two flat plate members, at their lower sides mutually connected to pivot over a limited angle. When in the retracted position, these members are bearing flat against each other. Once inserted in the subsea bottom, they can be brought in the extended position by e.g. pulling such that each can pivot over an angle of 90° to arrive in a mutually registered position.
FIG. 5 shows an anchor 1 that has a star shape in top view. Each of the three plate shaped arms 14 has at both sides an extendable flap 15 pivotably connected at its upper side to the arm 14 .
FIG. 6 shows how this anchor 1 can be completely embedded within the suction space of a suction pile 8 . The anchor 1 preferably finds support at all sides against the inner side of the suction pile 8 . The anchor can also project slightly from below the suction pile 8 . It preferably projects such below the suction pile, that the suction pile still can connect to the subsea bottom 13 in an air and water tight manner. This amount of projection can depend on the type of subsea bottom. The weaker the bottom, the greater the self penetration of the suction pile and thus the more the anchor can project from below the suction pile. Thus an air and water tight coupling between the anchor 1 and the suction pile 8 is not required.
After sucking in to the desired depth (FIG. 6 b ) the anchor 1 is completely under ground. The suction pile 8 is lifted now (FIG. 6 c ), while the anchor is left behind.
During sucking in the flaps 15 must be extended in their active position. This can be done by fixing (FIG. 6 d ) a flexible pulling member 16 to each flap 15 with which the flaps can be extended. Those members 16 are e.g. fixed to the suction pile 8 . While lifting the suction pile 8 , the members are automatically pulled at. Those members 16 are e.g. temporarily fixed to the suction pile 8 , e.g. through a breach coupling 17 (FIG. 6 e ). As soon as the flaps 15 are conveniently extended, the connection to the suction pile 8 is disconnected and the suction pile is lifted alone and hoisted on board of the vessel again. The object to be anchored can now be coupled to the anchor line 11 . The anchor line 11 can be fixed to the members 16 .
Another possibility for extension is as follows: During sucking in, the flaps 15 are released for extension if the anchor 1 is already brought into the subsea bottom over a predetermined depth. By sucking in further the flaps 15 open now automatically. With the aid of an arresting mechanism they can be fixed in the extended position. Release for extension can be provided by allowing a mutual displacement between the anchor and the suction pile during insertion, e.g. by intermediate upward movement of the suction pile while the anchor remains behind in the soil, such that a latch mechanism is activated. In stead of a mutual displacement it is also feasible to temporarily decrease or remove the load of the suction pile on the anchor, to realise the desired release.
The flaps 15 are initially in a retracted position (FIG. 7 a and 8 ). Subsequently they are extended (FIG. 7 c ). If all flaps 15 are extended, the top view of the anchor 1 according to FIG. 9 is arrived at.
The suction pile 8 preferably has convenient arresting means therefor, to fix the anchor 1 with respect to the suction pile 8 , e.g. to prevent that during penetrating the subsea bottom 13 by the suction pile 8 , the anchor 1 displaces with respect to the suction pile 8 and/or to provide that during e.g. manipulating, the anchor 1 remains in position with respect to the suction pile 8 , e.g. does not slide outward with respect to the suction pile 8 .
In the following further possible features of the invention are mentioned.
The anchoring body is e.g. at least substantially sheet type, e.g. in top view star shaped (i.e. profiled as viewed in the direction of inserting) with three or more beams/arms. The anchoring body is preferably provided with coupling means for coupling at least one preferably supple anchoring member for mounting to the object to be anchored. The anchoring body is preferably provided with an anchoring amplifying means such as a convenient member that can be oriented perpendicular to the expected orientation of the pulling force, wherein said means can preferably be activated, e.g. is extendable, during or after providing the anchoring body into the subsea bottom, e.g. by a convenient, preferably remotely or automatically actuatable actuating means provided e.g. at the anchoring body and/or the suction pile. Activation e.g. takes place by moving the suction pile upward, e.g. after the anchoring body is brought at the desired depth within the subsea bottom. Activation e.g. takes place by actuation of a release means during an end phase of the sucking in, e.g. by intermediate preferably partly pressing or pulling out the suction pile from the subsea bottom, after which further sucking in takes place. During said further sucking in said activation (e.g. extension) e.g. takes place, e.g. in that the anchoring amplifying means is hingedly connected at its top side. The anchoring body is e.g. provided with at least one anchoring amplifying means extendably mounted thereto, having an enlarged supporting area, as viewed in the expected pulling direction, if in the extended position, wherein said supporting area is possibly larger than the inside diameter of the cross sectional area, as viewed in the direction of insertion, of the suction pile with which the installation takes place. With the aid of a detection means, e.g. an angle measuring means e.g. integrated in the pivoting element of the anchoring amplifying means or any other extendable element at the anchoring body, monitoring the extension is possible. With the aid of securing means the extended element can be secured in its extended position. A supple pulling means extends e.g. between the anchoring amplifying means and the suction pile such that during upward moving of the suction pile the anchoring amplifying means is activated. The activating means is preferably mounted to the suction pile with the aid of a frangible connection, such as a break pin or explosion pin, wherein said frangible connection is preferably of the automatic type, breaking when predetermined requirements during installing are fulfilled. With respect to that the frangible connection is e.g. strong enough such that the suction pile can pull at the anchoring amplifying body to activate it, but too weak to move, such as displace, particularly pulling from the subsea bottom, the anchoring body by pulling of the suction pile at the anchoring body with activated anchoring amplifying means. If a frangible connection of the forced type is used, e.g. an explosion pin, it is prefered, to activate the frangible means remotely, for which the frangible means is e.g. coupled to a receiver of a transmitter/receiver assembly. The activation means is preferably combined with the anchoring member or the coupling means for it, wherein the activation means is e.g. extended by the anchoring member or is integrated therewith.
The invention is also concerned with the combination of a feature/aspect indicated here, separated from possible features/aspects here indicated in combination therewith, with one or more other features/aspects indicated here, seperated from possible features/aspects here indicated in combination therewith.
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A combination of an installation device and a sea bottom anchor is adapted to install the anchor ( 1 ) into the subsea bottom by means of suction pressure. The anchor has one or more anchoring amplification members that can be brought into an active position from an inactive position to increase the anchoring capacity of the installed anchor.
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The present invention relates generally to printing presses and more particularly to variable cutoff printing presses.
BACKGROUND OF INVENTION
U.S. Pat. No. 5,950,536 discloses a variable cutoff offset press unit wherein a fixed cutoff press is adapted to a variable cutoff press while maintaining the size of the blanket cylinders. A plate cylinder sleeve has a variable outer diameter, whereby a length of an image to be printed is varied proportionally to a variable outer diameter while maintaining an outer diameter of the gapless blanket cylinder sleeve constant. The size of a plate cylinder is changed by using a sleeve mounted over the plate cylinder or adding packing under a plate to increase the diameter of the plate cylinder.
U.S. Pat. No. 6,327,975 discloses a method and apparatus for printing elongate images on a web. A first printing unit prints a first image portion on the web at prescribed spacings, by moving the impression cylinder away from the blanket cylinder each time one first image portion is printed. A second printing unit prints a second image portion on the spacings left on the web by the first printing unit, also by moving the impression cylinder away from the blanket cylinder each time one second image portion is printed. A variable velocity motor rotates each blanket cylinder, while each time the associated impression cylinder is held away to create a space on the web for causing printing of the first or the second printing portion at required spacings.
U.S. Pat. No. 7,066,088 discloses a variable cut-off offset press system and method of operation which utilizes a continuous image transfer belt. The offset printing system comprises at least two plate cylinders adapted to have thereon respective printing sleeves. Each of the printing sleeves is adapted to receive colored ink from a respective ink source. The system further comprises at least a impression cylinder, wherein the image transfer belt is positioned to contact each of the printing sleeves at respective nips formed between respective ones of the plate cylinders and the at least one impression cylinder.
BRIEF SUMMARY OF THE INVENTION
A variable cutoff printing press is provided. The printing press includes a first plate cylinder rotating at a constant angular velocity during each revolution about a first plate cylinder axis and a first blanket cylinder rotating at varying angular velocities and printing on a web during each revolution about a first blanket cylinder axis. The first blanket cylinder comes in and out of contact with the first plate cylinder during operation.
A method of variable cutoff printing is also provided. The method includes, during a single rotation of a first blanket cylinder about a first blanket cylinder axis, rotating the first blanket cylinder and bringing the first blanket cylinder into contact with a first plate cylinder carrying a first image and rotating at a first constant velocity, the blanket cylinder contacting the first plate cylinder and receiving the first image from the first plate cylinder; rotating the first blanket cylinder and bringing the first blanket cylinder out of contact with the first plate cylinder; varying a rotational velocity of the first blanket cylinder after the first blanket cylinder is brought out of contact with the first plate cylinder; rotating the first blanket cylinder and bringing the first blanket cylinder into contact with a web traveling at a second constant velocity, the first blanket cylinder contacting the web and printing the first image on the web; rotating the first blanket cylinder and bringing the first blanket cylinder out of contact with the web; and varying the rotational velocity of the first blanket cylinder again after the first blanket cylinder is brought out of contact with the web.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is described below by reference to the following drawings, in which:
FIG. 1 shows a printing unit of a printing press according to an embodiment of the present invention;
FIG. 2 a shows a table including predicted results for a printing section of the embodiment shown in FIG. 1 ;
FIG. 2 b shows a graph illustrating a surface velocity of a contacting portion of a blanket cylinder, for each revolution of the blanket cylinder, according to the predicted results shown in the table of FIG. 2 a;
FIG. 3 shows a printing unit of a printing press according to an embodiment of the present invention;
FIG. 4 shows a schematic side view of a four color offset printing press including one central impression cylinder according to an embodiment of the present invention; and
FIG. 5 shows a schematic side view of a four color offset printing press according to an embodiment of the present invention.
DETAILED DESCRIPTION
FIG. 1 shows a printing unit 10 of a printing press according to an embodiment of the present invention. Printing unit 10 includes a first printing section 20 and a second printing section 30 printing images on a web 14 as web 14 passes over a central impression cylinder 16 . A nip roll 18 guides web 14 as web 14 comes into contact with impression cylinder 16 . Each printing section 20 , 30 includes inkers 22 , 32 , a plate cylinder 24 , 34 , and a blanket cylinder 26 , 36 , respectively, and prints images on web 14 . Inkers 22 , 32 provide the same color ink to plate cylinders 24 , 34 , respectively. Blanket cylinders 26 , 36 print images on web 14 at areas 42 , 44 , respectively, where nips are formed when blanket cylinders 26 , 36 , respectively, contact web 14 .
Inkers 22 disperse ink to plate cylinder 24 , which rotates about an axis of plate cylinder 24 and transfers a first inked image to blanket cylinder 26 . Blanket cylinder 26 rotates about an axis of blanket cylinder 26 and prints the first inked image on web 14 . Axes of blanket cylinder 26 and plate cylinder 24 remain stationary during printing. Inkers 22 and plate cylinder 24 are being rotated so that inkers 22 each have a constant surface velocity that is equal to the surface velocity of plate cylinder 24 . Impression cylinder 16 and web 14 also travel at constant velocities so that a surface velocity of impression cylinder 16 equals a velocity of web 14 .
The surface velocity of plate cylinder 24 may vary from the surface velocity of impression cylinder 16 and the velocity of web 14 . However, while blanket cylinder 26 is receiving a first image from plate cylinder 24 the surface velocity of blanket cylinder 26 is equal to the surface velocity of plate cylinder 24 and while blanket cylinder 26 is printing the first images on web 14 the surface velocity of blanket cylinder 26 is equal to the surface velocity of impression cylinder 16 and the velocity of web 14 . Thus, during each 360 degree revolution, if the surface velocity of plate cylinder 24 varies from the surface velocity of blanket cylinder 26 , then blanket cylinder 26 accelerates and decelerates during each revolution.
Printing section 30 operates in a manner similar to printing section 20 to print second images on web 14 , with inkers 32 and plate cylinder 34 having constant equal surface velocities that may vary from the velocity of web 14 and the surface velocity of impression cylinder 16 . As with blanket cylinder 26 , blanket cylinder 36 may accelerate and decelerate during each 360 degree revolution when the surface velocity of plate cylinder 34 varies from the surface velocity of impression cylinder 16 and the velocity of web 14 .
In this embodiment, a position where blanket cylinder 26 contacts web 14 and a position where blanket cylinder 26 contacts plate cylinder 24 are separated by 180 degrees with respect to the axis of blanket cylinder 26 . Also, a position where blanket cylinder 36 contacts plate cylinder 34 and a position where blanket cylinder 36 contacts web 14 are separated by 180 degrees with respect to an axis of blanket cylinder 36 . In other embodiments, different angles of separation may be used.
As shown in FIG. 1 , blanket cylinders 26 , 36 may include relieved portions 25 , 35 , respectively, to allow blanket cylinders 26 , 36 to accelerate and decelerate during each revolution without disrupting the rotation of plate cylinders 24 , 34 , respectively, or impression cylinder 16 or disrupting the travel of web 14 . Relieved portions 25 , 35 do not come into contact with plate cylinders 24 , 34 or web 14 during normal printing operations. The portions of each blanket cylinder 26 , 36 that are not relieved contact plate cylinders 24 , 34 , respectively, during each revolution and may be referred to as contacting portions 27 , 37 . Blanket cylinders 26 , 36 receive respective first and second images and print the images using respective contacting portions 27 , 37 . Each contacting portion 27 , 37 has a pitch radius Rc that is greater than a pitch radius Rr of each respective relieved portion 25 , 35 .
In this embodiment, which is a preferred embodiment, printing sections 20 , 30 are configured in the same manner, with plate cylinder 24 being the same size as plate cylinder 34 , blanket cylinder 26 being the same size as blanket cylinder 36 , and contacting portions 27 , 37 being the same size. In an alternative embodiment, printing sections 20 , 30 may be configured differently from each other.
In operation, blanket cylinder 26 contacts plate cylinder 24 with contacting portion 27 and receives a first image from plate cylinder 24 . After contacting portion 27 receives the first image from plate cylinder 24 and contacting portion 27 is no longer in contact with plate cylinder 24 , blanket cylinder 26 may be accelerated or decelerated so that contacting portion 27 has a surface velocity that is equal to the velocity of web 14 when contacting portion 27 contacts web 14 . When contacting portion 27 prints the first image on web 14 and is no longer in contact with web 14 , blanket cylinder 26 may be accelerated or decelerated so that the surface velocity of contacting portion 27 is equal to the surface velocity of plate cylinder 24 when contacting portion 27 comes into contact with plate cylinder 24 again to receive a next first image. As blanket cylinder 26 contacts plate cylinder 24 , blanket cylinder 26 is aligned with respect to plate cylinder 24 so that a first inked image carried by plate cylinder 24 is properly transferred to contacting portion 27 . After blanket cylinder 26 receives the next first image and comes out of contact with plate cylinder 24 , blanket cylinder 26 may be accelerated or decelerated so that contacting portion 27 has a surface velocity that is equal to the velocity of web 14 as contacting portion 27 contacts web 14 and so that contacting portion 27 is properly aligned to print the next first image on web 14 .
After blanket cylinder 26 prints a first image on web 14 and the first image passes by area 44 , blanket cylinder 36 prints a second image on web 14 directly behind the first image. As blanket cylinder 36 prints the image, blanket cylinder 36 is being rotated so that the surface velocity of blanket cylinder 36 equals the velocity of web 14 and the surface velocity of impression cylinder 16 . After blanket cylinder 36 finishes printing the second image on web 14 , blanket cylinder 36 may be accelerated or decelerated so that contacting portion 37 has a surface velocity that equals the surface velocity of plate cylinder 34 , and is in proper image receiving position when contacting portion 37 contacts plate cylinder 34 to receive a next second image. After blanket cylinder 36 contacts plate cylinder 34 and receives the next second image and contacting portion 37 is out of contact with plate cylinder 34 , blanket cylinder 36 may need to be accelerated or decelerated so that the surface velocity of contacting portion 37 equals the velocity of web 14 and so that contacting portion 37 is in a proper position as blanket cylinder 36 prints the next second image on web 14 .
Blanket cylinder 26 prints first images on web 14 that are separated from one another by a distance that is equal to the length of each second image printed by blanket cylinder 36 . Blanket cylinder 36 prints second images on web 14 that are separated from each other by a distance that is equal to the length of each first image printed by blanket cylinder 26 . Thus, blanket cylinders 26 , 36 are phased so that each blanket cylinder 26 , 36 prints every other image on web 14 and no unprinted space is left between adjacent first and second images printed by blanket cylinders 26 , 36 , respectively, on web 14 .
In one embodiment, each first image printed on web 14 by blanket cylinder 26 may be a first image portion and each second image printed on web 14 by blanket cylinder 36 may be a second image portion, so that the each first image portion and each second image portion form a single continuous image. Thus, together blanket cylinders 26 , 36 may act together to print a single image on web 14 .
Each cylinder 16 , 24 , 26 , 34 , 36 may be driven by a motor 101 , 102 , 103 , 104 , 105 , respectively. Motors 101 , 102 , 103 , 104 , 105 may be controlled by a controller 110 , which acts to ensure that blanket cylinders 26 , 36 are traveling at appropriate surface velocities when blanket cylinders 26 , 36 contact plate cylinders 24 , 34 , respectively, and web 14 and that blanket cylinders 26 , 36 print images on web 14 at appropriate locations. Motors 102 , 104 may also drive inkers 22 , 32 , respectively. In an alternative embodiment, plate cylinders 24 , 34 may be driven by a single motor.
In order to vary a cutoff of images printed by printing unit 10 , plate cylinders 24 , 34 may be altered so that plate cylinders 24 , 34 transfer respective first and second replacement images to blanket cylinders 34 , 36 . This may be accomplished by removing plates, which may be disposed about plate cylinders 24 , 34 and carry the respective first and second images, from plate cylinders 24 , 34 and replacing the plates with replacement plates that carry the respective first and second replacement images. When the first and second replacement images are of a length that varies from the length of contacting portions 27 , 37 , respectively, the velocity that blanket cylinders 26 , 36 are rotated and the phasing of blanket cylinders 26 , 36 may be adjusted so that blanket cylinders 26 , 36 properly receive the first and second replacement images from plate cylinders 24 , 34 , respectively, and print the first and second replacement images in proper alignment on web 14 .
FIG. 2 a shows a table including predicted results for printing section 20 of the embodiment shown in FIG. 1 , under five scenarios 201 , 202 , 203 , 204 , 205 , where the velocity of web 14 is constant. Because printing sections 20 , 30 operate in the same manner, the predicted results may also apply to printing section 30 .
For scenario 201 , blanket cylinder 26 prints first images on web 14 during 180 degrees of each revolution. The surface velocity of plate cylinder 24 is equal to the velocity of web 14 and blanket cylinder 26 travels at a constant speed during each revolution, with a surface velocity of contacting portion 27 equal to the velocity of web 14 . Blanket cylinder 26 does not accelerate or decelerate throughout each revolution.
For scenario 202 , blanket cylinder 26 prints first images on web 14 during 120 degrees of each revolution and contacting portion 27 makes up one third of the circumference of blanket cylinder 26 . The surface velocity of plate cylinder 24 is more than twice the velocity of web 14 . Blanket cylinder 26 accelerates for 60 degrees after printing a first image on web 14 and decelerates for 60 degrees after receiving a first image from plate cylinder 24 . After printing a first image on web 14 , blanket cylinder 26 rotates 240 degrees in the time it takes web 14 to travel a distance that equals a length of a second image printed by contacting portion 37 , in order to be back in proper printing position. While not printing on web 14 , contacting portion 27 has an average surface velocity that equals twice the velocity of web 14 .
For scenario 203 , blanket cylinder 26 prints first images on web 14 during 90 degrees of each revolution. The surface velocity of plate cylinder 24 is more than three times the velocity of web 14 . Blanket cylinder 26 accelerates for 90 degrees after printing a first image on web 14 and decelerates for 90 degrees after receiving a first image from plate cylinder 24 . After printing a first image on web 14 , blanket cylinder 26 rotates 270 degrees in the time it takes web 14 to travel a distance that equals a length of a second image printed by contacting portion 37 , in order to be back in proper printing position. While not printing on web 14 , contacting portion 27 has an average surface velocity that equals three times the velocity of web 14 .
For scenario 204 , blanket cylinder 26 prints first images on web 14 during 72 degrees of each revolution. The surface velocity of plate cylinder 24 is more than four times the velocity of web 14 . Blanket cylinder 26 accelerates for 108 degrees after printing a first image on web 14 and decelerates for 108 degrees after receiving a first image from plate cylinder 24 . After printing a first image on web 14 , blanket cylinder 26 rotates 288 degrees in the time it takes web 14 to travel a distance that equals a length of a second image printed by contacting portion 37 , in order to be back in proper printing position. While not printing on web 14 , contacting portion 27 has an average surface velocity that equals four times the velocity of web 14 .
For scenario 205 , blanket cylinder 26 prints first images on web 14 during 60 degrees of each revolution. The surface velocity of plate cylinder 24 is more than five times the velocity of web 14 . Blanket cylinder 26 accelerates for 120 degrees after printing a first image on web 14 and decelerates for 120 degrees after receiving a first image from plate cylinder 24 . After printing a first image on web 14 , blanket cylinder 26 rotates 300 degrees in the time it takes web 14 to travel a distance that equals a length of a second image printed by contacting portion 37 , in order to be back in proper printing position. While not printing on web 14 , contacting portion 27 has an average surface velocity that equals five times the velocity of web 14 .
FIG. 2 b shows a graph illustrating the surface velocity of contacting portion 27 for each 360 degree revolution of blanket cylinder 26 for scenarios 202 , 203 , 205 shown in the table of FIG. 2 a . The graph assumes uniform acceleration and deceleration of blanket cylinder 26 between printing on web 14 and receiving images from plate cylinder 24 . Web 14 is traveling at a constant velocity of 100 fpm and equals a minimum surface velocity of blanket cylinder 26 in scenarios 202 , 203 , 205 . Each scenario 202 , 203 , 205 has a different maximum surface velocity, which equals a surface velocity of plate cylinder 24 for the respective scenario 202 , 203 , 205 . For scenario 202 , blanket cylinder 26 has a maximum surface velocity of 300 fpm. For scenario 203 , blanket cylinder 26 has a maximum surface velocity of 500 fpm. For scenario 205 , blanket cylinder 26 has a maximum surface velocity of 900 fpm.
FIG. 3 shows a printing unit 310 of a printing press according to an embodiment of the present invention. Printing unit 310 includes printing sections 320 and 330 that operate in essentially the same manner as printing sections 20 , 30 except that blanket cylinders 326 , 336 of printing unit 310 do not include relieved portions and contacting portions and the axes of blanket cylinders 326 , 336 do not remain stationary during operation. Inkers 22 , 32 feed ink to plate cylinders 24 , 34 , which transfer inked images to blanket cylinders 326 , 336 .
Blanket cylinder 326 is translated between two positions 326 a , 326 b by an actuator 130 during each revolution. In position 326 a , blanket cylinder 326 receives first images from plate cylinder 24 and a surface velocity of blanket cylinder 326 equals the surface velocity of plate cylinder 24 . In position 326 b , blanket cylinder 326 prints first images on web 14 and the surface velocity of blanket cylinder 326 equals the velocity of web 14 . As blanket cylinder 326 is translated between positions 326 a , 326 b blanket cylinder 26 may be accelerated or decelerated to ensure that blanket cylinder 326 is traveling at an appropriate velocity when blanket cylinder 326 comes into contact with plate cylinder 24 or web 14 .
Blanket cylinder 336 is translated between two positions 336 a , 336 b by an actuator 132 during each revolution. In position 336 a , blanket cylinder 336 receives second images from plate cylinder 34 and a surface velocity of blanket cylinder 336 equals the surface velocity of plate cylinder 34 . In position 336 b , blanket cylinder 336 prints second images on web 14 and the surface velocity of blanket cylinder 336 equals the velocity of web 14 . As blanket cylinder 336 is translated between positions 336 a , 336 b blanket cylinder 336 may be accelerated or decelerated to ensure that blanket cylinder 336 is traveling at an appropriate velocity when blanket cylinder 336 comes into contact with plate cylinder 34 or web 14 .
In order to vary a cutoff of images printed by printing unit 310 , plate cylinders 24 , 34 may be altered so that plate cylinders transfer first and second replacement images to blanket cylinders 34 , 36 . This may be accomplished by removing plates, which may be disposed about plate cylinders 24 , 34 and carry the respective first and second images, from plate cylinders 24 , 34 and replacing the plates with replacement plates that carry the respective first and second replacement images. The velocity that blanket cylinders 326 , 336 are rotated and the phasing of blanket cylinders 326 , 336 may be adjusted so that blanket cylinders 326 , 336 properly receive the first and second replacement images from plate cylinders 24 , 34 , respectively, and print the first and second replacement images on web 14 so the first and second replacement images are properly aligned and there are no unprinted spaces between the first and second replacement images. The translation of blanket cylinders 326 , 336 between respective positions 326 a , 336 a and respective positions 326 b , 336 b may also be adjusted so that blanket cylinders 326 , 336 contact plate cylinders 24 , 36 and web 14 for the proper amount of time to receive and print the replacement images on web 14 .
FIG. 4 shows a schematic side view of a four color offset printing press 400 including one central impression cylinder 405 according to an embodiment of the present invention. Four printing units 402 , 404 , 406 , 408 are disposed about central impression cylinder 405 and print on a web 410 that passes over an outer surface of central impression cylinder 405 . Each printing unit includes two plate cylinders 424 , 434 and two blanket cylinder 426 , 436 , as well as a set of inkers for each plate cylinder 424 , 434 . Printing units 402 , 404 , 406 , 408 may be configured the same as and operate in essentially the same manner as printing unit 10 shown in FIG. 1 or printing unit 310 shown in FIG. 3 . Blanket cylinders 426 , 436 may include contacting and relieved portions or blanket cylinders 426 , 436 may be translated between positions of contacting web 410 and plate cylinders 424 , 434 , respectively. Each printing unit 402 , 404 , 406 , 408 prints in a different color on web 410 , so that printing units 402 , 404 , 406 , 408 print images that overlap and form four color images on web 410 .
FIG. 5 shows a schematic side view of a four color offset printing press 500 according to an embodiment of the present invention. Printing press 500 includes four printing units 502 , 504 , 506 , 508 printing images on a web 510 . Each printing unit 502 , 504 , 506 , 508 includes two plate cylinders 524 , 534 , two blanket cylinder 526 , 536 , and one impression cylinder 516 , as well as a set of inkers for each plate cylinder 524 , 534 . Printing units 502 , 504 , 506 , 508 may be configured the same as and operate in the same manner as printing unit 10 shown in FIG. 1 or printing unit 310 shown in FIG. 3 . Blanket cylinders 526 , 536 may include contacting and relieved portions or blanket cylinders 526 , 536 may be translated between positions of contacting web 510 and plate cylinders 524 , 534 , respectively. Each printing unit 502 , 504 , 506 , 508 prints in a different color on web 510 , so that printing units 502 , 504 , 506 , 508 print images that overlap and form four color images on web 510 . In one alternative embodiment each printing unit 502 , 504 , 506 , 508 may include two impression cylinders in place of impression cylinder 516 , with each blanket cylinder 526 , 536 contacting one impression cylinder. In another alternative embodiment printing press 500 may be a perfecting printing press with printing units 502 , 504 , 506 , 508 printing on both sides of web 510 .
In the preceding specification, the invention has been described with reference to specific exemplary embodiments and examples thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of invention as set forth in the claims that follow. The specification and drawings are accordingly to be regarded in an illustrative manner rather than a restrictive sense.
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A variable cutoff printing press is provided. The printing press includes a first plate cylinder rotating at a constant angular velocity and printing on a web during each revolution about a first plate cylinder axis and a first blanket cylinder rotating at varying angular velocities during each revolution about a first blanket cylinder axis. The first blanket cylinder comes in and out of contact with the first plate cylinder during operation. A method of variable cutoff printing is also provided.
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BACKGROUND OF THE INVENTION
The field of the invention is generally related to a multi-purpose portable table and hand truck or dolly of the type used for displaying and transporting items.
Multi-purpose portable tables are often utilized for both indoor and outdoor activities to provide support for displaying items or a work/play space for a wide variety of activities. However, the term “portable table” is often relative because many such tables though movable and transportable are, in fact, very difficult to transport. In addition, even when the portable table is amenable to being transported, the user often must make several trips from their original location to their destination in order to separately and individually transport items that are to be located on the workspace of the table. In order to overcome these shortcomings, background art portable tables have often been enhanced by being equipped with wheels and base plates that facilitate transporting the portable table and moving items to be used in the workspace of the table. However, further enhancements of portable tables could provide an even more user friendly portable table apparatus.
Some examples of background art in this field of invention include U.S. Pat. Nos. 4,565,382 and 4,934,718. The 382' patent is a combined portable table top 11 and hand truck 10 with an open-sided load supporting rack 28 for transporting items and with retaining means 32 for controlling the items being transported. The 718' patent is a multi-purpose hand truck 1 having an open-sided toe plate 7 for transporting items and a table top 10 for a workspace. However, the open-sided nature of the plate for transporting items of the hand trucks of the 718' and 382' patents do not allow the hand trucks of these patents to be effective for carrying small items that can not be easily restrained or that may roll and thus, need to be contained while in transport.
Other examples of the background art in this field of invention include U.S. Pat. Nos. 3,064,989 and 5,161,811. The 989' patent is a wheeled dolly 10 with a foldable supporting frame 6 having an open-sided support member 19 for transporting items when used as a dolly/hand truck. The 811' patent is a trolley/hand truck with a foldable seat 22 instead of a table top and a support frame 13 that, as in the 989' patent, provides an open-side support member for transporting items when used as a hand truck. In addition, both the wheeled dolly of the 989' patent and the trolley/hand truck of the 811' patent provide a minimal amount of supporting surface (i.e., merely the support frame members) behind the items being transported when used as a hand truck. Thus, the 989' and 811' patents have the same shortcomings as the 382' and 718' patents discussed above and additional disadvantages with regard to the limited amount of supporting surface available for use when transporting items.
Yet other examples of the background art in this field of invention include U.S. Pat. Nos. 5,957,472 and 6,371,495. The 472' patent is an apparatus 10 forming a combined hand truck and table top/machine support 16 . The combined hand truck and table top of the 472' patent includes an open-sided base plate 34 for transporting items, and thus, the 472' patent has the same shortcomings as the 382', 718' and 811' patents discussed above.
The 495' patent is a table frame 60 with fold out legs 40 and a trolley 30 with a support plate 90 . In contrast to the above discussed patents, support plate 90 further includes support blocks 92 which partially enclose the sides of the support plate 90 . However, the 495' patent is still not effective for transporting small items that can not be easily restrained or that may roll between the openings in the support blocks.
Therefore, there is a need in the art for a combined multi-purpose portable combined table and dolly/hand truck that can be easily set-up; and conveniently move and securely transport items of various shapes, sizes and configurations from one location to another.
SUMMARY OF THE INVENTION
The present invention is directed to a collapsible combined table and dolly that is portable and capable of securely transporting items or various sizes and configurations. The present invention provides ease o 1 operation through a collapsible/expandable table top and convenient means of transporting and storing items for use in the display/workspace of the table.
An embodiment of the present invention is a collapsible combined table and dolly comprising: a stand-alone support frame; a removable handle adjustably connected to an upper portion of the support frame; a table rotatably connected to the upper portion of the support frame by a first set of hinges; expandable support means rotatably connected to the table and the support frame, that gradually raise table to a horizontal open configuration or assist with closing table to a vertical stowed position; a spring-activated release/locking mechanism, connected to one side of the support frame that, when manually-activated, releases the table to be raised by the expandable supports into a horizontal position, or locks the table; when it is manually-closed in a vertical stowed position;
telescoping legs rotatably connected to the table by a second set of hinges, that when manually deployed, use pivot levers to release/lock legs at selected height with audible sound when locked; wheels rotatably connected to a back side of a lower portion of the support frame that include a spring-actuated locking mechanism for each wheel, mounted on the support frame; a four-sided dolly supporting plate with one side connected to a front side of the lower portion of the support frame; the three remaining sides of the supporting plate are connected on each side, by hinges, to corresponding, smaller flush-mounted plates; the Three corresponding plates can be raised to a vertical position from the supporting plate, to interlock with each other and the support frame, to create a four-sided material containment box for secure transportation of goods by the combined table and dolly when table is in a stowed position; and supporting legs configured to support the dolly supporting plate.
Preferably, the handle is configured to be adjustable or can be removable to provide for a flush table surface. Further, the adjustable handle preferably includes spring loaded pins that facilitate the height adjustment or total removal of the adjustable handle. Alternatively, the adjustable handle may include manual pins with clips for height adjustment.
Preferably, the release mechanism is configured to release the table from a collapsed configuration so that the table rises to an open configuration. Further, the release mechanism is preferably foot-activated. Furthermore, the table preferably includes hydraulic or gas-charged struts as the expandable support mechanism that is configured to gradually raise the table top into the open configuration.
Preferably, the locking mechanism is foot-activated and configured to lock the wheels of the table and dolly. Further, the wheels preferably include ball bearings so the combined table and dolly can be configured for towing by a low-speed vehicle, such as a golf-cart.
Preferably, the dolly support plate further includes wire mesh that encloses the sides of the support plate. Alternatively, the support plate may include sides at least one of wire mesh panels and solid panels that can be collapsed or folded down flat and to the level of the surface plate in order to further increase the useful area of the surface plate. Further, the wire mesh is preferably configured to securely contain items while the items are being at least one of transported by the dolly and stored beneath the table. Alternatively, the dolly support plate may be made of a solid material that contains items of all sizes.
Preferably, the telescoping legs include spring loaded pins configured to provide for height adjustment of the telescoping legs. Further, the telescoping legs are preferably made of at least one of aluminum, steel and plastic. In one embodiment, the telescoping legs are connected to one another by a brace located between the telescoping legs. Moreover the telescoping legs include grips at the ends of the telescoping legs that contact the ground and leg locking braces to further stabilize the table by locking the telescoping legs into position.
Preferably, the table is made of at least one of aluminum, steel, plastic and wire mesh. Further, the table is preferably configured to support at most 150 pounds. Furthermore, the table is preferably configured to include hinges that rotate the telescoping legs into an extended position in the open configuration and clips that lock the telescoping legs in a collapsed position in a collapsed configuration.
Preferably linking pins and linking notches and or linking clips or bands can be configured to provide a secure interconnect of a first combined table and dolly to a second combined table and dolly in order to extend the size of the surface of the table. In addition, table connecting pins and notches and or linking clips or bands are used to link the tables of multiple combined table and dolly apparatus end-to-end to extend length of tables in the direction of travel and provide one contiguous table surface. Alternatively linking pins and linking notches and or linking clips or bands can he used to connect tables side-by-side to extend width.
Preferably, when the telescoping legs are retracted, the table closes into a vertical position by manual pressure until the release/locking mechanism that is configured to hold the table in the closed position is engaged.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be described in greater detail with the aid of the following drawings.
FIG. 1 . is a front elevational view of an exemplary embodiment of the collapsible combined table and dolly in an open configuration.
FIG. 2 . is a right side elevational view of an exemplary embodiment of the collapsible combined table and dolly in an open configuration.
FIG. 3 . is a rear elevational view of an exemplary embodiment of the collapsible combined table in an open configuration.
FIG. 4 . is a top side elevational view of an exemplary embodiment of the collapsible combined table and dolly in an open configuration.
FIG. 5 . is a bottom side elevational view of an exemplary embodiment of the collapsible combined table and dolly in an open configuration.
FIG. 6 . is a right side elevational view of an exemplary embodiment of the collapsible combined table and dolly in a collapsed configuration.
FIG. 7 . is a front elevational view of an exemplary embodiment of the collapsible combined table and dolly in a collapsed configuration.
FIG. 8 . is a back elevational view of an exemplary embodiment of the collapsible combined table and dolly in a collapsed configuration.
FIG. 9 . is a front elevational view of an alternative exemplary embodiment of the collapsible combined table and dolly in an open configuration.
FIG. 10 . is a fragmental view in elevation of the height alignment assembly of the alternative embodiment with portions broken away to show functional details.
FIG. 11 . is a side elevational view of an exemplary embodiment of two collapsible combined table and dolly apparatus in a linked configuration.
FIG. 12 . is a side elevational view of an alternative exemplary embodiment of two collapsible combined table and dolly in a linked configuration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Example applications of the collapsible combined table and dolly include industrial, delivery, and construction settings as well as craft shows, flea markets, catering or other events where easily manageable display/work space is required.
FIG. 1 . is a front side elevational view of an exemplary embodiment of the collapsible combined table and dolly in an open configuration. In particular, FIG. 1 shows the table 1 in the open position and supported by the telescoping legs 3 , 4 and expandable supporting means 7 , 8 . The telescoping table legs 3 , 4 are preferably made of at least one of aluminum, steel and plastic. The table 1 is attached to the support frame 13 by hinges 25 , 26 . The expandable supporting means 7 , 8 are attached to both the table 1 and the support frame 13 and ball studs and clips. Preferably, the expandable supporting means 7 , 8 are hydraulic or gas struts. The hydraulic or gas-charged struts 7 , 8 are configured to gradually raise the table 1 to an open configuration. The hydraulic or gas-charged struts 7 , 8 rotate on the ball studs as the table opens. Typical hydraulic or gas-charged struts may be obtained from Monroe Shocks and Struts, One International Drive, Monroe, Mich. 48161; or STRUTWISE, 14468 88 Avenue, Surrey BC V3S 2R9, Canada. An exemplary gas-charged strut is the Monroe Max-Lift® Gas-Charged Lift Support.
In addition, FIG. 1 shows the telescoping legs 3 , 4 are attached to the table 1 through hinges 23 , 24 . The telescoping table legs 3 , 4 preferably include spring loaded pins (not shown) that can be aligned using the height alignment holes 27 , 28 . With height alignment, the telescoping table legs 3 , 4 can be configured to properly adjust the height of the table 1 in accordance with the level of the surface that each individual telescoping table leg 3 , 4 is contacting. The telescoping table legs 3 , 4 also preferably include grips 5 , 6 at the ends that are contacting the surface. The grips 5 , 6 are preferably made of rubber to provide some traction for the combined table and dolly in the open configuration.
Further, FIG. 1 shows a dolly support plate 9 that is connected to the support frame 13 . The dolly support plate 9 preferably includes a wire mesh bottom 10 and wire mesh or solid sides 33 , 34 , 35 , 36 that can enclose and contain items of various shapes, sizes and configurations that may be transported by the dolly or stored beneath the table. Alternatively, the bottom 10 of the dolly support plate 9 may be also be made of a solid materials, such as plastic, aluminum or steel, in order to prevent items that are stored or transported from falling out or off of the dolly support plate 9 . In addition, the dolly support plate 9 also includes support legs 11 , 12 with grips, preferably of rubber, for traction.
Furthermore, FIG. 1 shows wheels 17 , 18 that make the combined table and dolly easily movable. Preferably, the wheels 17 , 18 include ball bearings so the combined table and dolly can be configured for towing by a low-speed vehicle, such as a golf cart. Moreover, FIG. 1 , shows locking means 19 , 20 that can be, but are not limited to, foot activated. The locking means 19 , 20 are configured to lock the wheels 17 , 18 of the combined table and dolly when the table 1 is in use. Typical locking means can be obtained from Associated Technocrats Pvt. Ltd, A-318, Ansal Chambers-I3, Bhikaji Cama Place, New Delhi-110 066, India. An exemplary device is the DURATOOL HDTC-35 Toggle Clamp. In addition, a release/locking mechanism 52 is configured to both release the table top to an open position and secure the collapsed table top in a closed position. The release/locking mechanism 52 can be, but are not limited to, foot activated.
Moreover, FIG. 1 shows table connecting pins 21 , 22 . Table connecting pins 21 , 22 are used to link the tables 1 of multiple combined table and dolly apparatus to extend and provide one contiguous table surface by connecting tables end-to-end using a bracket to connect the pins 21 , 22 and hold the tables in place. Alternatively linking pins 53 and linking notches 54 can be used to connect tables side-by-side. In an alternative embodiment, linking pins 53 and linking notches 54 may also be mounted on the ends of the table and used to connect the tables end-to-end. Various embodiments of these linked table configurations are shown in FIG. 11 and FIG. 12 and will be discussed in more detail below. In addition, pins located by the handle allow for handle height adjustment.
FIG. 2 . is a right side elevational view of an exemplary embodiment of the collapsible combined table and dolly in an open configuration. FIG. 2 shows the table 1 in the open position and supported by the telescoping leg 3 and expandable supporting means 7 . The table 1 is attached to the support frame 13 by hinge 25 . The expandable supporting means 7 is attached by ball studs and clips to both the table 1 and the support frame 13 . The telescoping leg 3 is attached to the table 1 through hinge 23 . The telescoping table leg 3 also includes grip 5 at the end that contacts the ground. In addition, the support legs 11 , 12 of the surface plate 9 include grips 11 ′, 12 ′ that contact the ground.
Further, FIG. 2 shows dolly support plate 9 is connected to the support frame 13 . The dolly support plate 9 preferably includes a wire mesh bottom 10 . Alternatively, bottom of the dolly support plate 9 may be also be made of a solid material.
As shown in FIG. 2 , wire mesh or solid sides 55 can be folded upward and secured in a raised position to fully enclose the dolly support plate 9 . Cut-outs and hooks are located in at least the corners of the wire mesh or solid sides 55 in order to easily lock and unlock the sides 55 together when folded upward to fully enclose the dolly support plate 9 . The cut-outs are preferably square and the hooks are preferably L-shaped and provide an interlocking mechanism that secures the sides 55 . A hinge on the wire mesh or solid sides 55 allows the sides to fold down and outward to a position flush with the surface of the dolly support plate 9 . The folded down position of the wire mesh or solid sides 55 provides an expanded surface area for the dolly support plate 9 . Typical foldable wire mesh sides can be obtained from Midwest Homes for Pets, Box 1031, Muncie, Ind. 47308. An exemplary wire mesh device with sides that can be folded up or down is Model 1624UL.
In addition, the dolly support plate 9 also includes support leg 11 . Further, FIG. 2 shows wheel 17 with locking means 19 and notches 54 for connecting tables side-by-side. The notches 54 are matched by complimenting pins 53 located on the opposite side of the table 1 .
Furthermore, FIG. 2 shows the operation of the adjustable handle 15 that is configured to include spring loaded or manual pins 29 so that the adjustable handle 15 can be at least one of adjusted in height or totally removed. The height adjustment is obtained by way of aligning the spring loaded or manual pins 29 with the height adjustment slots 31 , 32 . Alternatively, the adjustable handle 15 can be totally removed to provide a flush surface for the table 1 .
FIG. 3 . is a rear elevational view of an exemplary embodiment of the collapsible combined table and dolly in an open configuration. FIG. 3 shows the table 1 in the open position and supported by the telescoping legs 3 , 4 and expandable supporting means 7 , 8 . The table 1 is attached to the support frame 13 by hinges 25 , 26 . The expandable supporting means 7 , 8 are attached to both the table 1 and the support frame 13 by clips and ball studs. The telescoping leg 3 , 4 are attached to the table 1 through hinges 23 , 24 . The telescoping table leg 3 , 4 also includes grips 5 , 6 at the ends that are in contact with the ground. FIG. 3 also shows adjustable handle 15 , wheels 17 , 18 with locking means 19 , 20 , and table linking pins 21 , 22 , and release/locking mechanism 52 .
FIG. 4 . Is a top side elevational view of an exemplary embodiment of the collapsible combined table and dolly in an open configuration. FIG. 4 shows the table 1 and table linking pins 21 , 22 , linking pins 53 , and notches 54 are located near at least one of the front, rear, left and right sides of table 1 . Linking pins 53 on one side of the table 1 have corresponding linking notches 54 on the opposite side of the table 1 (e.g., front-rear, left-right). Also shown in FIG. 4 are the adjustable handle 15 , wheels 17 , 18 locking means 19 , 20 , and release/locking mechanism 52 that is spring-actuated 57 .
FIG. 5 . is a bottom side elevational view of an exemplary embodiment of the collapsible combined table and dolly in an open configuration. FIG. 5 shows the table 1 and table linking pins 21 , 22 located near the front edge of table 1 . Alternatively, linking pins 53 and linking notches 54 may be used for linking tables. The telescoping legs 3 , 4 are attached to the table 1 through hinges 23 , 24 . Also shown in FIG. 5 are the wheels 17 , 18 and locking means 19 , 20 . Further, FIG. 5 provides a bottom view of the support plate 9 that includes a wire mesh bottom 10 with wire mesh or solid sides 33 , 34 , 35 , 36 . The front end side of the support plate 9 further includes support legs 5 , 6 .
FIG. 6 . is a right side elevational view of an exemplary embodiment of the collapsible combined table and dolly in a collapsed configuration. FIG. 6 shows the table 1 in the collapsed position and supported with the telescoping leg 3 and expandable supporting means 7 located within the inside surface of table 1 . The dolly/table 1 is supported in the collapsed position by the wheels 17 , 18 and the support legs 11 , 12 of the support plate 9 . The collapsed table 1 is attached to the support frame 13 by hinge 25 . Further, FIG. 6 shows dolly support plate 9 is connected to the support frame 13 .
As shown in FIG. 6 , wire mesh or solid sides 55 can be folded upward and secured in a raised position to fully enclose the dolly support plate 9 . Cut-outs and hooks are located in at least the corners of the wire mesh or solid sides 55 in order to easily lock and unlock the sides 55 together when folded upward to fully enclose the dolly support plate 9 . The cut-outs are preferably square and the hooks are preferably L-shaped and provide an interlocking mechanism that secures the sides 55 . A hinge on the wire mesh or solid sides 55 allows the sides to fold down and outward to a position flush with the surface of the dolly support plate 9 . The folded down position of the wire mesh or solid sides 55 provides an expanded surface area for the dolly support plate 9 . Typical foldable wire mesh sides can be obtained from Midwest Homes for Pets, Box 1031, Muncie, Ind. 47308. An exemplary wire mesh device with sides that can be folded up or down is Model 1624UL.
In addition, the dolly support plate 9 also includes support leg 11 . Further, FIG. 6 shows wheel 17 with locking means 19 , and linking pins 53 and notches 54 for connecting tables side-by-side. The notches 54 are matched by complimenting linking pins 53 located on the opposite side of the table 1 .
Furthermore, FIG. 6 shows wheel 17 with locking means 19 . Moreover, adjustable handle 15 is configured to include spring loaded or manual pins 29 so that the adjustable handle 15 can be at least one of adjusted in height or totally removed. The height adjustment is obtained by way of aligning the spring loaded pins 29 with the height adjustment slots 31 . In addition, linking pins 53 and linking notches 54 for connecting tables are included.
FIG. 7 . is a front elevational view of an exemplary embodiment of the collapsible combined table and dolly in a collapsed configuration. In particular, FIG. 7 shows the table 1 in the collapsed position and with the telescoping legs 3 , 4 and expandable supporting means 7 , 8 folded within the inside surface of the table 1 . The telescoping table legs 3 , 4 also preferably include grips 5 , 6 at the ends. Further, FIG. 7 shows a dolly support plate 9 that is connected to the support frame 13 . Wheels 17 , 18 make the combined table and dolly easily movable and locking means 19 , 20 that are configured to lock the wheels 17 , 18 of the combined table and dolly when required. Moreover, FIG. 7 shows table connecting pins 21 , 22 , linking pins 53 and linking notches 54 . Table connecting pins 21 , 22 , linking pins 53 and linking notches 54 are used to link the table 1 of multiple combined table and dolly apparatus to provide an extended and continuous table surface.
FIG. 8 . is a back elevational view of an exemplary embodiment of the collapsible combined table and dolly in a collapsed configuration. FIG. 8 shows the telescoping legs 3 , 4 and expandable support means 7 , 8 folded within the inside surface of table 1 . The table 1 folds down through the connection to hinges 25 , 26 . The table 1 is secured in the collapsed position through a release/locking mechanism 52 . The telescoping legs 3 , 4 fold against the table through hinges 23 , 24 and are secured by clips 41 , 42 . The collapsed telescoping legs 3 , 4 preferably include grips 5 , 6 at the ends and the height of adjustable handle 15 may be determined using height adjustment holes 31 , 32 . Moreover, table connecting pins 21 , 22 , linking pins 53 , and linking notches 54 are used to link the tables 1 of multiple combined table and dolly apparatus. A cross brace is used between the telescoping legs 3 , 4 .
Further, FIG. 8 shows a dolly support plate 9 that is connected to the support frame 13 . The support plate 9 also includes support legs 11 , 12 with grips 11 ′, 12 ′. Wheels 17 , 18 make the combined table and dolly easily movable and locking means 19 , 20 that are configured to lock the wheels 17 , 18 of the combined table and dolly when required.
FIG. 9 . is a front elevational view of an alternative exemplary embodiment of the collapsible combined table and dolly in an open configuration. In particular, FIG. 9 shows the table 1 in the open position and supported by the telescoping legs 3 ′, 4 ′ and expandable supporting means 7 , 8 . The telescoping legs 3 ′, 4 ′ of the alternative embodiment further include height alignment assemblies 27 ′, 28 ′. The telescoping legs 3 ′, 4 ′ are also connected in the alternative embodiment by crossbar element 29 . The telescoping table legs 3 ′, 4 ′ and crossbar element 29 are preferably made of at least one of aluminum and steel. Typical telescoping legs can be obtained from Carrand Companies, Inc., 1415 West Artesia Boulevard, Rancho Dominguez, Calif. 90220. The table 1 is attached to the support frame 13 by hinges 25 , 26 . The expandable supporting means 7 , 8 are attached to both the table 1 and the support frame 13 . Preferably, the expandable supporting means 7 , 8 are hydraulic or gas-charged struts. The hydraulic or gas-charged struts 7 , 8 are configured to gradually release the table 1 into an open configuration. As discussed above, an exemplary device is the Monroe Max-Lift® Gas-Charged Lift Support.
In addition, FIG. 9 shows the telescoping legs 3 ′, 4 ′ are attached to the table 1 through hinges 23 , 24 . The telescoping table legs 3 ′, 4 ′ preferably can be aligned using the height alignment assemblies 27 ′, 28 ′. With height alignment, the telescoping table legs 3 ′, 4 ′ can be configured to properly adjust the height of the table 1 to achieve a level table surface in accordance with the level of the surface that each individual telescoping table leg 3 ′, 4 ′ is contacting. The telescoping table legs 3 ′, 4 ′ also preferably include grips 5 , 6 at the ends that are contacting the surface. The grips 5 , 6 are preferably made of rubber to provide some traction for the combined table and dolly in the open configuration.
Further, FIG. 9 shows a dolly support plate 9 that is connected to the support frame 13 . The dolly support plate 9 preferably includes a wire mesh bottom 10 and sides that can enclose items of various shapes, sizes and configurations that may be transported by the dolly or stored beneath the table. Alternatively, the bottom 10 of the dolly support plate 9 may be also be made of a wire mesh or solid materials such as plastic, aluminum, steel in order to prevent items that are stored or transported from falling out or off of the dolly support plate 9 . In addition, the dolly support plate 9 also includes support legs 11 , 12 with grips 11 ′, 12 ′.
Furthermore, FIG. 9 shows wheels 17 , 18 that make the combined table and dolly easily movable. Preferably, the wheels 17 , 18 include ball bearings so the combined table and dolly can be configured for towing by a low-speed vehicle, such as a golf cart. Moreover, FIG. 9 , shows locking means 19 , 20 . The locking means 19 , 20 are configured to lock the wheels 17 , 18 of the combined table and dolly when the table 1 is in use. Moreover, FIG. 9 shows table connecting pins 21 , 22 , linking pins 53 and linking notches 54 . Table connecting pins 21 , 22 , linking pins 53 and linking notches 54 are used to link the table 1 of multiple combined table and dolly apparatus to provide one extended and contiguous table surface.
FIG. 10 . is a fragmental view in elevation of the height alignment assembly 27 ′, 28 ′ of the alternative embodiment with portions broken away to show functional details. FIG. 10 shows the telescoping legs 3 ′, 4 ′ with pin holes 51 set for predetermined height adjustments. The height alignment assembly 27 ′, 28 ′ includes a pivot mechanism 33 with a pin 35 for insertion into a pin hole 51 at a desired height. The pin 35 is kept in place by the pressure supplied by spring 37 against the pivot mechanism 33 . When a change in the height of a telescoping leg 3 ′, 4 ′ is desired, the pivot mechanism 33 is pressed so as to: (1) compress the spring 37 ; (2) move the pivot mechanism 33 in an inward direction 34 ; and (3) withdraw the pin 35 from a current pin hole 51 . The alignment assembly 27 ′, 28 ′ is then moved either up or down to locate an other pin hole 51 ′ at another desired height. Resilient surface 34 provides the user with a firm grip on the alignment assembly 27 ′, 28 ′ when the height adjustment is to be made. Once the other pin hole 51 ′ at the desired height is located, the pivot mechanism 33 is released and the pin 35 is inserted in the other pin hole to set the height of the telescoping leg 3 ′, 4 ′.
FIG. 11 . is a side elevational view of an exemplary embodiment linking two collapsible combined table and dolly apparatus in a linked configuration. A first collapsible combined table and dolly is represented in the FIG. 11 with primed reference numbers (e.g., 1 ′, 3 ′, 5 ′) in accordance with the descriptions above. A second collapsible combined table and dolly is represented in the FIG. 11 in accordance with the descriptions and the view of FIG. 2 above. A linking clip or band 39 can be used to connect the first and second collapsible combined table and dolly apparatus by connecting the linking clip or band 39 to linking pins 22 and 21 , respectively. This linked table configuration allows one to combine multiple tables and extend the length of the work/display surface, as well as providing multiple storage locations beneath the tables 1 , 1 ′. In an alternative embodiment, linking pins 53 and linking notches 54 may also be mounted on the front and rear ends of the table and used to connect the tables end-to-end. Alternatively linking pins 53 and linking notches 54 can also be used to connect tables side-by-side. Linking pins 53 and linking notches 54 can be used for connecting tables 1 , 1 ′ in a side-by-side configuration. The linking notches 54 are matched by complimenting linking pins 53 located on the opposite side of the tables 1 , 1 ′.
FIG. 12 . is a side elevational view of an alternative exemplary embodiment linking two collapsible combined table and dolly in a linked configuration. A first collapsible combined table and dolly is represented in the FIG. 12 with primed reference numbers (e.g., 1 ′, 3 ′, 5 ′) in accordance with the descriptions above. A second collapsible combined table and dolly is represented in the FIG. 12 in accordance with the descriptions above. A linking clip or band 39 is used to connect the first and second collapsible combined table and dolly apparatus by connecting to linking pins 22 and 21 , respectively. This linked table configuration allows one to combine multiple tables and extend the length of the work/display surface, as well as providing multiple storage locations beneath the tables 1 , 1 ′. In an alternative embodiment, linking pins 53 and linking notches 54 may also be mounted on the front and rear ends of the table and used to connect the tables end-to-end. Alternatively linking pins 53 and linking notches 54 can also be used to connect tables side-by-side. Linking pins 53 and linking notches 54 can be used for connecting tables 1 , 1 ′ in a side-by-side configuration. The linking notches 54 are matched by complimenting linking pins 53 located on the opposite side of the tables 1 , 1 ′.
The foregoing description illustrates and describes the present invention. Additionally, the disclosure shows and describes only the preferred embodiments of the invention, but as mentioned above, it is to be understood that the invention is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings and/or skill or knowledge of the relevant art. The embodiments described hereinabove are further intended to explain best modes known of practicing the invention and to enable others skilled in the art to utilize the invention in such or other embodiments and with the various modifications required by the particular applications or uses of the invention. Accordingly, the description is not intended to limit the invention to the form or application disclosed herein. Also, it is intended that the appended claims be construed to include alternative embodiments.
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The present invention is directed to a collapsible combined table and dolly that is portable and capable of securely transporting items of various sizes and configurations. The collapsible combined table and dolly provides ease of operation through a collapsible/expandable table top and convenient means for transporting and storing items for use in the display/workspace of the table.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an electric heating device for heating air which is in particular suited to be employed as additional electric heating in motor vehicles.
2. Description of the Related Art
For the employment in motor vehicles, in particular those with engines of which the consumption is optimized, electric heating devices are used to heat the passenger compartment andor the engine. An additional electric heating is in particular required after the starting of the engine as long as the internal combustion engine does not yet provide sufficient thermal energy. Internal combustion engines of which the consumption is optimized even principally require the use of an additional electric heating.
However, the use of such heating devices is not restricted to the field of motor vehicles; they are also suited for a plurality of other applications, for example in the field of domestic installations (room air conditioning), industrial plants and the like.
An electric heating device for motor vehicles is known from EP-A1-1 395 098. The described heating device comprises several heating elements assembled to a heating block. The heating block is held in a common frame together with a control means for controlling the heating elements. The control means thus forms a constructional unit together with the heating block held in the frame. The control means comprises power electronics with electronic switches which are provided each with a heat sink. The control means is arranged such that a portion of the air flow to be heated flows against the control means, in particular the cooler elements for cooling the electronic switches.
The electronic switches, in particular in the form of power transistors which control the current that is supplied to the heating elements, are mounted directly on a printed circuit board with one side. To dissipate the thermal loss generated by the power transistors, a cooler element is provided on the opposite side of the printed circuit board. Such a cooler element which directly contacts the power transistor can dissipate the thermal loss of the power transistor in a simple manner and in a sufficient amount.
In the above-mentioned prior art, a U-shaped heat sink with cooling fins or fingers, respectively, which project from a base, is employed. A pin is provided at the bottom side of the heat sink and can be inserted in the printed circuit board to contact the power transistor. However, a cooler element in the sense of the present invention can be any component which is suited to dissipate heat from the power transistors by heat conduction and emit it effectively to the air flowing around it by heat transfer. To this end, the cooler element is exposed to the air which is to be heated by the electric heating device, i.e. which flows in a channel leading to the electric heating device. However, it cannot be excluded that moisture collects in the channel which is either directly introduced with the inflowing air or is condensed from the air that has flowed in.
OBJECT OF THE INVENTION
It is therefore the object of the present invention to further develop an electric heating device of the type mentioned in the beginning, so that the same can be easily manufactured and the control means of the electric heating device can be reliably protected from penetrating moisture.
To achieve this object, an electric heating device having the features of claim 1 is provided with the present invention. It differs from the generic prior art in that the control means is held at a control means support and that between the control means support and a heating block housing accommodating the heating block sealing elements are provided through which the contact or cooler elements project and which are sealed by clamping between the control means support and the heating block housing.
In the electric heating device according to the invention, the constructional unit is provided in that the control means support is connected to the heating block housing. The contact elements which take care of the supply of the heating block with electric current as well as the cooler elements effecting the cooling of the electronic switches extend between the control means support and the heating block housing. The contact or cooler elements, respectively, project through at least one sealing element. The tightness of the sealing element is provided in that the sealing element is clamped between the control means support and the heating block housing. This permits to first mount the sealing elements without stresses and to clamp the respective sealing elements to achieve a sealing contact not before the constructional unit of the control means and the heating block is created, i.e. when the control means support is connected to the heating block housing. The electric heating device according to the invention can thereby be manufactured in a simple manner without having to dispense with a reliable sealing of the control means.
The electric heating device according to the invention can be particularly simply and therefore economically manufactured if the cooler element or elements, respectively, isare embodied as pin or plate-shaped solid bodies which are lead through the printed circuit board for their connection to the electronic switch (e.g. power transistor) and which project over the printed circuit board at the bottom side facing away from the electronic switch. In the contact area with the sealing element, at the cooler element or elements as well as at the contact elementor contact elements, sealing or contact surfaces for the sealing elements can be provided which differ from a cylindrical and thus the simple shape. Such embodiments are in particular preferred with respect to a radial clamping of the sealing elements against the inside circumference of the contact or cooler elements, respectively. Alternatively, the control means support andor the heating block housing can comprise conical mountings for the sealing elements which surround the passages for the contact or cooler elements, respectively. To generate a sealing contact of the sealing elements at the inside circumference of the passages on the one hand and the outside circumference of the contact elements or the cooler elements on the other hand, the sealing elements are fixed between the heating block housing and the control means support preferably axially, i.e. in the longitudinal direction of the cooler or contact elements, respectively. When the constructional unit consisting of the heating block housing and the control means support is being completed, the sealing elements through which the contact or cooler elements, respectively, project are compressed in the longitudinal direction of these elements leading to a sealing contact in the radial direction.
In electric heating devices of the type mentioned above, several electronic switches can be provided. Moreover, usually more than two contact elements for supplying the individual heating elements are provided, which practically project over the heating block housing at the frontal side at which the control means support is located. With respect to an assembly of the electric heating device as simple as possible, it is suggested according to a further preferred embodiment of the present invention to connect the sealing elements with each other to form an integral sealing unit. This integral sealing unit can be, for example, pre-fixed during the assembly in that the sealing unit is shifted onto the contact elements projecting over the heating block housing. In this manner, the sealing elements for the cooler elements at the heating block housing are also brought to a predetermined position corresponding to the position of the cooler elements if the control means support is connected to the heating block housing. The sealing unit can be manufactured as injection-molded part from a heat resisting thermoplastic elastomer. Such an injection-molded part can also be inserted, for example, as an insert into an injection mold which is used to manufacture the control means support or the heating block housing or a housing half of the same. In this manner, the joining steps for the manufacture of the heating device can be reduced.
If the sealing unit is, however, embodied as an insert which is separately mounted, it is preferred to connect the sealing elements with each other by a base section. To increase tightness, it can be preferred to clamp this base section at the edge of the passages between the heating block housing and the control means support in a sealing manner. Thereby, in addition to a possibly existing radial sealing effected by the sealing elements themselves, a sealing acting at right angles to the same is created. To generate clamping forces as high as possible, it is furthermore preferred to provide a projecting collar surrounding the mountings for the sealing elements on the side of the housing. With respect to an embodiment of the heating block housing as simple as possible, it is preferred here to provide this projecting collar at the control means support which should, for the same reason, also comprise the conical mountings for the sealing elements.
To improve sealing, it is suggested according to a further preferred embodiment of the present invention to embody the sealing element to each of the contact or cooler elements, respectively, with several sealing contact surfaces arranged on after the other in the longitudinal direction with respect to these contact or cooler elements. These are preferably arranged conically stepped with respect to each other and are preferably predetermined by sealing beads arranged one after the other. In the latter preferred embodiment, the sealing beads are situated spaced apart in the longitudinal direction of the contact or cooler elements, respectively, wherein the material of the sealing elements connecting the respective sealing beads with each other preferably forms a find of film hinge which permits a certain movability of the individual sealing beads with respect to each other in the longitudinal direction of the contact or cooler elements, respectively. This promotes the sealing contact of the individual sealing contact surfaces at the contact or cooler elements and the passages or the conical mountings, respectively.
To precisely fix the sealing elements or the sealing unit during the assembly of the electric heating device, it is suggested according to a further preferred embodiment of the present invention to provide a cross web at the heating block housing which covers window openings formed at the heating block housing, the cross web forming a contact surface for the base section of the sealing element and thereby first improving the sealing. To this end, the cross web practically forms an essentially plane contact surface for the base section. However, the cross web further comprises centering mountings according to a further preferred embodiment of the present invention, in which centering projections formed at the base section are received. These centering projections are preferably located at the bottom side of the base section facing away from the sealing elements. This bottom side is placed on the plane contact surface, whereby, due to the centering mountings, an accurate positioning of the sealing unit is effected which also favors the insertion of the contact or cooler elements during the further assembly of the electric heating device. To this end, the centering mountings preferably surround the passages for the cooler andor the contact element(s).
The constructional unit between the control means and the heating block is preferably prepared in that the heating block housing is connected to a control means housing which comprises the control means support. The control means housing has a housing lid which comprises at least one interface for the supply and control of the heating device. The control means housing furthermore surrounds a printed circuit board with cooler elements essentially projecting at right angles therefrom and electronic switches. The control means housing is to effect in particular a certain mechanical protection of the control means. It is not absolutely necessary for this control means housing to seal the control means against liquids. The control means housing is in particular used for the electric connection of the electric heating device as well as possibly the fixing of the control means or the complete heating device.
To easily manufacture the constructional unit, it is however preferred to press the parts accommodated in the control means housing and electrically connected with each other onto each other in the longitudinal direction of the contact or cooler elements. To this end, the housing lid preferably comprises a contact bar which is electrically connected to at least one of the interfaces as well as to the printed circuit board and is placed onto the printed circuit board, which means that the contact bar extends essentially at right angles to the plane of the printed circuit board. The printed circuit board furthermore comprises flexible tongues cooperating with the contact elements. These flexible tongues are electrically connected to strip conductors of the printed circuit board, the flexible tongues being dimensioned such that the contact elements lying against the flexible tongues are securely electrically connected to the printed circuit board. This connection is usually effected when the contact elements are introduced into the passages recessed at the control means support. The cooler elements firmly mounted to the printed circuit board here project through passages which are recessed at the heating block housing, preferably at the cross web. At the end of this introduction movement, the sealing elements are clamped between the control means support and the heating block housing.
The thus prepared constructional unit is preferably secured in that the control means support or the control means housing, respectively, is locked with the heating block housing.
Further advantageous embodiments of the present invention are given in the subclaims.
The present invention will be described below with reference to an embodiment in connection with the drawing. In the drawing:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective exploded view of an embodiment of an electric heating device according to the invention;
FIG. 2 shows a longitudinal section of an embodiment modified compared to FIG. 1 in an assembled condition; and
FIG. 3 shows an enlarged detail of the longitudinal section shown in FIG. 2 at the phase interface between the heating block housing and the control means housing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 , a perspective exploded drawing is shown essentially in form of a side view of an embodiment of the electric heating device according to the invention. As essential elements, it comprises a heating block housing 1 as well as a control means housing 2 . A sealing unit 3 is provided between the two housings 1 , 2 . The control means housing 2 surrounds a control means 4 .
The heating block housing 1 consists of two essentially identical frame halves 10 a , 10 b which are embodied in the present case as injection-molded plastic parts and at the surface of which a stiffening grid structure is embodied. A heating block 11 consisting of a plurality of layered or stacked heating elements 12 is arranged between the grid structures of the two frame halves 10 a , 10 b . Each of the heating elements 12 consists of one or several resistance heating elements, which in the representation according to FIG. 1 are covered behind the longitudinal struts of the stiffening grid, and of radiators 13 arranged adjacent thereto which are in the present case formed by sheet metal strips folded in a meandering manner. In view of a good heat transfer and contact of the radiators 13 at the resistance heating elements which are preferably formed by so-called PTC elements, a plane sheet metal strip is disposed between the PTC elements and the radiator 13 of a heating element 12 .
The heating block 11 of the heating elements 12 is held in the frame 10 formed by the two frame halves 10 a , 10 b . To this end, the frame 10 comprises oblong longitudinal spars 14 a , 14 b and lateral spars 15 a , 15 b extending at right angles thereto.
Between the upper lateral spar 15 a in FIG. 1 and the heating block 11 , window openings 16 are recessed in the shown embodiment. The longitudinal webs 17 separating adjacent window openings 16 surround a free end of the sheet metal strips arranged between the radiators 13 and the resistance heating elements which are continued outwards to form a contact stud 18 . The contact studs 18 project over the upper edge of the frame 10 in FIG. 1 .
The control means housing 2 has an essentially two-piece design with a lower housing part 21 comprising a control means support 20 and a housing lid 22 placed upon it. The lower housing part 21 has an essentially trough-like design and comprises mounting flanges 23 at its respective frontal sides for assembling the electric heating device at the chassis of a motor vehicle. The bottom of the lower housing part 21 forms the control means support 20 of which the surface that points to the inner side of the control means housing 2 is completely plane. The control means support 20 has several slotted first passages 24 a which are arranged so as to alternate with round passages 24 b in the longitudinal direction of the control means support 20 one after the other.
The first passages 24 a with rectangular cross-sections are formed in the longitudinal and transverse directions of the control means support 20 towards the control means housing 2 in a tapering manner. The second passages 24 b with a round cross-sectional area are formed so as to taper in the same direction. At the bottom side of the control means support 20 facing away from the interior of the control means housing, first and second collars 25 a , 25 b are located, the cross-sectional shape of which corresponds to the shape of the passages 24 . These collars 25 a , 25 b form the major portion of internal side walls of tapered mountings 26 a , 26 b . The control means support 20 is bordered by a double groove 27 opened to the bottom side which is embodied such that the edge of the heating block housing 1 on the frontal side fits inside the double grooves 27 .
The housing lid 22 forms a plug mounting 28 in which electric control contacts 29 are received. The housing lid 22 furthermore comprises two electric supply interfaces 30 a , 30 b which are shielded from each other by upright walls forming supply plug mountings 31 a , 31 b . The electric supply interface 30 b is electrically connected to a contact bar 32 which is formed by an electrically conductive sheet metal which comprises several contacts 33 at its frontal side facing the control means support 20 . Analogously, the control contacts 32 are electrically connected to each other with another control contact bar provided so as to be covered behind the contact bar 32 , which control contact bar also embodies contact pins at its frontal side.
The control means 4 is disposed between the lower housing part 21 and the housing lid 22 and comprises a printed circuit board 34 on the upper side of which four double-acting flexible tongues 35 and four power transistors 36 are arranged in contact with each other in an alternating manner in the longitudinal direction. The power transistors 36 are connected to cylindrical cooler elements 37 which are lead through openings recessed in the printed circuit board 34 and project over the bottom side of the printed circuit board 34 . The cylindrical cooler elements 37 are aligned with the second passages 24 b and the mountings 26 b embodied corresponding thereto.
The sealing unit 3 is formed of a heat resisting elastic material as a one-piece component, for example by means of injection molding or casting, and it comprises a band-shaped base section 40 . First and second sealing elements 41 a , 41 b project over the upper side of this base section, which points to the control means housing 2 . Corresponding to this, the bottom side of the base section 40 comprises centering mountings 47 a , 47 b ) cooperating with centering projections 42 a , 42 b of the sealing unit 3 . Each of the sealing elements 41 consists of two first and second sealing beads 43 a , 43 b arranged one after the other in the longitudinal direction of the cooler elements 37 or the contact studs 18 . The first sealing beads 43 a comprise a rectangular base with a recess embodied corresponding thereto, the second sealing beads 43 b comprise a correspondingly embodied circular basic shape. The lower sealing bead 43 ′ arranged adjacent to the base section 40 has larger dimensions than the sealing bead 43 ″ located thereabove. Each of the sealing beads 43 forms circumferential sealing contact surfaces 44 at its outer circumferential surface which lead, due to the stepped arrangement of the sealing beads 43 a , 43 b , to a conical embodiment of the outer sealing surface formed by the respective scaling element 41 a , 41 b (cf. FIG. 3 ). The inside circumference of the respective sealing beads 43 a , 43 b is essentially constant, so that the internal sealing contact surface 45 formed by the) beads 43 a , 43 b has a cylindrical extension.
To assemble the embodiment shown in the FIGS, for example the heating block housing 1 as well as the control means housing 2 are first completely prepared with the heating and control elements accommodated therein. To join the three essential elements, heating block housing 1 , control means housing 2 and sealing unit 3 , the sealing unit 3 is, for example, pre-assembled on the side of the heating block. To this end, the first sealing elements 41 a are shifted onto the contact studs 18 until the base section 40 rests on a cross web 46 represented in FIG. 3 which covers the window openings 16 on the upper side and recesses centering mountings 47 a , 47 b for the centering projections 42 as well as passages 48 for the cooler elements 37 leading to the window openings 16 . Then, the preassembled control means housing 2 is connected to the heating block housing 1 to form a constructional unit. The cooler elements 37 are to this end inserted into the associated sealing elements 41 b so as to be aligned with them until the upper edge of the heating block housing 1 is received in the internal double groove 27 . During this movement, the respective sealing elements 41 a , 41 b each enter the respective associated mountings 26 a , 26 b , are centered due to the conical embodiment and finally compressed in the radial direction as the base section 40 fixes the sealing unit 3 by the contact with the cross web 46 . At the same time, the free ends of the contact studs 18 are shifted through the passages 24 a into the interior of the control means housing 2 and between the double-acting flexible tongues 35 , whereby an electric contact between the flexible tongues 35 and the contact studs 18 is created.
At the end of the introduction movement, a radial pressure increasing with the introduction movement has built up and acts on the sealing elements 41 a , 41 b , which are now in sealing contact with the inside circumference of the mounting 26 on the one hand and with the outside circumference of the contact studs 18 or the cooler elements 37 , respectively. In the shown embodiment, there further is a particularity in that the height of the collars 25 a , 25 b is selected such that the collars 25 a , 25 b are placed against the base section 40 on the frontal side, which is thus clamped in the longitudinal direction of the cooler elements 37 or the contact studs 18 between the cross web 46 and the frontal sides of the collars 25 in a sealing manner.
In the constructional unit prepared in this manner, the control contacts 29 are in contact with the printed circuit board 34 by means of the control contact bar, the corresponding strip conductors of which are connected to the power transistors 36 . The contact pins 33 contact contact points provided at the printed circuit board 34 which lead to the power transistors 36 and can be applied to the flexible tongues 35 and thus to the contact studs 18 depending on the switching characteristic of the power transistors 36 . The electric supply interface 30 a for ground is electrically connected to the heating block housing 1 by means of electric strip conductors formed at the control means housing in the area of the double groove 27 . The cooler elements 37 are located with their front end in the respective window openings 16 .
The connection between the heating block housing 1 and the control means housing 2 can be secured in various manners, in particular by welding or gluing. The embodiment shown in the Figures is in particular suited for an inexpensive manufacture of the electric heating device as the lower housing part 21 as well as the housing lid 22 of the control means housing 2 , as well as the two housing halves 10 a , 10 b can be manufactured by means of injection molding. The sealing unit 3 is connected to the housings 1 , 2 during the assembly as insert manufactured separately from this housing.
The embodiment shown in FIG. 2 only differs from the one shown in FIG. 1 in that slotted heat conducting plates 49 are provided in the window openings 16 which are clipped to the front end of the cooler elements.
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An electric heating device that provides additional heating for motor vehicles includes several heating elements assembled to form a heating block, and a controller for controlling the heating elements. The controller forms a constructional unit together with the heating block. Contact and/or cooler elements extend between the controller and the heating block. The controller is held at a control means support. Between the controller support and a heating block housing accommodating the heating block, sealing elements are provided through which the contact or cooler elements project and which are sealed by clamping between the controller support and the heating block housing.
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BACKGROUND OF THE INVENTION
The present invention relates in general to fuel heater elements and the structural design features that are associated with installation and removal of the fuel heater element from a housing. More specifically, the present invention relates to a rod-shaped heater for a fuel-water separator that includes a cam removal feature. As disclosed herein, the cam removal feature includes a cooperation between the fuel heater and a portion of the fuel-water separator housing that facilitates removal of the heater from the housing.
In the field of diesel engine technology, it is not uncommon for diesel fuel to require heating in order to reduce the chances that the fuel will assume a gel-like consistency that would in turn be difficult to deliver and process. Often, a suitable heater is assembled as part of a fuel-water separator to try and eliminate this potential problem. As the fuel is filtered, water and particulate are separated and collected for removal. Since such a filter/separator may be used in low temperature conditions, though not continuously, the fuel heater is controlled by a thermostat that monitors the fuel temperature and is set to activate at a preset temperature, such as 35° F. When the fuel heater is energized, it generates a beat increase to the interior of the housing. This in turn liquefies any gelled fuel, allowing the fuel to flow freely.
While there are a variety of heater designs that are currently available or have been offered for use in fuel-water separators, a couple of the more common styles can be improved upon and are improved upon by the present invention. One such prior style is a ring heater that is installed into the filter/separator housing and is captured by its manner of insertion and attachment and/or by use of the closing lid. Ring heaters of the type described are relatively complex in construction and necessitate a fairly complex cooperating configuration within the filter housing. There may be added complexity, depending on the selected configuration and the interconnect with the thermostat and the electrical power connector.
One attempt to simplify the complexity of the ring heater is represented by the second prior style that can best be described as a rod heater. This descriptive name comes from the generally cylindrical shape of the fuel heater. This style of heater is typically threaded into a receiving bore in the fuel-water separator. Since there is fuel inside of the housing and since there is an internal pressure, it is important to adequately seal the interface between the heater and the separator housing. If a plastic housing is used, concerns have been raised as to whether sufficient tightening torque can be applied by way of the threaded engagement to adequately seal the threaded interface.
Another concern with a threaded engagement between the rod heater and the separator housing is the ability to establish the desired orientation for the electrical connector on the fuel heater relative to the housing. Over tightening or under tightening of the threaded engagement will cause the rotational position or orientation of the electrical connector to change. The starting point of the threaded engagement can also affect the orientation of the electrical connector. As such, the fuel heater may not be rotated into the preferred location for electrical connection to the heater wires from the wiring harness of the corresponding engine. It would therefore be an improvement if the heater could be installed in the housing with an automatic alignment capability. The present invention provides this improvement without relying on a threaded engagement between the heater and the fuel-water separator housing.
One of the realities of installing a rod heater into a fuel-water separator housing is the need to include a seal, such as an elastomeric O-ring seal, for establishing a sealed interface between the heater and the housing. Over time, the O-ring seal swells in size and becomes even tighter, tighter to the extent that it is difficult to break the O-ring seal free in order for removal of the heater. The effect of this O-ring seal swelling is to wedge the fuel heater into the separator housing to the point that the heater appears to be stuck and, as a result, not easily removed from the housing.
The present invention addresses this concern in a novel and unobvious way by creating a cooperating cam engagement between the fuel heater and the fuel-water separator housing. This cam action translates rotational motion of the fuel heater relative to the housing into an axial force to help break away the tightly wedged O-ring seal. Once the wedged seal is broken free, the fuel heater can be easily removed without the need for any special removal tool and without the risk of damaging the fuel heater. The fuel heater can be removed by hand and this provides yet another benefit attributable to the present invention.
SUMMARY OF THE INVENTION
The combination of a fuel filter housing and a fuel heater according to one embodiment of the present invention includes a heater-receiving bore and a notch opening into the bore as part of the fuel filter housing. The fuel heater is constructed and arranged for inserting into the heater-receiving bore and for being attached to the fuel filter housing. The fuel heater includes a protrusion that is constructed and arranged for engaging the notch such that turning the fuel heater causes the protrusion to cooperate with a ramp portion of the notch in order to facilitate removal of the fuel heater from the heater-receiving bore by a camming action.
One object of the present invention is to provide an improved installation interface between a fuel filter housing and a fuel heater to facilitate removal of the fuel heater from the fuel filter housing.
Related objects and advantages of the present invention will be apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a fuel heater installed into a fuel-water separator housing according to the present invention.
FIG. 2 is a partial, perspective view of the FIG. 1 fuel-water separator housing showing a heater-receiving bore.
FIG. 3 is a diagrammatic, perspective view of the FIG. 1 fuel heater.
FIG. 4 is an enlarged detail of a cam protrusion comprising a portion of the FIG. 3 fuel heater.
FIG. 5 is a perspective view of the initial step of installing the FIG. 3 fuel heater into the FIG. 2 heater-receiving bore.
FIG. 6 is a perspective view of a subsequent step of installing the FIG. 3 fuel heater into the FIG. 2 heater-receiving bore.
FIG. 7 is a diagrammatic view of a fuel-water separator housing notch that opens into the heater-receiving bore.
FIG. 8 is a diagrammatic view of the cooperating relationship between the FIG. 7 notch and the FIG. 4 protrusion.
FIG. 9 is a diagrammatic view of the cooperating relationship between the FIG. 7 notch and the FIG. 4 protrusion.
FIG. 10 is a diagrammatic view of an alternative fuel-water separator housing notch that opens into the heater-receiving bore.
FIG. 11 is a diagrammatic view of the cooperating relationship between the FIG. 10 notch and the FIG. 4 protrusion.
FIG. 12 is a diagrammatic view of the cooperating relationship between the FIG. 10 notch and the FIG. 4 protrusion.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
Referring to FIG. 1, there is illustrated a portion of a fuel-water separator 20 with a fuel heater 21 installed into a heater bore 22 that is defined by the wall of separator housing 23 . The boss 24 that surrounds bore 22 includes two mounting holes 25 that are constructed and arranged to receive threaded fasteners (not illustrated) that cooperate with fuel heater 21 to securely retain fuel heater 21 in bore 22 . The mounting holes can be internally threaded or self-tapping screws can be used for the referenced threaded fasteners. The fuel heater 21 includes a mounting flange 26 that is configured with clearance slots 26 a for receiving the threaded fasteners. Alternatively, the flange 26 can be constructed and arranged with clearance holes.
Referring now to FIG. 2, the inside surface 30 of bore 22 defines a notch 31 according to the present invention. Notch 31 opens into bore 22 and has a circumferential extent of not more than 90° relative to said heater receiving bore and cooperates with an oblong protrusion 32 that is constructed and arranged as part of the fuel heater 21 , according to the present invention, to facilitate removal of fuel heater 21 from the bore 22 of housing 23 , by a camming action.
Fuel heater 21 is illustrated in FIG. 3 and the protrusion 32 is illustrated in enlarged detail in FIG. 4 . It is intended for fuel heater 21 to be considered as a conventional fuel heater as far as its general shape, mechanical structure, and its electrical construction and properties. The only modification of this otherwise conventional fuel heater 21 is the addition of protrusion 32 . Protrusion 32 extends axially along a line that is parallel with the longitudinal axis of the fuel heater 21 and has a circumferential extent of not more than 90° relative to said fuel heater body. Fuel heater 21 includes mounting flange 26 and an O-ring seal 33 that is positioned around fuel heater 21 at a location along the length of fuel heater 21 so as to establish a liquid-tight interface between fuel heater 21 and the separator housing 23 .
When the fuel heater 21 is properly inserted into heater bore 22 , flange 26 is adjacent the outer surface 37 of boss 24 and the O-ring seal 33 is in contact with the cooperating sealing surface of the separator housing 23 . As the threaded fasteners are tightened into position, the fuel heater 21 becomes fully inserted, the O-ring seal 33 is compressed into liquid-tight contact, and flange 26 is drawn up tight against outer surface 37 . As this is occurring, the protrusion 32 is drawn into contact with a ramp portion of notch 31 .
Over time, with continued use of the fuel-water separator 20 , the O-ring seal 33 swells and creates interference that actually locks or wedges the fuel heater 21 in the heater bore 22 . As a result, any attempt to remove fuel heater 21 from bore 22 encounters added difficulty due to the interference created by the swelling of the O-ring seal 33 . In effect, the fuel heater is locked in position relative to separator housing 23 . In order to remove the fuel heater 21 from separator housing 23 , this locked condition needs to be broken. It would be preferable to be able to break the fuel heater 21 free from the separator housing 23 without the need for special tools. This is where the present invention is employed and it provides an improvement in the area of fuel heater removal.
With reference once again to FIG. 2, it will be seen that notch 31 is recessed down into the defining sidewall of boss 24 . The referenced ramp portion 38 has a first section 38 a with a convex curvature and a base section 38 b that is generally flat. The ramp portion 38 extends from the outer surface 37 to its inwardly most portion which is base section 38 b . In practice, the curved section 38 a can be convex, as diagrammatically illustrated in FIGS. 7, 8 , and 9 , or concave, as diagrammatically illustrated in FIGS. 10, 11 , and 12 . The FIG. 2 and FIGS. 7-9 configurations are consistent with each other. With respect to FIGS. 10, 11 and 12 , the intent is to show a second option (concave) for first section 38 a . This alternative is identified as notch 31 ′ and ramp portion 38 ′. The axial depth of notch 31 is set by ramp portion 38 . The radial depth of notch 31 is set by wall 39 and the construction of notch 31 is completed by wall 40 that is substantially flat and parallel with the bore axis of heater bore 22 . The overall shape and geometry of notch 31 can be seen in FIG. 2 and its cooperation with protrusion 32 (part of fuel heater 21 ) is diagrammatically illustrated in FIGS. 8 and 9.
Referring now to FIGS. 1, 5 , and 6 , the procedure for installing fuel heater 21 into housing bore 22 is illustrated. Beginning with fuel-water separator housing 23 and bore 22 , fuel heater 21 (see FIG. 3) is selected and the heating end 43 is inserted into bore 22 . Protrusion 32 is aligned with notch 31 and the installation procedure continues with the continued advancement of fuel heater 21 into separator housing 23 . As flange 26 is advanced close to outer surface 37 , it will be seen whether protrusion 32 is sufficiently close to notch 31 to be received within the notch. In order to fully insert the fuel heater 21 into housing 23 , including proper compression of the O-ring seal 33 , the protrusion 32 must be positioned up against wall 40 since this represents the location of the greatest or maximum axial depth of notch 31 and in turn the positioning of protrusion 32 . If the fuel heater is not turned relative to bore 22 so that the protrusion lines up with the greatest axial depth location of notch 31 , the protrusion 32 will presumably abut up against another part of ramp portion 38 that is axially outwardly relative to the maximum axial depth of notch 31 . However, with continued advancement of the fuel heater 21 into the housing, the protrusion 32 is caused to slide down the first section 38 a of ramp portion 38 , allowing the fuel heater 21 to turn slightly in a clockwise direction so as to cooperate with the travel of the protrusion. The rounded tip of protrusion 32 facilitates the sliding action of the protrusion 32 against the ramp portion 38 . In addition, as the fuel heater 21 turns so as to assume the desired position of protrusion 32 within notch 31 , the clearance slots 26 a are caused to line up with the boss mounting holes 25 .
With protrusion 32 bottomed out against the base section 38 b of ramp portion 38 at a location adjacent wall 40 , the fuel heater 21 is properly oriented relative to separator housing 23 . This proper orientation includes the correct positioning of electrical connector 44 for connection to the wires of the vehicle wiring harness for powering the fuel heater 21 . The proper orientation and positioning of fuel heater 21 relative to boss 24 includes the correct positioning of the two flange slots 26 a relative to the two mounting holes 25 for receiving the selected mounting hardware, in this case, externally-threaded fasteners.
When it is desired to remove fuel heater 21 from housing 23 , the first step is to remove the two threaded fasteners (not illustrated) that secure flange 26 to outer surface 37 . While it might be expected that this would be all that is needed, the swelling of the O-ring seal 33 causes the fuel heater 21 to be “stuck” in the heater bore 22 . It thus becomes necessary to break loose the O-ring seal 33 and it would be an improvement to prior methods that use removal tools, some of which may have a specialized form, to be able to remove the fuel heater 21 by hand. This is where the present invention, with its cooperating protrusion 32 and notch 31 , is used. With the present invention, all that has to be done in order to break the fuel heater 21 free is to turn (rotate) the fuel heater 21 in a counter clockwise direction, based upon the orientation of the fuel heater 21 in FIG. 1 . The manual torque applied (by hand) to the outside diameter of the fuel heater 21 causes the protrusion 32 to slide across the surface of first section 38 a of ramp portion 38 from a starting location adjacent wall 40 upwardly toward outer surface 37 . Since the axial depth of ramp portion 38 is less as the counter clockwise rotation continues, the manual torque is converted into an axial force exerted through the protrusion against the ramp portion 38 . This axial force helps to break free the fuel heater 21 and acts in pushing the fuel heater 21 out of heater bore 22 . What results is a camming action using the cooperating relationship between the protrusion 32 and notch 31 , specifically the ramp portion 38 , to help the fuel heater 21 break free of any stuck or “frozen” condition due to the swelling of the O-ring seal 33 . Once the fuel heater 21 breaks free, it can be easily removed from the fuel-water separator housing 23 . The entire removal procedure is done by hand, without the need for any tools, special or conventional.
While the illustrated notch 31 has a circumferential arc length that is approximately about 30 degrees, this arc length can be increased which would result in a longer, more gradual ramp incline on portion 38 . A 90 degree arc length for notch 31 would result in a quarter turn design for breaking free the fuel heater 21 from any stuck or wedged condition within bore 22 due to the swelling of O-ring seal 33 . A 180 degree arc length would result in a half-turn design. An arc length of between 30 degrees and 90 degrees is likely preferred, but almost any are length will work in accordance with the present invention.
Another design consideration and option is to vary the axial depth of notch 31 . While the functional and structural characteristics of fuel heater 21 have to be considered, the only obvious effect of a deeper notch is the need to lengthen the protrusion so that once the heater is fully seated into the heater bore 22 , the protrusion 32 continues to ride on the ramp portion 38 . As would be understood, the curvature of first section 38 a of ramp portion 38 is a function of the overall are length of the notch as well as the axial depth of the notch relative to outer surface 37 .
Another design variation that is contemplated for the present invention is to add a second notch and a second protrusion. This second cooperation combination of notch and protrusion would be spaced apart from the first cooperation combination. Preferably the spacing is envisioned to be less than 180 degrees so that the fuel heater 21 cannot be installed upside down, i.e., inverted 180 degrees from its designed orientation (see FIG. 1 ). A spacing of approximately about 120 degrees would avoid the 180 degree issue and avoid any interference with a location of either of the two mounting holes 25 .
A still further design variation contemplated by the present invention is to reverse the notch and the protrusion. Rather than placing the protrusion as part of the fuel heater, the protrusion could be included as part of the separator housing and design a cooperating notch into the fuel heater. Accordingly, the present invention specifically contemplates a cooperating relationship between the fuel heater and the separator housing that employs a camming action resulting from the turning or rotation of the fuel heater in a counter clockwise direction. Accordingly, the present invention can be described in the context of a fuel heater having a first camming member and a separator housing having a second camming member where these two camming members cooperate in order to facilitate removal of the fuel heater from the separator housing.
A still further design variation contemplated for the present invention involves changing the overall size and shape of the protrusion. Although the design illustrated includes a generally rectangular solid form with a rounded or radiused tip, other sizes and shapes may be suitable and are intended to be encompassed by the present invention.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.
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A fuel filter housing and fuel heater combination for a fuel-water separator includes, as part of the fuel filter housing, a heater-receiving bore and a notch, opening into the heater-receiving bore. The notch is constructed and arranged with a ramp portion extending axially into the fuel filter housing. The fuel heater is constructed and arranged for inserting into the bore and includes a flange that is attached to the housing for securing the fuel heater in position. The fuel heater includes a protrusion that inserts into the notch and is seated against the ramp portion when the fuel heater is fully installed. O-ring seal swelling may cause the fuel heater to be locked into the bore and the protrusion cooperates with the ramp portion by way of a camming action to facilitate removal of the fuel heater from the bore under such conditions.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. Application Ser. No. 035,159, filed May 2, 1979 abandoned.
BACKGROUND OF THE INVENTION
The invention relates broadly to a packer tool for plugging off a well casing. More specifically, the invention covers a packer tool of the permanent type.
In the production of oil and gas there are various downhole operations which require plugging off the well casing at a given point, or at more than one point. Examples of such operations are hydraulic fracturing of a producing zone, and placing of propping materials, such as sand, in the fracture opening. When such operations are to be performed, the well casing is usually plugged off with a packer tool, either a permanent-type packer, or a retrievable packer.
The packet tools now available are not entirely satisfactory because of various problems. A major problem is in the "setting" of the packer in the casing. When force is applied from the wellhead, to "set" the tool in place, the teeth of the upper and lower slips on the tool grip into the casing wall simultaneously. At the same time, the rubber packing elements are only partly compressed, so that they do not set tightly against the casing wall. As additional force is applied, to further set the packing elements, the packer tool moves down and the slips drag along the casing wall. This causes the slip teeth to become dull in a very short time, and the packer is then unable to form a good fluid-tight plug in the casing.
The packer tool of this invention, which is designed to be permanently set in a well casing, avoids the problem described above. This tool is designed such that the lower slips are set first, followed by setting of the upper slips, with only a slight movement of the packer in the casing during the setting operation.
The tools described in U.S. Pat. Nos. 2,753,941 (Hebard et al.), 3,061,013 (Williams), and 3,517,742 (Thomas) are representative of prior art packers and bridging plugs which are used in plugging off a well casing to perform a downhole operation. Although the tools described in these references are suitable for plugging off a well casing, the structure and operation of each tool is substantially different than the packer tool of the present invention. In particular, none of the prior tools have the capability for setting the slip members in the manner of the present packer, to avoid the drag problem described above.
SUMMARY OF THE INVENTION
The packer tool of this invention is designed to be permanently set, in a packed off position, in a well casing. The basic component of the tool is an elongate mandrel, which has a section of teeth defined in the outer surface of the mandrel. The mandrel is enclosed by several upper components, which include an upper cone, an upper sleeve, a set of upper slips, and a means for locking the upper cone into a first and second position on the mandrel. The mandrel is also enclosed by lower components which include a lower cone and a set of lower slips.
A set of packing elements are also fitted around the mandrel and positioned between the upper and lower cones. When the packer tool is being run into the well casing, that is, before the slips are set, the upper cone is positioned on the mandrel such that it can slide downwardly. The upper sleeve is fastened to the mandrel and to the upper cone. The upper slips, which are slideable downwardly on the upper cone, are seated against the upper sleeve prior to setting of these slips. The lower cone is secured to the mandrel; and the lower slips, which are slideable upwardly on the lower cone, are seated against a lower guide on the mandrel prior to setting of these slips.
During setting of the upper and lower slips, the packing elements are compressed, such that they expand outwardly and push against the well casing to form a fluid-tight seal. In the setting operation, the lower slips are set against the well casing first, and the lower cone is locked against the mandrel, in a given position, by the lock means. Thereafter, the upper slips are set against the casing and the upper cone moves to a second position on the mandrel, where it is held in place by the lock means.
DESCRIPTION OF THE DRAWINGS
FIG. 1A is a partial view, in front elevation, and partly in section, which illustrates the upper part of the present packer tool. FIG. 1B illustrates the lower part of the tool. In these Figures, the tool is shown in its running-in position.
FIG. 2A is a partial view, in front elevation, and partly in section, showing only the upper part of the packer tool after the lower slips have been set. FIG. 2B shows only the lower part of the tool after setting the lower slips.
FIG. 3A is a partial view, in front elevation, and partly in section, showing only the upper part of the packer tool after both the lower and upper slips have been set. FIG. 3B shows only the lower part of the tool after setting of the lower and upper slips.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the drawings, the letter T generally indicates the packer tool of this invention. The basic tool is made up of a hollow, elongate mandrel 10. The mandrel includes a section of teeth 11, which is machined into the outer wall surface of the mandrel near the middle of this component. A lower guide member 12 is threaded onto the bottom end of the mandrel 10 and held in place by a set screw 13. A sleeve 14 is fitted to the mandrel 10 just below the top of the mandrel. The sleeve is held in place on the mandrel by several shear screws, indicated by numeral 15.
An upper cone 16 is fitted to the mandrel 10 and held in place by several shear screws 17, which are threaded through the sleeve 14. A set of upper slips 18 are fitted to the cone 16, such that they can slide downwardly along the cone. A lock ring 19 is threaded onto the upper cone 16. The inside of this ring has a teeth section (not numbered) which engages the teeth section 11 on mandrel 10. Ring 19 is also fastened to the cone 16 by a set screw 20.
An expanding gage ring 21 is fitted to mandrel 10 below the upper cone 16. Farther down on mandrel 10 is a similar gage ring 22. Between the two gage rings is a set of packer elements which fit around the mandrel. These elements are made up of two outer packer elements, 23 and 24, and a center element 25. A lower cone 26 fits around the mandrel below the gage ring 22 and the cone is secured to the mandrel by several set screws, indicated by numeral 27. Means for setting the lower part of the packer tool T is provided by a set of lower slips 28, which are positioned to slide upwardly along cone 26.
Operation
The basic operation of the present packer tool will now be described to illustrate the practice of this invention. In a typical down hole operation, the top of the mandrel 10 is connected to a wire line setting tool, which, in turn, is fastened to the bottom end of a tubing string. The setting tool and the tubing string are not shown in the drawing. The packer tool T is then lowered on the string into the well casing 29, until it reaches the point where the casing is to be packed off. At this point, the tool is in its running in position, as shown in FIGS. 1A and 1B. The next step is to set the lower slips 28, as shown in FIGS. 2A and 2B.
A sleeve (not shown) on the setting tool seats against the sleeve 14. The resulting downward force against the sleeve 14 off the screws 15, so that sleeve 14 moves downwardly on the mandrel 10. Upper cone 16 also moves downwardly along with sleeve 14, because the cone is held securely to the mandrel by the larger shear screws 17. As cone 16 moves down, the inside teeth on the lock ring 19 "ratchet" downwardly on the mandrel teeth 11. When cone 16 reaches its lowest point of travel, the ring 19 locks the cone against the mandrel 10, to prevent undesired upward movement of the packer components.
The downward movement of upper cone 16 compresses the packer elements 23, 24 and 25 between cone 16 and the lower cone 26. This causes the packer elements to expand outwardly and push against the outside wall of the casing 29, to form a fluid-tight seal at this point in the casing. The compression of the packer elements also forces the expanding gage ring 22 to push down on lower cone 26, with enough force to shear off the screws 27. As cone 26 moves down, the lower slips 28 ride upwardly on the cone and move outwardly until they grip into the wall of casing 29. The lower slips are then in the fully set position shown in FIG. 2B.
The next step is to set the upper slips 18, as illustrated in FIGS. 3A and 3B. This sequence is started by applying enough additional downward force, through the setting tool, to shear off the larger shear screws 17, which secure the sleeve 14 to the upper cone 16. When these screws are sheared, the sleeve 14 moves downwardly on the upper cone. At the same time, the sub piece pushes the upper slips 18 downwardly on the upper cone. This causes the upper slips to move outwardly until they grip into the wall of casing 29. The upper slips are then in the fully set position shown in FIG. 3B.
The next step is to release the setting tool from the packer tool. This is done by applying enough additional downward force against the setting tool to shear the connection which fastens the setting tool to the top of mandrel 10. This connection is not shown in the drawings. When the connection is broken, the tubing string and setting tool are then pulled out of the casing, so that the packer tool is left in the casing as a permanent structure.
Adequate clearance is required between the lock ring 19 and the upper cone 16 to allow the lock ring to ratchet and advance along teeth section 11 on the mandrel.
A slotted back-up ring 21A is positioned between the packer element 23 and the expanding gage ring 21. A similar back-up ring 22A is positioned between the packer element 24 and the gage ring 22. The purpose of the back-up rings is to cover the enlarged slots of the expanded gage ring and to thereby prevent extrusion of the packer elements past the openings in the expanded gage ring during compression of the packer elements and after setting of the lower and upper slips. The purpose is conveniently achieved by positioning the back-up rings in such a way that the slots in the back-up ring are staggered relative to the slots in the expanding gage ring. Usually the slots in the expanding gage rings are uniformly positioned around the rings and also around the back-up rings. The number of slots in the expanding gage rings is not critical, but Application has found an even number of slots to be convenient (e.g. 4, 6, 12, etc.). Likewise, the number of slots in the back-up rings is not critical, but Applicant has found it convenient to use the same number of slots in the back-up ring as is used in the associated expanding gage ring. For example, if the expanding gage ring contains 6 slots uniformly positioned around the ring (which is typical), then normally the back-up ring would also contain 6 slots uniformly positioned around its circumference; however, other combinations could obviously be used (e.g. 12 slots in the expanding gage ring and 6 slots in the back-up ring, or 6 slots in the expanding gage ring and 3 slots in the back-up ring.
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A packer tool, and method for permanently setting the tool, in a packed off position, in a well casing, is disclosed. The tool includes lower slips which are slideable upwardly on a lower cone, and upper slips which are slideable downwardly on an upper cone. The lower slips are set against the casing wall first by applying downward force against the lower cone. After the lower slips have been set, additional downward force is applied against the packer tool to set the upper slips against the casing wall.
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TECHNICAL FIELD
[0001] The present invention relates to an axle assembly, in particular an axle assembly for a heavy vehicle such as a lorry or truck.
BACKGROUND
[0002] Road vehicles are known which include driven rear axles. The rear axles include a crown wheel and pinion and differential. The pinion is driven via a drive shaft or the like connected to a prime mover such as an engine. The pinion and drive shaft rotate about a longitudinal axis of the vehicle. The pinion together with the crown wheel enables the crown wheel to rotate about an axis which is laterally orientated relative to the vehicle. The crown wheel drives a differential mechanism which drives a right and left hand drive shaft (known as half shafts). The right hand drive shaft drives a right hand wheel rotatably mounted to the axle and the left hand drive shaft drives a left hand wheel rotatably mounted to the axle. In this way the vehicle can be driven over the ground.
[0003] The crown wheel, pinion and differential assembly require lubrication and cooling and a fluid, typically an oil, will perform this dual function. The crown wheel, pinion and differential assembly are mounted on a differential carrier assembly that is fixed to the axle housing by bolts. When the vehicle is driven, the axle housing and the differential carrier assembly experience vertical, longitudinal and torsional forces, which cause deformation of the axle housing and the differential carrier assembly. This causes leakage of the fluid from the resulting gaps between the differential carrier assembly and the axle housing.
[0004] It is known to include gaskets or sealants between the differential carrier assembly and the axle housing in order to prevent leakage, however leakage of fluid still occurs. This is a particular problem for lightweight axle housings, for which the reduced weight results in greater deformation.
[0005] The leakage of fluid from the axle housing results in high warranty costs and so an axle assembly with improved resistance to vertical, longitudinal and torsional forces is required.
SUMMARY
[0006] Thus according to the present invention there is provided an axle assembly including an axle housing having a central portion for receiving a differential, a first axle tube extending from the central portion, and a second axle tube extending from the central portion, the central portion having an opening defined by an axle flange, the axle flange having a first mating surface. The axle assembly further includes a differential carrier assembly having a differential mounted on a carrier, the carrier having a carrier flange which has a second mating surface. The first mating surface is sealed to the second sealing surface by seal. At least one of the first and/or second mating surfaces includes a groove.
[0007] The groove may be formed in at least one of the first and/or second mating surfaces such that the at least one of the first and/or second mating surfaces forms a wall surrounding the groove. The groove may be formed in at least one of the first and/or second mating surfaces such that the groove is spaced apart from an outer edge of the at least one first and/or second mating surfaces. The groove may be formed in at least one of the first and/or second mating surfaces such that the groove is spaced apart from an inner edge of the at least one first and/or second mating surfaces. The groove may not extend to an outer edge of the at least one first and/or second mating surfaces. The groove may not extend to an inner edge of the at least one first and/or second mating surfaces. The groove may form a trough in the at least one of the first and/or second mating surfaces. The groove may be a hollow in the at least one of the first and/or second mating surfaces. The groove may be a depression in the at least one of the first and/or second mating surfaces. The groove may have a continuous outer edge or wall that is formed in a flat surface of the at least one of the first and/or second mating surfaces.
[0008] The groove may accommodate, house or contain a volume of the seal.
[0009] Advantageously including a groove in at least one of the mating surfaces reduces the leakage of fluid from the axle assembly. The groove enables the inclusion of a thicker seal, which fills a larger gap than standard seal. Because the gap to be filled is larger, then the local thickness of the seal is thicker and this locally thicker seal can better withstand deflections, and thereby better prevent leakage of fluid.
[0010] The central portion may be formed by casting. The opening may be generally circular. The first mating surface may be generally flat.
[0011] The differential carrier assembly may include a crown wheel in driving engagement with a pinion. The carrier may be cast. The carrier flange may be generally circular. The second mating surface may be generally flat.
[0012] The seal may include a mechanical seal, for example a gasket or a sealant such as a gasket maker or a flange sealant. The mechanical seal may include a ductile material. Ductility is the ability of a material to be permanently deformed without breaking when a force is applied. The extent to which a specimen stretches before fracture is its percentage elongation. The elongation of the mechanical seal may be more than 200% of the thickness of the seal, preferably more than 500% of the thickness of the seal. The ductile material may include a polymer, for example silicone. The seal may be an elastomeric sealant.
[0013] The groove may be elongate. The groove may be circumferentially oriented with respect to the first and/or the second mating surface. The groove may extend around less than 45 degrees of the first and/or second mating surface, preferably less than 30 degrees, more preferably less than 20 degrees. The groove may have a length of less than 200 millimeters, preferably less than 100 millimeters. The groove may have a depth of less than 2 millimeters. The groove may preferably have a depth that is less than or equal to 1 millimeter. The groove may be machined in the first and/or second mating surface. Alternatively, the groove may be cast in the first and/or second mating surface.
[0014] The axle flange may have a plurality of fastener holes. The plurality of fastener holes may be spaced circumferentially around the axle flange. The plurality of fastener holes may be threaded to receive a threaded stud or a threaded bolt.
[0015] The groove may have a first end that is adjacent to a first fastener hole and a second end that is adjacent to a second fastener hole, wherein the first fastener hole and second fastener hole are positioned sequentially around the circumference of the axle flange.
[0016] The axle flange and/or the carrier flange may include a first notch and a second notch to accommodate the crown wheel. The groove may be located on the first mating surface adjacent to one of the first or the second notches. The axle assembly may include a second groove located on the same mating surface as the first groove. The second groove may be located adjacent to the other of the first or second notches.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The invention will now be described, by way of example only, with reference to the accompanying drawings in which:
[0018] FIG. 1 is a partial exploded view of an axle assembly according to the present invention;
[0019] FIG. 2 is a partial exploded view of the axle assembly of FIG. 1 ;
[0020] FIG. 3 is a plan view of the axle housing of the axle assembly of FIGS. 1 and 2 ; and
[0021] FIG. 4 is a partial perspective view of the axle housing of FIG. 3 .
DETAILED DESCRIPTION
[0022] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
[0023] With reference to FIGS. 1 to 4 , there is shown an axle assembly 10 according to the present invention. The axle assembly 10 includes an axle housing 11 and a differential carrier assembly 15 .
[0024] The axle housing 11 is defined by a first part 12 , a second part 14 and a center portion 20 (also known as a central bowl).
[0025] The first part 12 includes a first axle tube 16 (in this case a left hand axle tube or left hand housing leg) having a first end 16 a (or outboard end) and a second end 16 b (or inboard end). The first axle tube 16 has a first opening (not shown) at the first end 16 a and a second opening (not shown) at the second end 16 b.
[0026] The second part 14 includes a second axle tube 18 (in this case a right hand axle tube or right hand housing leg) having a first end 18 a (or outboard end) and a second end 18 b (or inboard end). The second axle tube 18 has a first opening 18 c at the first end 18 a and a second opening (not shown) at the second end 18 b.
[0027] The center portion 20 is a hollow structure, cast from a metal such as cast iron. The center portion 20 includes an opening 22 , which is generally circular. The opening 22 is defined by an axle flange 24 . The axle flange 24 is generally annular and has a generally flat mating surface 26 . The first mating surface 26 includes twelve fastener holes 28 a , 28 b , 28 c , 28 d , 28 e , 28 f , 28 g , 28 h , 28 i , 28 j , 28 k , 28 l , which are spaced circumferentially around the first mating surface 26 . Each of the fastener holes 28 a , 28 b , 28 c , 28 d , 28 e , 28 f , 28 g , 28 h , 28 i , 28 j , 28 k , 28 l is threaded.
[0028] The axle flange 24 also includes a pair of notches 30 a , 30 b and a groove 60 .
[0029] The pair of notches 30 a , 30 b extend from the axle flange 24 into the opening 22 of the center portion 20 . Notch 30 a is located on an upper portion 24 a of the axle flange 24 and notch 30 b is located on a lower portion 24 b of the axle flange 24 .
[0030] The groove 60 is elongate and has a first end 62 and a second end 64 . The groove 60 is positioned adjacent to the notch 30 a on the upper portion 24 a of the axle flange 24 . The first end 62 of the groove 60 is positioned adjacent to fastener hole 28 a in the first mating surface 26 and the second end 64 of the groove 60 is positioned adjacent to fastener hole 281 in the first mating surface 26 . Fastener hole 28 a is positioned adjacent to fastener hole 28 l around the periphery of the first mating surface 26 . The groove 60 is less than 200 millimeters long and extends around less than 30 degrees of the first mating surface 26 . The groove has a depth of approximately 1 millimeter. The groove 60 is surrounded by a continuous edge or wall in the generally flat mating surface 26 of the axle flange 24 , thus forming a trench in the generally flat mating surface 26 .
[0031] The first axle tube 16 is connected to the center portion 20 such that the second opening at the second end 16 b of the first axle tube 16 opens into the center portion 20 . Similarly, the second axle tube 18 is connected to the center portion 20 such that the second opening at the second end 18 b of the second axle tube 18 opens into the center portion 20 . In this way, the first and second axle tubes 16 , 18 are connected by the center portion 20 .
[0032] The differential carrier assembly 15 has a carrier 32 . The carrier 32 includes a carrier flange 34 and a mount 40 . The carrier flange 34 is generally annular and has a second mating surface 36 that is generally flat. The second mating surface 36 includes twelve fastener holes 38 a , 38 b , 38 c , 38 d , 38 e , 38 f , 38 g , 38 h , 38 i , 38 j , 38 k , 38 l (only some of which are shown in FIGS. 1 and 2 ), which are spaced circumferentially around the second mating surface 36 . Each of the fastener holes 38 a , 38 b , 38 c , 38 d , 38 e , 38 f , 38 g , 38 h , 38 i , 38 j , 38 k , 38 l is threaded.
[0033] The mount 40 supports a crown wheel 42 , and a differential 46 .
[0034] The differential carrier assembly 15 includes bearings to rotatably support the pinion 44 . Further bearings rotatably support the crown wheel 42 . These bearings are mounted on mount 40 connected to the differential carrier assembly 15 . The crown wheel 42 is in meshing engagement with the pinion 44 in a manner known in the art.
[0035] The center portion 20 is sized and shaped to accommodate the crown wheel 42 , pinion 44 , differential 46 and the mount 40 . The opening 22 is sized and shaped to allow the crown wheel 42 , pinion 44 , differential 46 and the mount 40 to be passed through the opening 22 and to be received in the center portion 20 . The notches 30 a , 30 b in the axle flange 24 are sized and positioned to provide additional space for the outer diameter of the crown wheel 42 , thereby facilitating rotation of the crown wheel 42 when the axle housing 11 and differential carrier assembly 15 are assembled. The differential carrier assembly 15 acts as a cover to close the opening 22 of the center portion 20 . In this way, a fluid for example oil (not shown) for lubricating and cooling the crown wheel 42 , pinion 44 and differential 46 can be retained within the axle housing 11 and the differential carrier assembly 15 .
[0036] The axle assembly 10 is assembled as follows.
[0037] The pinion 44 is mounted on the carrier 32 . The crown wheel 42 , and differential 46 are mounted on the mount 40 of the carrier 32 .
[0038] The differential carrier assembly 15 , upon which the crown wheel 42 , pinion 44 and differential 46 are mounted, is brought into contact with the axle housing 11 such that the crown wheel 42 , pinion 44 and differential 46 and the mount 40 are accommodated within the center portion 20 .
[0039] A layer of sealant 54 , for example an elastomeric sealant e.g., a silicone sealant, such as Dow Corning 7091, Loctite 509, Loctite 518, Permabond LH195 or Permabond LH197, is applied to the first mating surface 26 . The sealant 54 is applied to fill the groove 60 in the first mating surface 26 .
[0040] The second mating surface 36 of the differential housing assembly 14 is brought into contact with the layer of sealant 54 on the first mating surface 26 , such that each of the fastener holes 38 a , 38 b , 38 c , 38 d , 38 e , 38 f , 38 g , 38 h , 38 i , 38 j , 38 k , 38 l in the second mating surface 36 is lined up with each of the fastener holes 28 a , 28 b , 28 c , 28 d , 28 e , 28 f , 28 g , 28 h , 28 i , 28 j , 28 k , 28 l in the first mating surface 26 . The sealant 54 provides a sealing connection between the first mating surface 26 and the second mating surface 36 .
[0041] Threaded bolts or studs 48 (only 4 of which are shown in FIGS. 1 and 2 ) are passed through the fastener holes 38 a , 38 b , 38 c , 38 d , 38 e , 38 f , 38 g , 38 h , 38 i , 38 j , 38 k , 38 l of the second mating surface 36 and the fastener holes 28 a , 28 b , 28 c , 28 d , 28 e , 28 f , 28 g , 28 h , 28 i , 28 j , 28 k , 28 l of the first mating surface 26 in order to secure the carrier assembly 15 to the axle housing 11 . The threaded bolts 48 have a threaded portion 48 a at one of their ends and a second threaded portion 48 b at the other of their ends. The threaded portion 48 a of each of the threaded bolts 48 engages the threaded portion (not shown) of each of the fastener holes 28 a , 28 b , 28 c , 28 d , 28 e , 28 f , 28 g , 28 h , 28 i , 28 j , 28 k , 28 l in the first mating surface 26 . The threaded portion 48 b of each of the threaded bolts 48 engages the threaded portion (not shown) of each of the fastener holes 38 a , 38 b , 38 c , 38 d , 38 e , 38 f , 38 g , 38 h , 38 i , 38 j , 38 k , 38 l in the second mating surface 36 .
[0042] The axle assembly 10 is connected to the engine by a drive shaft (not shown) that extends through opening 58 in the differential carrier assembly 15 to the pinion 44 . The engine (not shown) causes the drive shaft (not shown) and pinion 44 to rotate about a longitudinal axis of the vehicle (not shown).
[0043] The pinion 44 is drivingly engaged to the crown wheel 42 to enable the crown wheel to rotate about an axis which is laterally orientated relative to the vehicle (not shown).
[0044] The left hand drive shaft 50 extends through the opening (not shown) in the left hand axle tube 16 and the right hand drive shaft 52 extends through opening 18 c in the right hand axle tube 18 .
[0045] In this way, the left and right hand drive shafts 50 , 52 are caused to rotate in a direction which is laterally orientated relative to the vehicle. The left hand drive shaft 50 drives a left hand wheel (not shown) that is rotatably mounted to the axle and the right hand drive shaft 52 drives a right hand wheel rotatably mounted to the axle.
[0046] The differential 46 interacts with the crown wheel 42 to enable the left and right hand drive shafts 50 , 52 to rotate at different speeds, for example when the vehicle is driving around a corner.
[0047] During movement of the vehicle, the axle housing 11 and differential carrier assembly 15 are exposed to vertical, longitudinal and torsional forces caused by movement of the vehicle, the wheels and the axle shafts.
[0048] These forces cause deformation of the axle assembly 10 . The formation of gaps between the axle housing 11 and the differential carrier assembly 15 is prevented by the sealant 54 within the groove 60 and in the between the first mating surface 26 and the second mating surface 36 .
[0049] The elongation of the sealant material is 600% of the thickness of the sealant applied to the first mating surface 26 . In use, the additional sealant 54 within the groove 60 is able to deform to fill any gaps that might otherwise form between the axle housing 11 and the differential carrier assembly 15 as a result of vertical, longitudinal and torsional forces acting on the axle assembly 10 caused by movement of the vehicle. In this way, leakage of fluid from within the axle assembly is prevented.
[0050] The groove 60 is positioned between adjacent fastener holes so that the sealant 54 is provided at a region of the axle assembly 10 that is not secured or fastened together by threaded bolts or studs 48 , i.e., the sealant 54 is provided at a region that is at risk of gaps forming when the axle assembly 10 is exposed to vertical, longitudinal and/or torsional forces.
[0051] The groove 60 is positioned adjacent to the notches 30 a , 30 b since this is a region of the axle flange 24 where the width of the first mating surface 26 is reduced. This region of the axle flange 24 is at risk of gaps forming when the axle assembly 10 is exposed to vertical, longitudinal and/or torsional forces.
[0052] In the embodiment described above, the center portion 20 of the axle housing 11 is cast with the groove 60 on the first mating surface 26 . In alternative embodiments, the groove may be formed by machining.
[0053] In the embodiment described above, the groove 60 is positioned adjacent to the notch 30 a on the upper portion 24 a of the axle flange 24 , with the first end 62 of the groove 60 positioned adjacent to fastener hole 28 a and the second end 64 of the groove 60 positioned adjacent to fastener hole 281 . The fastener hole 28 a is adjacent to the fastener hole 28 l . The fastener holes 28 a , 28 l are positioned next to each other, or contiguous, or physically adjacent, or neighboring, around the periphery or circumference of the axle flange 24 . In alternative embodiments, the groove may be positioned adjacent to the notch 30 b on the lower portion 24 b of the axle flange 24 , with the first end 62 of the groove positioned adjacent to fastener hole 28 f and the second end 64 of the groove positioned adjacent to fastener hole 28 g . The fastener hole 28 f is adjacent to the fastener hole 28 g . The fastener holes 28 f , 28 g are positioned next to each other, or contiguous, or physically adjacent, or neighboring, around the periphery or circumference of the axle flange 24 . In alternative embodiments, the groove may be positioned such that the first end 62 is adjacent to one of the fastener holes 28 a , 28 b , 28 c , 28 d , 28 e , 28 f , 28 g , 28 h , 28 i , 28 j , 28 k , 28 l and the second end 64 is adjacent to a second of the fastener holes, the second of the fastener holes being positioned adjacent to, contiguous with or next to, or physically adjacent, or neighboring, the first of the fastener holes.
[0054] In the embodiment described above, the groove 60 is located on the first mating surface 26 of the axle flange 24 . In alternative embodiments, the groove may be located on the second mating surface 36 of the differential carrier assembly 15 . The groove may be machined in the second mating surface 36 of the differential carrier assembly 15 . In this way, a differential carrier assembly 15 having a groove may be retrofitted to an existing axle assembly.
[0055] In the embodiment described above, the sealant is a silicone sealant. In alternative embodiments, the sealant may include any material suitable for adhering and/or sealing the first mating surface 26 to the second mating surface 36 , for example any gasket maker. In alternative embodiments, the sealant may be a gasket, for example a gasket including silicone.
[0056] In the embodiment described above, and as shown in FIGS. 1 and 2 , the threaded bolts or studs 48 have threaded portions 48 a , 48 b at each of their ends. In alternative embodiments, bolts with threads at only one of the ends may be used.
[0057] In the embodiment described above, the axle flange 24 and the carrier flange 34 each have twelve fastener holes. In alternative embodiments, any number of fastener holes may be included on each of the axle flange 24 and the carrier flange 34 .
[0058] 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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An axle assembly and method of reworking an axle assembly. The axle assembly has an axle housing and a differential carrier assembly. A central portion of the axle housing has an opening that is defined by an axle flange that has a first mating surface. The differential carrier assembly has a differential mounted on a carrier. The carrier has a carrier flange that has a second mating surface. The first mating surface is sealed to the second mating surface by seal. At least one of the first and second mating surfaces includes a groove.
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RELATED APPLICATIONS
The present application is related to and claims the benefit of U.S. Provisional Application No. 60/722,626, filed Sep. 29, 2005, entitled “FAN CONTROLLER WITH ALERT CAPABILITY,” naming Steven P. Larky and Darrin Vallis as the inventors, assigned to the assignee of the present invention. That application is incorporated herein by reference in its entirety and for all purposes.
BACKGROUND OF THE INVENTION
Many electronic systems require cooling to dissipate heat generated by electronic components. Since radiation and conduction are less-effective heat transfer methods in an enclosed system, convective cooling solutions are often used. As such, a common electronic system may have one or more fans to drive air over components, exhaust warm air from the system and draw cooler air into the system.
Regardless of the implementation, a spinning cooling fan will emit some noise. Noise often results from the fan motor bearing, air moving past the fan blades and body of the fan, and the placement of the fan with respect to other objects (e.g., a vent in an electronic system chassis). Additionally, a more pronounced noise may result from multiple fans spinning at different speeds, where the noise profiles from the fans intersect to produce a “beating” sound. Given that the beating sound is often much louder and more annoying than the sound from an individual fan, conventional fan controllers attempt to spin proximately-located fans at precisely the same speed to reduce the beating sound.
Although the reduction of fan interference sounds is often important in a single electronic system with multiple fans, it becomes even more of an issue when multiple systems are placed in proximity to one another (e.g., in a computer server room). Since each system is likely to have at least one fan, the placement of multiple systems in the same room can dramatically increase the number of fans which may interfere with one another and create beating sounds. And moreover, given that the ambient air temperature of rooms containing multiple systems is often higher than rooms containing a single system, systems designed to be placed in the presence of other systems often contain more fans or larger fans that produce more noise. As such, the beating sounds are often louder, more prevalent and more annoying than those associated with a single system.
Despite attempts by conventional fan controllers to spin fans at the same speed, some fan speed differential and associated beating sound is likely to remain, especially in environments with multiple systems. Additionally, even if all fan speed differentials were eliminated, the ambient noise from the many fans is often very loud even without any beating. As such, it is often hard to identify audible faults. And even if a fault is identified, it is often hard to discern which system a given fault is associated with. Similarly, given the large number of solid and blinking lights on multiple systems placed near one another, visual faults (e.g., a blinking light) are also hard to identify and distinguish. Thus, given that most electronic systems are equipped with such audible and visual fault indicators, the price of the systems is increased while still providing poor fault indication.
SUMMARY OF THE INVENTION
Accordingly, a need exists for improved alert notification in a computer system environment. A need also exists for alert notification with reduced system cost. Additionally, a need exists for alert notification which more clearly identifies which system or systems to which a fault pertains. Embodiments of the present invention provide novel solutions to these needs and others as described below.
Embodiments of the present invention provide a system, fan controller and method for enhanced alert notification. More specifically, embodiments provide an effective mechanism for utilizing system fans to create alert tones or messages, where fan speed differentials may be adjusted to alter the frequency of the fan interference sounds. As such, existing hardware can be used to reduce cost by producing audible alerts which may be heard above ambient noise in a room with one or more electronic systems. Further, the frequency of the interference sounds may be altered to more clearly identify one or more systems to which a fault pertains.
In one embodiment, a system includes a first fan and a fan controller coupled to the first fan and operable to control the first fan. The system also includes a first interface coupled to the fan controller for receipt of alert signals. The alert signals may be associated with one or more components of the system (e.g., ethernet hardware, power supply, etc.) and may indicate a condition warranting attention (e.g., battery low, power failure, component failure, overheated component, required system reboot, etc.). Alternatively, the alert signal may be that which is optionally routed to a light-producing device, speaker, etc. Additionally, the fan controller is further operable to vary a speed differential between the first fan and a second fan, wherein the speed differential is operable to create an audible sound, and wherein a variation in the speed differential is used to change a frequency of the audible sound in response to a received alert signal. As such, one or more fans may be used to create an audible alert from a received alert signal, where the frequency of the audible alert may be varied such that the alert comprises speech, music, a siren, or the like. Thus, not only may the alert be heard above ambient room noise, but the alert may more clearly identify one or more systems to which a fault pertains.
In another embodiment, a fan controller includes a first interface for receiving an input signal. A processor is coupled to the first interface, where the processor is for generating an alert signal in response to a received input signal. A fan speed control is coupled to the processor, where the fan speed control is for varying a speed differential between a first fan and a second fan in response to a received alert signal. The speed differential is operable to create an audible sound representing an alert, where a variation in the speed differential is used to change a frequency of the audible sound in response to the received alert signal. Additionally, the fan controller may include a memory coupled to the processor for storing alert information, where the processor is operable to determine a portion of the alert information associated with the received input signal, and where the portion of alert information is used to generate the alert signal. Further, the fan controller may also include a second interface coupled to the processor and for receiving temperature signals associated with a plurality of hardware components cooled by airflow from at least one of the first fan and the second fan, and wherein the fan controller is operable to change a speed of at least one of the first fan and the second fan in response to a received temperature signal.
And in yet another embodiment, a method for enhanced fault notification includes receiving an input signal. An alert signal is generated in response to receipt of the input signal, wherein the alert signal is operable to control a speed differential between a first fan and a second fan, and wherein the speed differential is operable to create an audible sound. The speed differential is varied to change a frequency of the audible sound. Additionally, a portion of alert information associated with the input signal may be determined, wherein the portion of alert information is used to generate the alert signal. Further, the method may include receiving a temperature signal associated with a plurality of hardware components, wherein the plurality of hardware components are cooled by airflow from at least one of the first fan and the second fan. A speed of at least one of the first fan and the second fan may be adjusted in response to the temperature signal.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements.
FIG. 1 shows an exemplary fan speed graph of a variable-speed fan and a constant-speed fan in accordance with one embodiment of the present invention.
FIG. 2 shows a block diagram of an exemplary fan controller coupled to a fan in accordance with one embodiment of the present invention.
FIG. 3 shows a block diagram of an exemplary fan controller in accordance with one embodiment of the present invention.
FIG. 4 shows an exemplary fan speed graph of two variable-speed fans in accordance with one embodiment of the present invention.
FIG. 5 shows a block diagram of an exemplary fan controller coupled to multiple fans in accordance with one embodiment of the present invention.
FIG. 6 shows a block diagram of an exemplary fan controller coupled to multiple fans with external fan speed controls in accordance with one embodiment of the present invention.
FIG. 7 shows a block diagram of an exemplary fan controller coupled to multiple fans with external and internal fan speed controls in accordance with one embodiment of the present invention.
FIG. 8 shows a process for enhanced alert notification in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings. While the present invention will be discussed in conjunction with the following embodiments, it will be understood that they are not intended to limit the present invention to these embodiments alone. On the contrary, the present invention is intended to cover alternatives, modifications, and equivalents which may be included with the spirit and scope of the present invention as defined by the appended claims. Furthermore, in the following detailed description of the present invention, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, embodiments of the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, components, and circuits have not been described in detail so as not to unnecessarily obscure aspects of the present invention.
FIG. 1 shows exemplary fan speed graph 100 of a variable-speed fan and a constant-speed fan in accordance with one embodiment of the present invention. As shown in FIG. 1 , a first fan speed 110 and second fan speed 120 are graphed with respect to time. First fan speed 110 represents a variable-speed fan, whereas second fan speed 120 represents a fan spinning at a substantially-constant speed. As such, variation of first fan speed 110 with respect to second fan speed 120 creates fan speed differentials (e.g., first fan speed differential 130 and second fan speed differential 140 ), where the differential between the two fan speeds may vary with respect to time. For example, first fan speed differential 130 is larger than second fan speed differential 140 .
If a first fan whose speed may be represented by first fan speed 110 is located close enough to a second fan whose speed may be represented by second fan speed 120 , a fan interference sound (e.g., a “beating” sound) may occur. The fan interference sound can be caused by an intersection of the noise profiles of the two fans, where a “beat” may be produced by a summation of the amplitudes of the noise profiles. As such, the first and second fans may be located within the same system (e.g., a computer system, computer server, etc.), or located in different systems that are near enough to produce a fan interference sound. Alternatively, one fan may be located with a system, while the other fan may be located outside a system (e.g., as part of a HVAC system, a room fan, etc.).
The frequency of the fan interference sound may vary based upon the magnitude of the fan speed differential. As such, the speed of the first fan (e.g., represented by first fan speed 110 ) may be varied to change the magnitude of the fan speed differential, thereby altering the frequency of the resulting interference sound. In one embodiment, an increase in the magnitude of the fan speed differential may decrease the frequency of the fan interference sound, whereas a decrease in the magnitude of the fan speed differential may increase the frequency of the fan interference sound. For example, first fan speed differential 130 may produce a lower frequency interference sound than second fan speed differential 140 given that differential 130 is larger than differential 140 .
Additionally, the intensity or sound level of the resulting interference sound may be varied by increasing or decreasing the speed of the fans. For example, an increase in the average speed of the fans (e.g., those represented by fan speeds 110 and 120 ) may contribute to an increase in intensity of the fan interference sound. For example, first fan speed differential 130 is depicted in FIG. 1 with a larger average fan speed than second fan speed differential 140 , and therefore, the fan interference sound corresponding to fan speed differential 130 may be more intense than a fan interference sound corresponding to fan speed differential 140 . Conversely, if the average speed of the fans decreases, then the intensity may reduce. As a further example, if the speed of both fans change with little change in the magnitude of the fan speed differential, then an increase in speed of the fans would create an increase in the average fan speed, thereby increasing the intensity of the interference sound. Conversely, if the speed of both fans reduces with little change in magnitude of the fan speed differential, then the intensity of the interference sound may decrease given a drop in average fan speed.
Although FIG. 1 depicts a specific relationship between the speeds of two fans (e.g., fan speed 120 is constant and fan speed 130 follows a depicted speed variation), it should be appreciated that the two fan speeds may be alternatively represented in other embodiments. For example, second fan speed 120 may vary in other embodiments, or alternatively, may comprise a combination of constant and varying periods. Similarly, first fan speed 110 may be alternatively varied, or in another embodiment, may comprise a combination of constant and varying periods.
Additionally, although FIG. 1 depicts a change in the magnitude of a fan speed differential for only two fans, it should be appreciated that more than two fans may produce fan interference sounds in other embodiments. As such, one or more fan interference sounds may co-exist based on one or more fan speed differentials. Thus, a resultant frequency and/or intensity of the fan interference sound may be based on a combination of multiple fan interference sounds.
FIG. 2 shows block diagram 200 of an exemplary fan controller coupled to a fan in accordance with one embodiment of the present invention. As shown in FIG. 2 , fan controller 210 is coupled to fan 220 for controlling its speed in response to temperature and/or alert inputs. The speed of fan 220 may be represented by first fan speed 110 of FIG. 1 .
As shown in FIG. 2 , temperature inputs may be fed to fan controller 210 for monitoring temperatures within a system (e.g., for which fan 220 provides heat dissipation). As such, fan controller 210 may then control the speed of fan 220 to respond to changes in the system temperature, where the temperature input may comprise one or more temperatures from various locations within the system. For example, if fan controller 210 detects a rise in system temperature at one or more locations, then the speed of fan 220 may be increased to reduce the system temperature to an acceptable level. The properties of the control system implemented by fan controller 210 may be preconfigured (e.g., by a user, during manufacture, etc.), where control system parameters may be stored in a memory coupled to or integrated within fan controller 210 . Alternatively, the control system may be dynamically configured on-the-fly by a system coupled to or integrated within fan controller 210 .
Alert signals may also be input to fan controller 210 (e.g., for monitoring faults associated with a system, etc.). The alert signals may be associated with one or more components of the system (e.g., ethernet hardware, power supply, etc.) and indicate a condition warranting attention (e.g., battery low, power failure, component failure, overheated component, required system reboot, etc.). Alternatively, the alert signal may be that which is optionally routed to a light-producing device, speaker, etc. of the system. As such, fan controller 210 may be integrated in place of or in conjunction with existing hardware.
Upon detecting a request for an alert, fan controller 210 may control the speed of fan 220 to produce an audible alert generated by a differential in speed of fan 220 with respect to fan 230 (e.g., as discussed above with respect to FIG. 1 ). Fan 230 may be driven at a substantially-constant speed (e.g., 120 of FIG. 1 ) in proximity to fan 220 such that the speed of fan 220 (e.g., 110 of FIG. 1 ) may be varied to change the magnitude of the fan speed differential, thereby changing the frequency and intensity of the fan interference sound (e.g., as discussed above with respect to FIG. 1 ). As such, the fan controller 210 may control the frequency and intensity of the fan interference sound to produce an alert comprising speech, music, a siren, or the like. Thus, an alert may be detected above ambient room noise and more clearly identify one or more systems to which a fault pertains, thereby providing enhanced fault notification and/or isolation using existing system hardware to reduce cost.
Although FIG. 2 shows only one fan (e.g., 220 ) coupled to fan controller 210 , it should be appreciated that more than two fans may be coupled to fan controller 210 for control thereof in other embodiments. Additionally, although fan 230 has been described as being spun at a substantially-constant speed to simplify the discussion, it should be appreciated that speed of fan 230 may be varied in other embodiments.
FIG. 3 shows block diagram 300 of an exemplary fan controller in accordance with one embodiment of the present invention. As shown in FIG. 3 , fan controller 210 is coupled to fan 220 for controlling its speed in response to temperature and/or alert input signals fed into input interface 310 . Signals input via input interface 310 may be conveyed to processor 320 for processing. As such, fan controller may monitor temperatures and alerts as discussed above with respect to FIG. 2 .
Upon accessing a temperature signal from input interface 310 , processor 320 may determine a temperature associated with the system and also whether additional airflow is required based upon the determined temperature. If additional airflow is needed, processor 320 may send a signal to fan speed control 330 to increase the speed of fan 220 . Fan speed control 330 may control fan 220 using a pulse width modulation (PWM) signal, analog signal, or the like, and may receive fan speed information (e.g., a digital or analog signal indicating revolutions per minute, a voltage proportional to its speed, etc.) from fan 220 , a tachometer (not shown) coupled to processor 320 , or the like. Alternatively, if it is determined that a received temperature has been reduced to an acceptable level, processor 320 may instruct fan speed control 330 to reduce the speed of fan 220 . As such, fan speed controller 210 may be used to set a baseline fan speed such that system temperatures are maintained at a given level, where the control system properties may be either preconfigured or dynamically configured on-the-fly as discussed above with respect to FIG. 2 . Additionally, control system parameters may be stored within memory 350 (e.g., for access by processor 320 ).
Upon accessing an alert input signal from input interface 310 , processor 320 may determine the nature of the alert (e.g., to which portions of the system it pertains). Thereafter, processor 320 may access alert information 340 from coupled memory 350 , where alert information may comprise information (e.g., data, instructions, etc.) relevant to the requested alert that processor 320 may use to implement an audible alert. For example, alert information 340 may comprise fan speed information required to implement a given siren, speech or other alert. Alternatively, alert information 340 may comprise frequency information that processor 320 may use to derive fan speed information for implementing the siren, speech or other alert. As such, once fan speed information is obtained from the relevant alert information (e.g., 340 ), processor 320 may instruct fan speed control 330 to adjust the speed accordingly (e.g., using fan speed feedback as discussed above) to implement the alert by varying the frequency and/or intensity of the fan interference sounds.
Processor 320 may perform frequency calibration using frequency detector 360 , where frequency detector 360 is capable of measuring a frequency and/or intensity of sound. Frequency detector 360 may comprise a microphone, or alternatively, may comprise a microphone and one or more signal processing components required to measure the frequency and/or intensity of sound. Frequency calibration may be used to determine a fan speed (e.g., of fan 220 ) required to produce a given frequency when the speed of a second fan (e.g., 230 ) is unknown. Alternatively, frequency calibration may be used to fine-tune a system for which fan speeds are known or reasonably approximated. As such, processor 320 may vary the speed of fan 220 until a desired frequency is produced, where the frequency is determined by processor 320 based upon input from frequency detector 360 . By more accurately determining a fan speed for which a given frequency is produced, processor 320 may more accurately implement a given alert for which fan speed or frequency information (e.g., alert information 340 ) is available (e.g., within memory 350 ).
As shown in FIG. 3 , fan speed controller 210 may be implemented using a programmable system on a chip (PSOC) microcontroller. As such, input interface 310 may be implemented using one or more PSOC ports (e.g., digital input/output, analog input/output, etc.), which are coupled to a PSOC core implementing processor 320 . Memory 350 may be implemented using one or more memories (e.g., SRAM, SROM, flash, etc.) coupled to the core. Frequency detector 360 and fan speed control 330 may be implemented as PSOC peripherals using one or more digital and/or analog blocks, where the peripherals may also utilize various PSOC system resources to perform frequency detection and fan speed control operations. Additionally, control system parameters for configuring fan controller 210 may be input via one or more system resources (e.g., I2C, etc.), where configuration may be performed manually (e.g., by a user) or dynamically (e.g., by another system, device, component, etc.) via a host coupled to the PSOC.
Although FIG. 3 shows only one fan coupled to fan controller 210 , it should be appreciated that multiple fans may be coupled to fan controller 210 in other embodiments. Additionally, more than one fan may be coupled to fan speed control in other embodiments. Further, although FIG. 3 shows only one fan speed control (e.g., 330 ), it should be understood that fan controller 210 may comprise more than one fan speed control in other embodiments. As such, each fan speed control component may be coupled to one or more fans. Alternatively, one or more of the fan speed control components may be unused and not coupled to any fans.
FIG. 4 shows exemplary fan speed graph 400 of two variable-speed fans in accordance with one embodiment of the present invention. As shown in FIG. 4 , a first fan speed 110 and second fan speed 420 are graphed with respect to time, similar to the fan speeds graphed in graph 100 of FIG. 1 . However, whereas second fan speed 120 of FIG. 1 represented a fan spinning at a substantially-constant speed, second fan speed 420 represents a variable-speed fan similar to first fan speed 110 . As such, a variation of either fan speed with respect to the other creates fan speed differentials (e.g., first fan speed differential 430 and second fan speed differential 440 ), where the differential between the two fan speeds may vary with respect to time. For example, first fan speed differential 430 is larger than second fan speed differential 440 .
As discussed above with respect to FIG. 1 , the magnitude of the fan speed differential may change the frequency of the resulting fan interference sounds (e.g., to implement alert notifications, etc.). Also, a variation in the average fan speed may create a change in intensity of the fan noise as discussed above with respect to FIG. 1 . However, given that both fan speeds (e.g., 110 and 420 ) are variable as depicted in graph 400 , a change in the magnitude of the fan speed differential may be controlled by changing the speed of either fan. As such, a fan speed controller may vary the speed of either fan, simultaneously or individually, to change the frequency and/or intensity of the fan interference noise. Additionally, the fans whose speeds are represented in FIG. 4 may be located with the same system, within different systems located near enough to produce an audible fan interference sound. Alternatively, at least one fan may be located outside a system.
Although FIG. 4 depicts a specific relationship between the speeds of two fans, it should be appreciated that the two fan speeds may be alternatively represented in other embodiments. For example, first fan speed 110 and/or second fan speed 420 may be alternatively varied, or in another embodiment, may comprise a combination of constant and varying periods. Additionally, although FIG. 4 depicts a change in the magnitude of a fan speed differential for only two fans, it should be appreciated that more than two fans may produce fan interference sounds in other embodiments. As such, one or more fan interference sounds may co-exist based on one or more fan speed differentials. Thus, a resultant frequency and/or intensity of the fan interference sound may be based on a combination of multiple fan interference sounds.
FIG. 5 shows block diagram 500 of an exemplary fan controller coupled to multiple fans in accordance with one embodiment of the present invention. As shown in FIG. 5 , fan controller 210 is coupled to fan 220 and fan 230 for controlling the speed of the fans (e.g., first fan speed 110 and second fan speed 420 ) in response to temperature and/or alert inputs. As such, fan controller 210 may use two fans to regulate system temperature (e.g., by adjusting the baseline fan speed, etc.), and also vary the magnitude of the fan speed differential (e.g., 430 , 440 , etc.) to implement audible alerts or notifications as discussed above (e.g., with respect to FIGS. 1 , 2 , 3 and 4 ). Alternatively, where fan controller 210 is coupled to more than two fans in other embodiments, fan controller 210 may perform such operations by controlling more than two fans.
FIG. 6 shows block diagram 600 of an exemplary fan controller coupled to multiple fans with external fan speed controls in accordance with one embodiment of the present invention. As shown in FIG. 6 , fan controller 610 is coupled to separate external fan speed controls 330 a and 330 b , where the combination of fan speed controller 610 and external speed controls 330 a and 330 b may operate analogously to fan controller 210 with internal fan speed controls (e.g., 330 ). As such, in response to receiving temperature and/or alert inputs, fan controller 610 may regulate system temperature (e.g., by adjusting the baseline fan speed, etc.), and also vary the magnitude of the fan speed differential (e.g., 430 , 440 , etc.) to implement audible alerts as discussed above (e.g., with respect to FIGS. 1 , 2 , 3 , 4 and 5 ). For example, fan speed control 330 a is operable to control the speed of coupled fan 220 in response to control signals sent from fan controller 610 . Similarly, fan speed control 330 b is operable to control the speed of coupled fan 230 in response to control signals sent from fan controller 610 . Upon receiving control signals from fan controller 610 , fan speed control 330 a and/or 330 b may vary the speed of a coupled fan (e.g., 220 and/or 230 ) by generating a PWM signal, analog signal, or the like (e.g., as discussed above with respect to FIG. 3 ).
Although fan controller 610 is shown coupled to two fans in FIG. 6 , it should be appreciated that fan controller 610 may control more than two fans in other embodiments. Additionally, fan controller 610 may utilize all internal fan speed controls (e.g., 330 ), all external fan speed controls (e.g., 330 a , 330 b , etc.), or a combination of internal and external fan speed controls to control coupled fans.
FIG. 7 shows block diagram 700 of an exemplary fan controller coupled to multiple fans with external and internal fan speed controls in accordance with one embodiment of the present invention. As shown in FIG. 7 , fan controller 710 may control coupled fans 220 and 230 analogously to fan controller 610 , except that fan controller 710 uses a combination of internal and external fan speed controls to control coupled fans. As such, in response to receiving temperature and/or alert inputs, fan controller 710 may regulate system temperature (e.g., by adjusting the baseline fan speed, etc.), and also vary the magnitude of the fan speed differential (e.g., 430 , 440 , etc.) to implement audible alerts as discussed above (e.g., with respect to FIGS. 1 , 2 , 3 , 4 , 5 and 6 ). For example, fan speed control 330 a is operable to control the speed of coupled fan 220 (e.g., using PWM signals, analog signals, etc.) in response to control signals sent from fan controller 710 . However, fan 230 may be directly controlled by fan controller 710 (e.g., by use of internal fan speed control 330 ), where fan controller 710 may control the speed of fan 230 by varying a PWM signal, analog signal, or the like.
Although fan controller 710 is shown coupled to two fans in FIG. 7 , it should be appreciated that fan controller 710 may control more than two fans in other embodiments. Additionally, fan controller 710 may utilize all internal fan speed controls (e.g., 330 ), all external fan speed controls (e.g., 330 a , 330 b , etc.), or a combination of internal and external fan speed controls to control coupled fans.
FIG. 8 shows process 800 for enhanced alert notification in accordance with one embodiment of the present invention. As shown in FIG. 8 , step 810 involves accessing temperature measurement signals. The temperature measurement signals may be accessed by a fan controller (e.g., 210 , 610 , 710 , etc.), and may represent temperatures within one or more locations of a single system or multiple systems. Additionally, the temperature measurement signals may be associated with a system or systems for which fans controlled by the fan controller may provide heat dissipation.
After accessing the temperature measurement signals, a fan speed baseline may be updated in step 820 based upon the measured temperatures. The fan speed baseline may represent an average fan speed for one or more fans controlled by a fan controller (e.g., 210 , 610 , 710 , etc.) to provide sufficient cooling for a system or systems (e.g., for which fans controlled by the fan controller provide heat dissipation). As such, an increase in a system temperature may indicate a need to raise the fan speed baseline to provide additional heat dissipation, thereby lowering the system temperature. Conversely, a decrease in a system temperature may indicate a need to lower the fan speed baseline to reduce heat dissipation, thereby raising the system temperature.
As shown in FIG. 8 , a determination is made in step 830 as to whether an alert is requested. An alert request may be detected by monitoring an alert input signal, where an alert input may identify a fault present in one or more components (e.g., ethernet hardware, power supply, etc.) of one or more systems (e.g., for which the fan speed baseline is updated in step 820 ) and indicate a condition warranting attention (e.g., component failure, overheated component, required system reboot, etc.). Alternatively, the alert signal may be that which is optionally routed to a light-producing device, speaker, etc. of the system. If an alert is not requested in step 830 , then steps 810 and 820 may be repeated. Alternatively, if an alert is requested in step 830 , then step 840 may be performed.
Step 840 involves making a determination as to whether multiple fans are present to generate fan interference sounds. Multiple fans may be present within the same system, where the presence of the fans may be detected by accessing data stored within a system (e.g., in a coupled memory), performing inter-system communication (e.g., a fan presence check performed by a fan controller), etc. Alternatively, the presence of a fan outside a given system (e.g., not accessible by a given fan controller, used for HVAC, etc.) may be detected by varying the speed of a system fan over a given rotational speed range and simultaneously monitoring the frequency (e.g., using frequency detector 360 ) of any resulting fan interference sound. If a fan interference sound is detected, then the presence of at least one non-system fan may be identified. Accordingly, if an additional system or non-system fan enabling the generation of fan interference sounds is not detected in step 840 , then steps 810 through 830 may be repeated. Alternatively, if an additional fan is detected such that fan interference sounds may be generated, then step 850 may be performed.
As shown in FIG. 8 , step 850 involves performing frequency calibration. Frequency calibration may be used to determine a fan speed (e.g., of fan 220 ) required to produce a given frequency when the speed of a second fan (e.g., 230 ) is unknown. Alternatively, frequency calibration may be used to fine-tune a system for which fan speeds are known or reasonably approximated (e.g., where the fans are both controlled by the same fan controller). As such, a fan controller may vary the speed of a coupled fan until a desired frequency is produced, where the frequency is determined by one or more components (e.g., frequency detector 360 ) coupled to or integrated within the fan controller. Additionally, frequency calibration may be performed for multiple frequencies and fan speeds such that accuracy is improved.
Step 860 involves accessing alert information associated with an alert requested in step 830 . The alert information (e.g., 340 of FIG. 3 ) may be accessed from a memory (e.g., 350 of FIG. 3 ) coupled to or integrated within a fan speed controller (e.g., 210 , 610 , 710 , etc.). Additionally, the alert information may comprise information (e.g., data, instructions, etc.) relevant to the requested alert that may be used to implement an audible alert. For example, the alert information may comprise fan speed information required to implement a given siren, speech or other alert. Alternatively, the alert information may comprise frequency information that may be used to derive fan speed information for implementing the siren, speech or other alert.
Once the relevant alert information is accessed, the requested alert may be implemented in step 870 by varying the fan speed accordingly (e.g., in accordance with fan speed information associated with the alert information). A fan controller (e.g., 210 , 610 , 710 , etc.) may vary the speed of the fan in accordance with the fan speed information (e.g., using fan speed feedback as discussed above with respect to FIG. 3 ), thereby varying the frequency and/or intensity of the fan interference sounds to implement the audible alert. Thereafter, steps 810 through 860 may be repeated to detect and correct for any undesirable change in temperature (e.g., resulting from implementing the alert, from a change in heat dissipation by one or more system components, etc.), and also to detect any requested alerts for which an audible alert may be implemented using fan interference sounds.
In the foregoing specification, embodiments of the invention have been described with reference to numerous specific details that may vary from implementation to implementation. Thus, the sole and exclusive indicator of what is, and is intended by the applicant to be, the invention is the set of claims that issue from this application, in the specific form in which such claims issue, including any subsequent correction. Hence, no limitation, element, property, feature, advantage, or attribute that is not expressly recited in a claim should limit the scope of such claim in any way. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.
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A system, fan controller and method for enhanced alert notification. Embodiments provide an effective mechanism for utilizing system fans to create alert tones or messages, where fan speed differentials may be adjusted to alter the frequency of the fan interference sounds. As such, existing hardware can be used to reduce cost by producing audible alerts which may be heard above ambient noise in a room with one or more electronic systems. Further, the frequency of the interference sounds may be altered to more clearly identify one or more systems to which a fault pertains.
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RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser. No. 09/918,915, filed on Jul. 31, 2001, which claims benefit to U.S. Provisional Application Serial No. 60/224,166, filed on Aug. 9, 2000, both of which are herein incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a novel process for the preparation of (R)-3-(4-Bromobenzyl)-1-(3,5-dichlorophenyl)-5-iodo-3-methyl-1-H-imidazo[1,2-α]imidazol-2-one. This compound is useful as an intermediate in the preparation of certain small molecules that are useful in the treatment or prevention of inflammatory and immune cell-mediated diseases. The present invention also relates to certain novel intermediates used in this novel process.
BACKGROUND OF THE INVENTION
[0003] -3-(4-Bromobenzyl)-1-(3,5-dichlorophenyl)-5-iodo-3-methyl-1-H-imidazo[1,2-α]-imidazo -2-one (1) is an advanced intermediate used in the preparation of certain small molecules that inhibit the interaction of cellular adhesion molecules, specifically by antagonizing the binding of human intercellular adhesion molecules (including ICAM-1, ICAM-2 and ICAM-3) to the Leukointegrins (especially CD 18/CD 11 a or “LFA-1”). As a result, these small molecules are useful in the treatment or prevention of inflammatory and immune cell-mediated diseases. See U.S. Nonprovisional Application No. 09/604,312 (Attorney Docket No. 9/162), Wu et al., filed on Jun. 27, 2000, herein incorporated by
[0004] reference.
[0005] The method that has been used to prepare compound 1 is illustrated in Scheme 1 below.
[0006] In this procedure, an amino-ester 2 was reacted with 3,5-dichlorophenylisothiocyanate 3 to provide thiohydantoin 4. To a solution of triphenylphosphine (PPh 3 ) was added the azide 5. After stirring at room temperature overnight, thiohydantoin 4 was added to provide 6. Treatment of 6 with trifluoroacetic acid provided 7. Iodination was then carried out by reaction of 7 with N-iodosuccinimide and pyridinium p-toluenesulfonate to provide 1. Recovered 7 may be recycled to provide additional 1.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to a novel process for the preparation of compound 1. A first aspect of the invention is directed to a process for preparing a compound of the formula 1:
[0008] said process comprising the following steps:
[0009] a) reacting a compound of the formula I with a compound of the formula
[0010] where R is C 1-6 alkyl, in an aprotic organic solvent, followed by adding a triarylphosphine, a carbon tetrahalide and a tertiary amine, to form a compound of the formula IIa where R is C 1-6 alkyl:
[0011] b) optionally hydrolyzing a compound of the formula IIa produced in step a) by reacting the compound of formula IIa with a base to form a compound of the formula IIb:
[0012] c) reacting a compound of the formula IIa produced in step a) with a Lewis acid and a phosphine oxide compound of the formula (R 1 ) 3 PO, wherein R 1 is C 1-6 alkyl or aryl, in an aprotic organic solvent to form a compound of the formula III:
[0013] when the optional step b) is performed, reacting a compound of the formula IIb produced in step b) with a coupling agent in an aprotic organic solvent to form a compound of the formula III:
[0014] d) reacting a compound of the formula III produced in step c) with a strong base and a compound of the formula (R 2 O) 2 POCl, wherein R 2 is C 1-6 alkyl, or aryl, in a polar organic solvent at a temperature of about −90° C. to about 0° C. to form a compound of the formula IV where R 2 is C 1-6 alkyl or aryl:
[0015] e) reacting a compound of the formula IV produced in step d) with trimethylsilyl iodide, or with sodium iodide and trimethylsilyl chloride, in an aprotic organic solvent to form a compound of the formula 1:
[0016] A second aspect of the invention is directed to the individual novel steps of the above inventive process. A third aspect of the invention is directed to the novel intermediates IIa, IIb, III and IV. A final aspect of the invention is directed to the novel urea intermediate of the following formula Ia produced in the first step of the inventive process and its process of preparation:
[0017] wherein R is C 1-6 alkyl.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The individual steps of the inventive process are described in detail below, along with other aspects of the present invention.
[0019] All terms as used herein in this specification, unless otherwise stated, shall be understood in their ordinary meaning as known in the art. For example, a “C 1-6 alkyl” is an alkyl group having from 1 to 6 carbon atoms, which group can be branched or unbranched. The term “aryl”, either alone or as part of another group, shall be understood to mean an optionally substituted 6-10 membered aromatic carbocycle; “aryl” includes, for example, phenyl and naphthyl, each of which may be optionally substituted.
[0020] Optimum reaction conditions and reaction times for the individual steps may vary depending on the particular reactants used. Unless otherwise specified, solvents, temperatures, pressures and other reaction conditions may be readily selected by one of ordinary skill in the art. Specific procedures are provided in the Synthetic Examples section. Typically, reaction progress may be monitored by thin layer chromatography (TLC) if desired. Intermediates and products may be purified by chromatography on silica gel and/or recrystallization. Unless otherwise set forth, the starting materials and reagents are either commercially available or may be prepared by one skilled in the art using methods described in the chemical literature.
Step (a)
[0021] Step a) of the inventive process comprises reacting a compound of the formula I with a compound of the formula
[0022] where R is C 1-6 alkyl, in an aprotic organic solvent, followed by adding a triarylphosphine, a carbon tetrahalide and a tertiary amine, to form a compound of the formula Ia where R is C 1-6 alkyl:
[0023] The starting material of formula I is prepared as described in Yee, N., “Self-Regeneration of Stereocenters: A Practical Enantiospecific Synthesis of LFA-1 Antagonist BIRT-377 ”, Org. Lett. 2000, 2, 2781-2783, which is herein incorporated by reference in its entirety. This process is set forth in detail below:
[0024] The commercially available (D)-N-Boc-alanine 9 is reacted with 3,5-dichloroaniline via a mixed anhydride intermediate (i-BuOCOCl, N-methylmorpholine, −10° C. to rt, THF) to give amide 10. Deprotection of the crude amide 10 by TFA in dichloromethane afforded amino N-aryl amide 11 in 92% yield over two steps.
[0025] The amino amide 11 is treated with pivalaldehyde in refluxing pentane. A crystalline solid is directly formed from the reaction mixture and identified as the desired trans imidazolidinone 12 as a single diastereomer in 74% yield. After protection of 12 (TFAA,
[0026] Et 3 N, 0° C. to rt, CH 2 Cl 2 , 98% yield) to obtain 13, the crude 13 in THF is deprotonated with LiN(TMS) 2 at −30 to −20° C. and then the resulting enolate is alkylated at −30°C. to 0° C. with 4-bromobenzyl bromide from the opposite face of the t-butyl group to give the 5,5-disubstituted 14 as a single diastereomer in 96% yield.
[0027] The trifluoroacetamide group of 14 is first hydrolyzed (1.5 eq. BnMe 3 NOH, 2.0 eq. 50% NaOH, rt to 40° C., dioxane) to give a mixture of the corresponding partially hydrolyzed N-unsubstituted acetal of 14, Schiff base of I, and I itself. Subsequent direct addition of 6N HCl to the above mixture resulted in complete hydrolysis to afford amino amide I in quantitative yield.
[0028] In step (a) of the present inventive process, the compound of formula I is first reacted with an isocyanatoacetate of the formula
[0029] where R is C 1-6 alkyl to form a urea of the following formula Ia in situ:
[0030] where R is C 1-6 alkyl. It is not necessary to isolate the novel urea Ia, although it has been isolated and characterized. The urea of formula Ia is dehydrated in situ by adding a triarylphosphine, a carbon tetrahalide and a tertiary amine to the reaction mixture. The resulting carbodiimide undergoes a spontaneous cyclization to provide the ester of formula IIa in good yield.
[0031] The formation of ureas from isocyanates in general is documented in the scientific literature (See, e.g., Chem. Rev. 1981, 589, and references cited therein). In the process of the present invention, however, it is not necessary to isolate the urea, which can be dehydrated in situ to afford a carbodiimide that further undergoes a spontaneous cyclization.
[0032] The dehydration of a urea to afford an intermediate carbodiimide is also documented in the literature (Appel, R., Kleinstuck, R., Ziehn, K. Chem. Ber. 1971, 104, 1335). However, the process of the present invention goes beyond the dehydration of the urea intermediate, since the carbodiimide is not isolated and undergoes a spontaneous cyclization to give IIa.
[0033] Moreover, the novel compound of formula Ia is another aspect of the present invention and is not disclosed in the above cited references.
[0034] Suitable C 1-6 alkyl R groups for the isocyanatoacetate and formula Ia in step a) include, for example, methyl and ethyl.
[0035] Step a) is performed in an aprotic organic solvent. Suitable aprotic organic solvents for this step include, for example, tetrahydrofuran, toluene, dichloromethane, dichloroethane and chloroform. Suitable triarylphosphines in step a) include, for example, triphenylphosphine, wherein the phenyl groups are optionally substituted, for example, with one or more methoxy or amino groups. Suitable carbon tetrahalides in step a) include, for example, CCl 4 and CBr 4 . Suitable tertiary amines in step a) include, for example, trialkylamine, 1-methylpyrrolidine or 1-methylmorpholine. A preferred tertiary amine for use in step a) is triethylamine.
Step (b)
[0036] Step (b) of the inventive process is an optional hydrolysis step and comprises hydrolyzing the ester compound of the formula IIa produced in step a) by reacting the compound of formula IIa with a base to form the corresponding acid compound of the formula IIb:
[0037] Suitable bases for this step include, for example, alkali metal hydroxides such as lithium hydroxide, sodium hydroxide or potassium hydroxide. The novel compound of formula IIb produced in this step is another aspect of the present invention.
[0038] In one embodiment of the inventive process, this optional hydrolysis step b) is not performed and the ester of formula IIa produced in step a) is used directly in the next step of the process, step c).
Step (c)
[0039] Step (c) of the inventive process comprises reacting a compound of the formula IIa produced in step a) with a Lewis acid and a phosphine oxide compound of the formula (R 1 ) 3 PO, wherein R 1 is C 1-6 alkyl or aryl, in an aprotic organic solvent to form a compound of the formula III:
[0040] or
[0041] when the optional step b) is performed, step c) comprises reacting a compound of the formula IIb produced in step b) with a coupling agent in an aprotic organic solvent to form a compound of the formula III:
[0042] When the ester compound of formula IIa is employed in step (c), the ester IIa is cyclized in the presence of a Lewis acid and a phosphine oxide compound to provide the imidazo-imidazole-3,5-dione of formula III in good yield. This is similar to a known procedure for the synthesis of lactams (Takahata, H., Banba, Y., Momose, T. Tetrahedron, 1991, 47, 7635). It was observed, however, that following the reaction conditions described in the literature failed to afford the desired product III in significant yield. It was discovered that the addition of a phosphine oxide compound of the formula (R 1 ) 3 PO, wherein R 1 is C 1-6 alkyl or aryl, was necessary for the reaction to proceed efficiently.
[0043] Step c) is performed in an aprotic organic solvent. Suitable aprotic organic solvents for this step include, for example, tetrahydrofuran, toluene, dichloromethane, dichloroethane or chloroform. Suitable Lewis acids for use in this step include, for example, AlCl 3 , TiCl 4 and trialkylaluminums of the formula (C 1-6 alkyl) 3 Al, such as Me 3 Al. Suitable phosphine oxides for this step include, for example, triarylphosphine oxides such as triphenylphosphine oxide, wherein the phenyl groups are optionally substituted with one or more methoxy or amino groups.
[0044] When the acid compound of formula IIb is employed in step (c), a coupling agent is used to cause cyclization via an intramolecular coupling between the carboxylic acid group and the amine group (i.e., a peptide-type coupling reaction). Suitable coupling agents for this purpose include conventional peptide coupling agents, for example, acetic anhydride, acetyl chloride, thionyl chloride and oxalyl chloride. Suitable aprotic organic solvents for this step are the same as described above.
[0045] The novel imidazo-imidazole-3,5-dione compound of formula III produced in step c) is another aspect of the present invention.
Step (d)
[0046] Step (d) of the inventive process comprises reacting a compound of the formula III produced in step c) with a strong base and a compound of the formula (R 2 O) 2 POCl, wherein R 2 is C 1-6 alkyl or aryl, in a polar organic solvent at a temperature of about −90° C. to about 0° C. to form a compound of the formula IV where R 2 is C 1-6 alkyl or aryl:
[0047] The synthesis of the vinyl phosphate compound IV is similar to a known procedure for the preparation of ketene aminal phosphates from lactams (Nicolau, K. C., Shi, G., Kenji, N., Bernal, F. Chem. Commun. 1998,1757).
[0048] The novel vinyl phosphate compound of formula IV produced in step d) is another aspect of the present invention and is not disclosed by the above cited reference.
[0049] Step d) is conducted in the presence of a strong base. In the context of this invention, a strong base is a base having a pKa of greater than 20. Suitable strong bases for use in this step include, for example, alkali metal amides, such as potassium bis(trimethylsilyl)amide, lithium bis(trimethylsilyl)amide, sodium bis(trimethylsilyl)amide and lithium diisopropylamide.
[0050] In one embodiment, the R 2 group in the chlorophosphate compound (R 2 O) 2 POCl and in the compound of formula IV is a C 1-6 alkyl group, preferably methyl or ethyl.
[0051] Step d) is conducted in a polar organic solvent. Suitable polar organic solvents include, for example, diethyl ether, dipropyl ether, diisopropyl ether, dibutyl ether, methyl tert-butyl ether (MTBE), dipentyl ether, diisopentyl ether, ethylene glycol dimethyl ether, diethylene glycol dimethyl ether, dioxane, tetrahydrofuran, N,N-dimethylformamide, N,N-dimethyl-acetamide, DMSO or N-methyl-2-pyrollidone.
[0052] Step d) is conducted at a temperature of about −90° C. to about 0° C., preferably about −50° C. to about −5° C., more preferably about −30 C. to about −10° C. In one embodiment, step d) is conducted at a temperature of about −20° C. The term “about” in this context means a temperature between 10% above and 10% below the recited value, inclusive. For example, “about −20° C.” means a temperature falling in the range −18° 0 C. to −22° C.
Step (e)
[0053] Step (e) of the inventive process is an iodination that comprises reacting a compound of the formula IV produced in step d) with trimethylsilyl iodide (TMSI), or with sodium iodide (Nal) and trimethylsilyl chloride (TMSCl), in an aprotic organic solvent to form a compound of the formula 1:
[0054] The synthesis of the compound of formula 1 from the vinyl phosphate compound of formula IV is related to a known procedure for the preparation of vinyl iodides from ketone-derived enol phosphates (Lee, K., Wiemer, D. F. Tetrahedron Lett. 1993, 34, 2433).
[0055] However, the enol phosphates in the literature procedure are ketone-derived vinyl phosphates and not lactam-derived ketene aminal phosphates like formula IV.
[0056] The iodination in step e) is conducted by reacting the vinyl phosphate compound of formula IV with trimethylsilyl iodide, or with sodium iodide and trimethylsilyl chloride. When sodium iodide and trimethylsilyl chloride are used, these two compounds react in situ to form trimethylsilyl iodide, which then reacts with formula IV to form the iodinated compound of formula 1.
[0057] Step e) is conducted in an aprotic organic solvent. Suitable aprotic organic solvents for this step include, for example, tetrahydrofuran, toluene, dichloromethane, dichloroethane, chloroform and acetonitrile.
[0058] Step (e) is optionally conducted in the presence of water. It has been found that water accelerates the formation of the iodide compound of formula 1. This step has been run with up to 6 equivalents of water, although higher amounts of water can be used. In one embodiment, the amount of water present is from about 0.5 to 1.5 equivalents, preferably about 0.8 to 1.2 equivalents.
SYNTHETIC EXAMPLES
[0059] The invention is further illustrated by the following non-limiting examples of the inventive process.
Example 1
(R) {3-[2-(4-Bromophenyl)-1-(3,5-dichlorophenylcarbamoyl)-1-methyl-ethyl]-ureido}-acetic acid ethyl ester
[0060] [0060]
[0061] Ethyl isocyanatoacetate (80.7 mL, 719 mmol) was added dropwise to a stirred solution of I (281 g, 698 mmol) and THF (2 L) at ambient temperature. The mixture was stirred at room temperature for 12 h and hexane (600 mL) was added. The resulting solid was collected by filtration. The filtrate was concentrated under reduced pressure and the resulting precipitate was again collected by filtration. The solid material was combined to afford a total of 325 g of product as a white solid: 1 H NMR (400 MHz, (D 3 C) 2 SO) δ1.17 (t, J=7.1 Hz, 3H), 1.23(s, 3H), 3.05(d, J=13.3 Hz, 1H), 3.29 (d, J=13.3 Hz,1H),3.75(dd, J=6.0 Hz, J=17.7 Hz, 1H), 3.84(dd, J=6.0, J=17.7 Hz, 1H), 4.10 (q, J=7.1 Hz, 2H), 6.35 (s, 1H), 6.40 (t, J=6.0 Hz, 1H), 7.10 (d, J=8.2 Hz, 2H), 7.23(t, J=1.8 Hz, 1H), 7.44(d, J=8.2 Hz, 2H), 7.74(d, J=1.8 Hz, 2H), 9.83 (s, 1H).
Example 2
(R)-[4-(4-Bromobenzyl)-1-(3,5-dichlorophenyl)-4-methyl-5-oxo-imidazolidin-2-ylideneamino]-acetic acid ethyl ester
Method A:
[0062] [0062]
[0063] Carbon tetrachloride (43.6 mL, 452 mmol) was added dropwise to a stirred solution of the product of Example 1 (120 g, 226 mmol), triethylamine (63.0 mL, 452 mmol), triphenylphosphine (119 g, 452 mmol) and dichloromethane (1.8 L) at room temperature. The mixture was stirred at ambient temperature for 12 h and concentrated under reduced pressure. Ethyl acetate (1.2 L) was added and the mixture was stirred for 5-10 min. The solids were removed by filtration and the organic layer was washed sequentially with 0.5 N HCl (450 mL) and saturated aqueous NaHCO 3 (450 mL). The mixture was concentrated under reduced pressure to afford an orange oil. Ethyl acetate (240 mL) was added to the mixture at 50° C. followed by MTBE (720 mL) and the mixture was stirred at 60° C. for a few min. The mixture was allowed to reach ambient temperature and was stirred for 12 h. The precipitate (triphenylphosphine oxide) was then removed by filtration and the filtrate was concentrated under reduced pressure to afford 134 g of an orange solid. 1 H NMR analysis of the crude material indicated it contained about 38% W/W triphenylphosphine oxide. A small sample was purified by chromatography for analytical purposes and the bulk of the material was used for the next step without further purification.
Method B
[0064] [0064]
[0065] Ethyl isocyanatoacetate (0.287 mL, 2.56 mmol) was added dropwise to a stirred solution of I (1.0 g, 2.49 mmol) and dichloromethane (5 mL) at room temperature. The mixture was stirred for 10 min at room temperature and the urea (product of Example 1) forms as a white precipitate. Stirring was continued for about 2 h thereafter to ensure complete conversion to the urea, and then triphenylphosphine (1.31 g, 4.98 mmol), triethylamine (0.69 mL, 4.98 mmol), and carbon tetrachloride (0.48 mL, 4.98 mmol) were added to the stirred suspension. The mixture was then stirred at ambient temperature for 12 h.
[0066] Aqueous workup (1 N HCl, dichloromethane, MgSO 4 ) afforded a yellow oil. Flash chromatography (silica gel, 4:1 hexane/ethyl acetate V/V) afforded 906 mg (71%) of product as a white solid: mp 103-105° C.; 1 H NMR (400 MHz, CDCl 3 ) δ1.31 (t, J=7.1 Hz, 3H), 1.52(s, 3H), 2.95 (d, J=12.9 Hz, 1H), 2.98 (d, J=12.9 Hz, 1H), 4.05-4.13 (m, 3H), 4.23 (m, 2H), 6.57 (d, J=1.6 Hz, 2H), 7.04 (d, J=8.2 Hz, 2H), 7.37 (m, 3H); 13 C NMR (CDCl 3 , 100 MHz) δ14.1, 23.7, 42.9, 44.2, 61.7, 70.4, 120.9, 125.6, 129.4, 130.8, 131.9, 133.2, 134.8, 136.1, 151.1, 169.6, 181.5; Anal. calcd for C 21 H 20 BrCl 2 N 3 O 3 : C, 49.15; H, 3.93; N, 8.19. Found C, 49.46; H, 3.92; N, 7.96.
Example 3
(R)-3-(4-Bromobenzyl)-1-(3,5-dichlorophenyl)-3-methyl-1,6-dihydroimidazo[1,2-α]imidazole-2,5-dione.
[0067] [0067]
[0068] Toluene (450 mL) was added to 76.9 g of a mixture of the product of Example 2(47.1 g, 91.7 mmol) and triphenylphosphine oxide (29.2 g, 105 mmol), and the resulting solution was cooled down to −10° C. Trimethylaluminum (46 mL of a 2 M solution in toluene, 92mmol) was added dropwise keeping the temperature at or below 0° C. and the mixture was then allowed to reach ambient temperature. The mixture was stirred at ambient temperature for two h and more trimethylaluminum (27.6 mL of a 2 M solution in toluene, 55.2 mmol) was added in two portions at two h intervals. The mixture was placed over an ice bath and slowly quenched with 1 N HCl (360 mL). The organic portion was separated and the aqueous portion was extracted with toluene (200 mL). The combined organic portions were washed with water and concentrated under reduced pressure to afford an orange oil. Flash chromatography (silica gel, hexane/ethyl acetete 4:1 V/V) afforded 38.1 g (89%) of product as an oil that solidified upon standing: mp 52-54° C.; 1 H NMR (400 MHz, CDCl 3 ) δ1.84 (s, 3H), 3.24 (d, J=13.8 Hz, 1H), 3.43 (d, J=13.8 Hz, 1H), 4.18(d,j=21.9 Hz, 1H), 4.30 (d, J=21.9 Hz, 1H), 6.95 (d, J=8.3 Hz, 2H), 7.29 (d, J=1.8 Hz, 2H), 7.33 (t, J=1.8 Hz, 1H), 7.38 (d, J=8.3 Hz, 2H); 13 C NMR (100 MHz, CDCl 3 ) δ21.5, 40.8, 61.3, 65.1, 122.3, 122.6, 128.5, 131.0, 132.0, 132.5, 132.7, 135.5, 154.6, 174.3, 174.9; Anal. calcd for Ci 19 H 14 BrCi 12 N 3 O 2 : C, 48.85; H, 3.02; N, 9.00. Found C, 48.89; H, 3.02; N, 8.81.
Example 4
Phosphoric acid (R) 5-(4-bromobenzyl)-7-(3,5-dichlorophenyl)-5-methyl-6-oxo-6,7-dihydro-5H-imidazo[1,2-α]imidazol-3-yl ester diethyl ester
[0069] [0069]
[0070] Potassium bis(trimethylsilyl)amide (265 mL of a 0.5 M solution in toluene, 133 mmol) was added dropwise to a stirred solution of the product of Example 3 (51.5 g, 110.3 mmol), diethyl chlorophosphate (23.9 mL, 165 mmol) and THF (700 ml) at −20° C. The mixture was stirred at −20° C. for one h. Aqueous workup (aqueous NH 4 Cl, ethyl acetate, MgSO 4 ) afforded an oil. Flash chromatography (silica gel, hexane/ethyl acetate 2:1 V/V) afforded 61.2 g (92%) of product as a yellow oil: 1 H NMR (400 MHz, CDCl 3 ) δ1.44 (t, J=7.1 Hz, 6H), 1.86 (s, 3H), 3.26 (d, J=13.9 Hz), 3.34 (d, J=13.9 Hz, 1H), 4.33 (m, 4 H), 6.50 (s, 1H), 6.84 (d, J=8.2 Hz, 2H), 7.24-7.28 (m, 3H), 7.58 (d, J=1.6 Hz, 2H).
[0071] Example 5
(R)-3-(4-Bromobenzyl)-1-(3,5-dichlorophenyl)-5-iodo-3-methyl-1H-imidazo[1,2-α]imidazol-2-one
[0072] [0072]
[0073] Trimethylsilyl chloride (42.8 mL, 338 mmol) was added dropwise to a stirred suspension of Nal (49.5 g, 330 mmol), the product of Example 4 (66.3 g, 110 mmol) and dichloromethane (1.1 L) at −10° C. The mixture was allowed to reach ambient temperature and stirred for 90 min. The mixture was placed over an ice bath and quenched with a mixture of saturated aqueous NaHCO 3 solution (360 mL) and 10% aqueous sodium thiosulfate (360 mL). The organic layer was set aside and the aqueous layer was extracted with dichloromethane (500 mL). The combined organic portions were dried (MgSO 4 ) and concentrated to afford 100 g of a light brown oil. Flash chromatography (silica gel, 6:1 hexane/ethyl acetate V/V) afforded 44.1 g (69%) of product as a colorless solid: 1 H NMR (400 MHz, CDCl 3 ) δ1.92(s, 3H), 3.24 (d, J=14 Hz, 1H), 3.54 (d, J=14 Hz, 1H), 6.789(d, J=8.3 Hz, 2H), 6.95 (s, 1H), 7.27 (m, 3H), 7.53 (d, J=1.8 Hz, 2H).
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A novel process for the preparation of (R)-3-(4-Bromobenzyl)-1-(3,5-dichlorophenyl)-5-iodo-3-methyl-1-H-imidazo[1,2-a]imidazol-2-one (1):
This compound is useful as an intermediate in the preparation of certain small molecules that are useful in the treatment or prevention of inflammatory and immune cell-mediated diseases. The present invention also relates to certain intermediates used in this novel process.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part application of U.S. patent application Ser. No. 09/977,929, filed on Oct. 15, 2001 now abandoned, which is hereby incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
The invention relates to compositions and methods for producing brine solutions, phosphate salt mixtures, food products, and coagulating collagen.
BACKGROUND OF THE INVENTION
Salts have certain desirable properties when dissolved in a solvent. Salts may affect the pH, osmolality, osmolarity, partial pressure and other physical properties of a solution. Salts also vary in solubility. For example, ten grams of a certain salt may dissolve completely in 90 grams of water while ten grams of another salt will remain undissolved in 90 grams of water. A mixture of different salts may also have increased or decreased solubility when compared to the individual constituents of the mixture alone. Dry salts, or salts substantially free of water, also impart a more rapid drying response when contacted with a wet surface. It is believed that the disruption by salt molecules of the ionic, Van der Waals, hydrogen-bonding forces and other physical forces between solvent molecules allows for more rapid dissipation of solvent molecules from the solution. Likewise, certain salts in solution may quickly dry a wet surface, membrane, or substrate when the chemical interactions of the solution are changed.
These properties of salts have particular significance in the food industry. Salts have been used for thousands of years to season food, preserve food from bacterial growth, and to dry food and bind water. Many of these foods are prepared by adding a particular food product such as meat, cheese, and vegetable matter into a membrane which is congealed upon addition of a dry salt or salt solution. Certain salts are also known to coagulate, or congeal, a protein in solution or on the surface of food products. The term “coagulate” means to remove water from the protein solution. Sausages are but one product of this mode of food preparation.
The art of sausage making is an ancient craft encompassing a diverse range of products. There are many types of sausages including (1) ground, fresh sausage products, (2) emulsion-type sausages such as frankfurters, wieners, bologna, liver sausage, and other processed sausage products, and (3) fermented sausage products. The present invention has application to the manufacture of any type of sausage that is put into a casing. In addition, the compositions and methods can be used not only in the production of sausages, but may also be used in the production of other food products containing collagen, such as fish, meat, vegetables and cheese. The term food product shall hereinafter refer to any edible substance which can incorporate or become surrounded by collagen.
Food grade acids are commonly used in the manufacture of sausage products to spray product surfaces prior to smoking or cooking. The acid reduces surface pH and promotes coagulation of protein at the surface. Acetic acid or vinegar are used extensively. Liquid smoke, when sprayed, dipped, or atomized onto sausage surfaces, imparts flavor, improves color, and aids peeling in some instances.
Various binders/extenders are added to sausage meat formulations to improve emulsion stability, to improve cooking yields, to improve slicing characteristics, to improve flavor, and to reduce formulation costs. Binders/extenders, when utilized, are typically added in amounts up to 3.5%. Typical binders/extenders include cereal byproducts, starch, vegetable flour, soy flour, soy protein concentrate, soy protein isolate, hydrocolloids, sugars, nonfat dry milk, and calcium-reduced nonfat dry milk. Finally, sausage formulations contain salt (sodium chloride), and sometimes alkaline phosphates. Depending on the type of sausage product, salt may be present in an amount of from 0–5% of the final product weight.
As is well-known in the art, once all the ingredients have been ground and/or chopped, mixed, and emulsified, the resulting sausage batter may be transferred to stuffers for extruding the batter mix into casings. After the emulsion is stuffed in the casings, the encased mass may be tied with thread or fastened with metal clips. The stuffed and linked sausage products may then be transferred to a smoke house wherein the sausage products undergo a specialized drying and cooking operation in which the sausage emulsion is coagulated. After smoking and cooking, the product is showered with cold water and then chilled by refrigeration. Finally, after properly chilling the product, usually to a temperature of 35° F. to 40° F., casings may be removed by a peeling operation.
In modern sausage and other food product processors, such as those disclosed in U.S. Pat. No. 6,054,155 to Kobussen, et al., herein incorporated by reference in its entirety, the sausage filling is coextruded along with a collagen gel, which will form the casing. In order to form the casing, the collagen gel must be dehydrated and the collagen protein structure is altered in order to have the strength and functionality for further processing. This casing has the disadvantage of requiring a coagulation and air drying stages being costly in terms of energy consumption, length and inefficiency of drying times. The food product is simply prepared in too great a quantity and at too rapid a rate to allow for the traditional coagulation and drying steps. The coagulation and drying steps are enhanced by a brine solution. Specifically, the prior art salts do not meet all the needs of sausage manufacturers, such as those salts found in the Kobussen, et al. reference above.
Thus, what is needed are compositions and methods of decreasing the coagulation and drying times of the collagen by contacting it with a quick drying, high solubility and neutral pH salt solutions to enhance the coagulation process. What is also needed are compositions and methods which allow the combination of these two steps by the addition of a salt spray which both coagulates and dries the food product in a single step.
The invention will be described further in connection with the Example set forth below which is for purposes of illustration only. All percentages are by weight unless otherwise indicated.
BRIEF SUMMARY OF THE INVENTION
In overcoming the above disadvantages, it is an object of the invention to produce brine solutions and dry phosphate salt mixtures that may be used to coagulate collagen and reduce drying times of food products in contact with collagen.
Accordingly, and in one aspect of the invention, a brine solution comprising at least about 40% by weight of a phosphate salt mixture wherein the phosphate salt mixture is comprised of at least two phosphate salts selected from the group consisting of monosodium phosphate, disodium phosphate, trisodium phosphate, monopotassium phosphate, dipotassium phosphate, and tripotassium phosphate is provided.
In a second aspect of the invention, a dry phosphate salt mixture comprising at least two phosphate salts selected from the group consisting of monosodium phosphate, disodium phosphate, trisodium phosphate, monopotassium phosphate, dipotassium phosphate, and tripotassium phosphate is provided.
In a third aspect of the invention, a food product is provided comprising a brine solution comprising at least about 40% by weight of a phosphate salt mixture.
In a fourth aspect of the invention, a method of preparing a brine solution by combining a solvent and a salt mixture comprising at least about 40% by weight of a phosphate salt mixture is provided.
In a fifth aspect of the invention, a method of coagulating collagen comprising the steps of preparing a brine solution by combining a solvent and a salt mixture comprising at least about 40% by weight of a phosphate salt mixture and contacting the brine solution with collagen is provided.
In a sixth aspect of the invention, a method of preparing a food product comprising the steps of preparing a brine solution by combining a solvent and a salt mixture comprising at least about 40% by weight of a phosphate salt mixture, combining a food product with collagen, and contacting the brine solution with collagen and the food product is provided.
These and other objects, advantages, and features of the invention will become apparent to those persons skilled in the art upon reading the details of the compounds and methods more fully described below.
DETAILED DESCRIPTION OF THE INVENTION
It has been discovered that certain phosphate salt mixtures provide for both improved collagen coagulation and improved drying times when compared with other salts while at the same time providing high solubility and neutral pH. The term “high solubility” means a salt mixture that that is capable of forming high concentrations of salt in solution (e.g., at least about 40% by weight of a salt mixture in solution). The term “neutral pH” means a pH preferably between about 5.0 and about 9.0, and more preferably near about 7.0. A brine solution comprising the phosphate salt mixtures of the present invention having a pH of about 9.0 or less was determined to provide acceptable collagen coagulation and improved flavor than salt solutions with a pH greater than about 9.0. Specifically, at pH values greater than about 9.0 the brine solution tends to impart a “soapy” flavor to food products. Additionally, utilizing a solution having a neutral pH enhances workplace safety. Certain salts are able to dissociate in solution to provide high osmotic strength. The ortho-phosphates referred to herein all dissociate in solution to provide high osmotic strength. These characteristics of phosphate salts enable the collagen in contact with the food product to coagulate and form casing which can be further processed.
The phosphate salt mixtures of the invention are combinations of two or more of the following salts: monosodium phosphate, disodium phosphate, trisodium phosphate, monopotassium phosphate, dipotassium phosphate, and tripotassium phosphate. These particular salt mixtures mixed at a concentration of at least about 40% by weight of a phosphate salt mixture in a solution tend to provide high solubility, high osmality, neutral pH, and acceptable and preferably optimal coagulation when applied to collagen in contact with a food product.
These salts may also be mixed with both inorganic and organic acids to aid in coagulation and drying. Examples of inorganic acids include, but are not limited to hydrochloric, hydrobromic, hydroiodic, sulfuric and phosphoric. Organic acids may be selected, for example, from aliphatic, aromatic, carboxylic and sulfonic classes of organic acids. Examples of suitable organic acids include, but are not limited to formic, acetic, propionic, succinic, glycolic, glucoronic, maleic, furoic, glutamic, benzoic, anthranilic, salicylic, phenylacetic, mandelic, embonic (pamoic), methanesulfonic, ethanesulfonic, pantothenic, benzenesulfonic, stearic, sulfanilic, algenic and galacturonic acids.
Additionally, the salts may be mixed, or combined, with one or more food grade alkali compositions. Such alkali composition are included, primarily, to modify, control, or select the pH of the brine solution. Examples of such food grade alkali compositions include sodium hydroxide, potassium hydroxide, sodium hydrogen carbonate, sodium carbonate, and mixtures thereof. These particular compounds are commonly used to raise pH values in the manufacture or processing of food products.
The proportions of individual phosphate salts in the phosphate salt mixture depend, in large part, upon the solubility and pH of the resulting solution. Example 1 below provides particular examples of the preferred proportions of the invention.
EXAMPLE 1
Different phosphate salt mixtures were dissolved in water at room temperature. The percent salt (% Salt) is measured as the weight of the salt(s) divided by the weight of the entire solution after mixing. The weight of individual dry phosphate salt constituents were measured on a scale and mixed. After mixing each of the dry salt constituents, this dry phosphate salt mixture was added to a solvent and stirred thoroughly. The solvent may be aqueous, or comprise aliphatic or other carbon-based constituents. The following abbreviations apply to Tables 1 and 2 below: dipotassium phosphate (DKP), disodium phosphate (DSP), and monosodium phosphate (MSP). As can be seen by the first two examples of DKP alone in a solution, the pH remains unacceptably high. A high pH salt solution has been determined to be less than optimal when sprayed on collagen in contact with a food product.
Certain ratios of phosphate salts in solution, however, show more neutral pH while retaining high solubility. Thus, the salts below in Table 1 that provide a clear solution and high solubility upon Final Observation tend to be preferred over salts that appear opaque or hazy upon Final Observation. Salts below that have a pH of about 9.0 or less in solution are likewise preferred over salt mixtures that have a pH greater than about 9.0 in solution. The Initial Observation (Initial Observ.) was determined when stirring the mixture was completed. The Final Observation (Final Observ.) was determined 5 to 10 minutes after the Initial Observation. The total percentage by weight of all salts in the solution is designated in the Full % Salt column.
The brine solution preferably has a neutral pH without the addition of other buffer agents or pH modifiers such as an acid or base. However, the hydronium ion concentration may be altered by the addition of an acid where the pH is too high. Preferable acids are acetic acid, adipic acid, citric acid, nitric acid, phosphoric acid, and sulfuric acid.
TABLE 1
Phosphate Salt
Mixtures
% Salt
Full % Salt
Mass Salts (g)
Water (g)
pH
Initial Observ.
Final Observ.
DKP
50
50
150
150
10.03
Medium yellow haze
Clear
DKP
50
50
150
150
9.95
Medium yellow haze
Clear
DKP:DSP
45:10
55
135.93:29.91
134.16
9.93
Light yellow haze
Clear
DKP:DSP
31:18
49
92.94:53.4
153.66
9.54
Light yellow haze
Clear
DKP:MSP
45:7
52
135:21
144
8.31
Light yellow haze
Clear
DKP:DSP:MSP
42:8:10
60
126:24:30
120
8.28
Medium haze
Clear
DKP:DSP:MSP
40:10:10
60
120:30:30
120
8.27
Heavy haze
Clear
DKP:DSP:MSP
42:6:12
60
126:18:12
120
8.03
Light haze
Clear
DKP:DSP:MSP
40:8:12
60
120:24:36
120
8.06
Medium haze
Clear
DKP:DSP:MSP
38:10:12
60
114:30:36
120
7.95
Medium haze
Clear
DKP:DSP:MSP
42:3:12
57
126:9:36
129
7.88
Clear w/trace
Clear
suspended
particulates
DKP:MSP
42:10
52
126:30
144
7.92
Clear w/trace
Clear
suspended
particulates
DKP:MSP
42:12
54
126:36
138
7.85
Clear w/trace
Clear
suspended
particulates
DKP:MSP
42:18
60
126:54
120
7.74
Medium haze
Medium haze
DKP:MSP
40:20
60
120:60
120
7.69
Medium haze
Medium haze
DKP:DSP:MSP
30:15:15
60
90:45:45
120
7.56
Medium haze
Clear
In addition, the preferred salt mixtures retain the more neutral pH when heated to 40° C. Other temperatures will be apparent to those skilled in the art. As can be seen by the first measurement, DKP alone retains an unacceptably high pH at 40° C., but certain phosphate salt mixtures provide more neutral pH at 40° C.
TABLE 2
Phosphate
Fi-
Salt Mix-
Full
Mass
Wa-
nal
tures At
%
%
Salts
ter
Initial
Ob-
40° C.
Salt
Salt
(g)
(g)
pH
Observ.
serv.
DKP
50
50
150
150
9.28
Light
yellow haze
DKP:MSP
42:10
52
126:30
144
7.94
Clear w/
trace
suspended
particulates
DKP:MSP
42:12
54
126:36
138
7.78
Clear w/
trace
suspended
particulates
It will be understood by those skilled in the art that the % Salt figures may also be represented as percentages in the dry phosphate salt mixtures before dissolving in solution. For example, the 42%:10% DKP:MSP salt mixture in solution may also be represented as an 86.5%:13.5% dry DKP:MSP salt mixture. The equation to obtain the remaining dry phosphate salt mixture figures may be calculated by the following equations:
(Weight Salt 1/Weight Salt 1 + Weight Salt 2) × 100 for two salt mixtures and (Weight Salt 1/Weight Salt 1 + Weight Salt 2 + Weight Salt 3) × 100 for three salt mixtures
These equations may be easily carried out for four-or-more salt mixtures by adding the weights of the additional salts to the denominator. Therefore, where a dry phosphate salt percentage is represented, this means the weight of an individual salt component of the dry salt mixture compared to the weight of the entire dry salt mixture. The term dry means substantially free of water. Thus, a dry phosphate salt mixture is a mixture of two or more phosphate salts that is substantially free of water.
Food products were tested with several brine solutions with different mixtures and ratios of phosphate salts. It was determined that a neutral pH and high solubility of the phosphate salt mixture was determinative of more rapid collagen coagulation and drying rates.
Although preferred embodiments of the invention have been described in the foregoing Detailed Description of the Invention, it will be understood that the invention is not limited to the embodiments disclosed but is capable of numerous modifications without departing from the spirit and scope of the present invention.
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Methods for coagulating collagen and producing a food product by contacting the collagen with a solution comprising at least about 40% by weight of a phosphate salt mixture wherein the phosphate salt mixture is comprised of at least two phosphate salts selected from the group consisting of monosodium phosphate, disodium phosphate, trisodium phosphate, monopotassium phosphate, dipotassium phosphate, and tripotassium phosphate.
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BACKGROUND OF THE INVENTION
This invention relates to an improved closure or diaphragm assembly for offshore platforms and the like used in well drilling and production where it is desired to remove a portion of the closure or diaphragm from the member on which it is installed.
Offshore platforms are generally fabricated in a harbor or on a shore location and are then towed to a marine site where they are tipped on end and lowered into position with the platform resting on the ocean floor. The platform legs are hollow structures having open ends so that pilings can be driven downwardly through the legs into subterranean formations below the floor of the marine site to anchor the platform in position.
It is desirable during platform setting operations to utilize the platform legs and/or pile sleeves for buoyancy to assist in the setting operations. In some instances, buoyancy tanks may be included on the offshore platform to add buoyancy above that provided by the legs and/or pile sleeves to the platform. It is also desirable to exclude foreign material from the platform leg and/or pile sleeve during platform setting operations to prevent the annulus between the piling and the leg and/or sleeve from becoming contaminated with foreign material which would prevent the filling of the annulus with grout or cement. Therefore, a closure structure which is easily severable when the piling is driven through the platform leg and/or pile sleeve is used to seal the end of the leg or sleeve during the setting of the platform.
Typical prior art closures or diaphragms are illustrated in U.S. Pat. Nos. 3,533,241; 4,087,978; 4,124,988; 4,178,112; 4,220,422; 4,230,424; 4,367,983; and 4,470,726. However, as such closures or diaphragms are fabricated for use on offshore platforms in deeper and deeper water depths, of necessity, the number of fabric reinforcing plies must be increased to increase the load bearing capacity of the closure or diaphragm. As the thickness of the closure or diaphragm increases it becomes increasingly difficult to pierce the closure with the piling to be driven through the platform leg or pile sleeve by merely dropping the piling upon the closure. If it becomes necessary to use the pile driving hammer upon the piling to cause the piling to pierce the diaphragm, such use is dangerous because the initial hammer blow may be of sufficient strength to not only cause the piling to pierce the closure but, also, cause the piling to be driven many feet into the floor of the marine site thereby suddenly unloading the pile driving hammer. If the pile driving hammer is unloaded suddenly, before the hammer may be stopped, the repeated unopposed blows of the hammer may cause substantial damage to the derrick on the derrick barge installing the offshore platform.
In this connection, while it has been proposed to use various devices to initially pierce the closure or diaphragm before driving the piling therethrough, the use of such devices is not an attractive option because such devices must be transported to and from the marine site and easily assembled and disassembled during repeated use during platform installation.
As an alternative to such prior art closures or diaphragms, it has been proposed to use frangible plate or disc closures or diaphragms to close the legs and/or pile sleeves of offshore platforms. Such typical prior art frangible plate or disc closures or diaphragms are described in U.S. Pat. Nos. 3,474,630; 3,613,381; 4,212,563; and 4,322,181. However, such frangible plate or disc closures or diaphragms are not generally satisfactory because they are difficult to fabricate, install and use, particularly where the repeatability of rupture strengths are desired.
Yet other types of releasable closures are described in U.S. Pat. Nos. 4,024,723; 4,142,371; 4,175,592; 4,183,698; 4,373,835; and 4,376,597.
However, the releasable closure described in the U.S. Pat. No. 4,024,723 patent is generally undesirable for use because the annular cutter used to pierce the diaphragm may be retained upon the end of the piling during the driving operation thereby causing the piling to deflect rather than driving straight.
The releasable closure described in the U.S. Pat. No. 4,142,371 patent is generally undesirable because it requires the molding and maintenance during molding of an annular wrapped continuous cable in a large amount of elastomeric material to form the releasable member. Even if the cable can be controlled during the molding process, after the removal of the closure from the platform leg and/or pile sleeve, a large residue of elastomeric material is retained on the leg or pile sleeve upon which a piling may foul upon insertion into the leg or pile sleeve.
Also, the closure described in the U.S. Pat. No. 4,376,597 patent may be difficult to install for satisfactory use as the elastomeric closure or diaphragm must be subjected to uniform forces retaining it between its annular retaining rims, otherwise, it will tend to pull free or pop-out from the retaining rims upon loading.
STATEMENT OF THE INVENTION
The present invention is directed to an improved closure or diaphragm assembly for use on offshore platforms and the like used in well drilling and production where it is desired to remove a portion of the closure or diaphragm from the member on which it is installed. The improved diaphragm assembly comprises a reinforced elastomeric diaphragm, a pair of flat annular plates, and a rip-out assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of the present invention installed on an annular member of a marine structure.
FIG. 2 is a bottom view of the reinforced elastomeric diaphragm of the present invention.
FIG. 3 is a cross-sectional view along line 3--3 of FIG. 2 of the reinforced elastomeric diaphragm of the present invention.
FIG. an enlarged view of a portion of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the closure or diaphragm assembly 10 of the present invention is shown installed on an annular member 1 of an offshore platform or marine structure.
The diaphragm assembly 10 comprises diaphragm 12, a pair of flat annular plates 14, and diaphragm rip-out assembly 16.
The diaphragm 12 may be of the type described in U.S. Pat. Nos. 4,178,112; 4,220,422; 4,230,424; 4,367,983; or 4,470,726 whose disclosures are incorporated herein by reference thereto.
The flat annular plates 14 each comprise a circular annular member having a plurality of apertures therein for a plurality of threaded fasteners 18 to extend therethrough, each fastener 18 containing a nut 20 thereon.
The diaphragm rip-out assembly 16 comprises rip-out shim 22, shim eyebolts 24, rip-out eyebolt 26, shim shackles 28, shim cables 30, rip-out shackle 32 connected to rip-out eyebolt 26, connecting cable 34 and rip-out cable 36 having one end thereof secured to rip-out eyebolt 26 and the other end thereof secured to rip-out shim 22 and a length thereof preferably shorter than that of connecting cable 34, although this is not always necessary.
Also shown connected to rip-out shackle 32 is cable 38 which runs through the annular member 1 and is used to remove or rip-out a portion of the diaphragm 12 from the annular member 1.
Referring to FIG. 2 the bottom of the diaphragm assembly 10 is shown as it is seen attached to one end of the annular member 1.
As shown, the rip-out shim 22 comprises an annular circular member 40 having secured thereto, circular V-shaped rip-out cable rim 42, a plurality of reinforcing members 44 which are secured to member 40 and rim 42, a plurality of eyebolt pads 46 against which the heads of eyebolts 24 bear, rip-out cable lug 48, and rip-out cable bearing pins 50.
The rip-out cable 36 is installed in or wrapped about rim 42 of rip-out shim 22 having an end secured thereto at cable lug 48 so that the cable 36 is wrapped at least one (1) full revolution about rim 42 and, preferably, approximately one and one-quarter revolutions about the rim 42 having the other end of cable 36 secured to rip-out eyebolt 26.
Referring to FIG. 3, the diaphragm assembly 10 of the present invention is shown in cross section.
As shown, the shim eyebolts 24 and rip-out eyebolt 26 extend through drilled apertures 50 in the diaphragm 12. To seal the apertures 50 in the diaphragm 12 and around shim eyebolts 24 and rip-out eyebolt 26 compression fittings 52 and 54 are used.
Referring to FIG. 4, a portion of the diaphragm assembly 10 of the present invention is shown.
Each compression fitting 52 comprises an annular circular member having an end surface 56 having an annular rib thereon which sealingly engages the surface of the diaphragm 12 and an annular recess 58 therein which, in turn, contains annular elastomeric seal 60 therein which sealingly engages the shim eyebolt 24 or rip-out eyebolt 26. Similarly, each compression fitting 54 comprises an annular circular member having an end surface 62 having an annular rib thereon which sealingly engages the surface of the diaphragm 12, an annular rim 64 which bears against eyebolt pad 46, and annular recess 66 which, in turn, contains annular elastomeric seal 68 therein which sealingly engages the shim eyebolt 24.
OPERATION OF THE INVENTION
Referring again to FIG. 1, to remove or rip-out a portion of the diaphragm 12 from the diaphragm assembly 10 the cable 38 is pulled by a suitable power means, such as derrick, winch, etc. Since the cable 38 is connected to rip-out shackle 32 which is, in turn, connected to rip-out eyebolt 26, the rip-out eyebolt 26 is pulled or ripped from the diaphragm 12. After the rip-out eyebolt 26 is pulled from the diaphragm 12, since the rip-out cable 36 has one end secured to the rip-out eyebolt 26, the continued movement of the rip-out eyebolt 26 away from the diaphragm 12 will cause the rip-out cable 36 to be ripped through the diaphragm 12 thereby severing the center portion of the diaphragm 12 from the periphery thereof retained between the flat annular plates 14. Since the rip-out cable 36 extends at least one (1) full revolution about rim 42, upon the pulling of rip-out cable 36 through diaphragm 12, the center portion of the diaphragm 12 is completely severed from the periphery thereof.
After the severing of the center portion of the diaphragm 12 from the periphery thereof, since one end of rip-out cable 36 is attached to rip-out eyebolt 26 while the other end thereof is secured to rip-out cable lug 48 of rip-out shim 22 and connecting cable 34 is secured to shim cables 30 which are, in turn, secured to shim eyebolts secured to rip-out shim 22, the continued movement of the movement of the rip-out eyebolt 26, connecting cable 34, and diaphragm shim 22 away from flat annular flanges 14 through member 1 allows the removal of the center portion of the diaphragm 12 from the annular member 1 via one end thereof.
It should be understood that the connecting cable 34 is of a length greater than that of the rip-out cable 36 so that the center portion of the diaphragm 12 may be severed before any forces are placed on the rip-out shim 22 to remove the center portion of the diaphragm 12 from the member 1.
It should be further understood that by severing the center portion of the diaphragm 12 from the periphery thereof an effective pile wiper may be formed by the periphery of the diaphragm assembly 10. By selecting the appropriate size of rip-out shim 22 the diameter of the inner lip of the newly created pile wiper formed by the periphery of the diaphragm assembly 10 may be controlled to the desired diameter to mate with the pile or other annular member to be installed through the annular member 1.
It will be appreciated that changes, substitutions and modifications may be made to the diaphragm assembly 10 of the present invention which are intended to be within the scope of the invention. Some examples of such changes, substitutions and modifications being that the shackles may be omitted and the connecting cable and the shim cables connected directly to the rip-out eyebolt and shim eyebolts, that the eyebolts may be replaced by other suitable type fastening means, etc.
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An improved diaphragm assembly for use in sealing annular members of marine structures comprising a diaphragm, a pair of flat annular plates and a rip-out assembly.
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PRIORITY
This patent application claims priority under 35 USC 119 from U.S. Utility application Ser. No. 13/454,030, which claims priority from U.S. Provisional Patent Application Ser. No. 61/517,589 filed Apr. 22, 2011, of common inventorship herewith entitled, “Sefe Visor.”
FIELD OF THE DISCLOSURE
The present invention pertains to the field of polyester film products containing images, and more specifically to the field of moving three dimensional holographic images in a clear or tinted, polarizing polymeric thin film applied to cycling helmets, visors, ski goggles, windshields, etc. the helmet, visor, ski goggles, etc can be made of a photochromic material.
BACKGROUND OF THE INVENTION
The sky is the limit for today's sport enthusiasts and athletes, and the more extreme the activity, the better. Not only do these sport enthusiasts and athletes enjoy pushing the envelope on the risks they take, but they insist on blazing a trail with a premium of individual style. Skiers and snowboarders may be bundled from head to toe, but still can be distinguished by their gear and by the graphics on their skis and snowboards. Long before the days of chopper builders on reality TV, motorcyclists always have taken pride in individually customizing their bikes, watercraft or other equipment as a personal statement. One thing that skiers, snowboarders, boaters, jet skiers and motorcyclists share is the need for clear vision and vision protection. For skiers and snowboarders the protection takes the form of goggles. For motorcyclists and boaters the protection takes the form of helmet visors and windscreens.
The prior art has put forth several designs for cyclist helmets, and tint and image applications. Among these are:
U.S. Pat. No. 5,269,858 to Gary S. Silverman describes a method of simulating stained glass art by applying liquid paints to the object which may be a glass window or sheet. The leading paint dries in approximately two to three hours and then colored paints are applied as a covering over the areas which are peripherally defined by the leading paint.
U.S. Pat. No. 5,896,587 to Debra Gentry describes a bicycle helmet having a transparent eye shade and various interchangeable sun shield portions, along with affixed and built in sun shield portions. Stickers of various styles can be adhered to all eye shade portions.
U.S. Pat. No. 5,035,474 to Gaylord E. Moss, Brian D. Cohn, Mao-Jin J. Chern, Lacy G. Cook, and John J. Ferrer describes a binocular holographic helmet mounted display used by pilots while flying in low light level environments. This mounted display also combines infrared or other image detection and instrumentation symbology which enhance a pilot's flight vision.
None of these prior art references describe the present invention.
SUMMARY
A system and method for varying hologram visibility is disclosed herein. Specifically the system can comprise a shield. The shield can comprise a first layer and a second layer. The first layer can comprise a photochromic material having a dark state and a light state. The second layer can comprise a hologram that is less visible the first layer is in the light state.
The method can comprise attaching a second layer to a first layer. The first layer can comprise a photochromic material having a dark state and a light state. The second layer can comprise a hologram. The hologram can be less visible when the first layer is in the light state than when the first layer is in the dark state.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a motorcycle helmet.
FIG. 2 illustrates a pair of goggles with a hologram.
FIG. 3 illustrates a motorcycle with a hologram.
FIG. 4 illustrates the integration of a hologram with a design of a motorcycle helmet.
FIG. 5 illustrates a motorcycle that integrates a hologram with a motorcycle's design.
FIG. 6 illustrates an embodiment of a second layer, wherein a second layer can be removable from a motorcycle helmet.
FIG. 7 illustrates an embodiment of a second layer, wherein a second layer can be removable from goggles.
FIG. 8A illustrates a hologram on goggles when a first layer is more opaque.
FIG. 8B illustrates a hologram on goggles when a first layer is clear.
FIG. 9A illustrates a hologram on a motorcycle helmet when a first layer is more opaque.
FIG. 9B illustrates a hologram on a motorcycle helmet when a first layer is clear.
DETAILED DESCRIPTION
Described herein is a system and method for fading and strengthening a hologram. The following description is presented to enable any person skilled in the art to make and use the invention as claimed and is provided in the context of the particular examples discussed below, variations of which will be readily apparent to those skilled in the art. In the interest of clarity, not all features of an actual implementation are described in this specification. It will be appreciated that in the development of any such actual implementation (as in any development project), design decisions must be made to achieve the designers' specific goals (e.g., compliance with system- and business-related constraints), and that these goals will vary from one implementation to another. It will also be appreciated that such development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the field of the appropriate art having the benefit of this disclosure. Accordingly, the claims appended hereto are not intended to be limited by the disclosed embodiments, but are to be accorded their widest scope consistent with the principles and features disclosed herein.
FIG. 1 illustrates a motorcycle helmet 100 . For purpose of this disclosure, motorcycle helmet 100 can be a protective headgear used by motorcycle riders. Motorcycle helmet 100 can be any type of headgear that can be used by motorcycle riders. Various type of headgear includes but is not limited to full-face helmet, off-road or motocross helmet, modular helmet, or open-face helmet. Motorcycle helmet 100 can comprise a body 101 and a shield 102 . Body 101 can be the base portion of motorcycle helmet 100 that covers the skull or head area of the user. Shield 102 can be attached at the front portion of body 101 . As such, shield 102 can be made of transparent material such as glass, polycarbonate, or plastics. Shield 102 can either cover the whole face or can only cover the eye area of the user. Shield 102 can be used to protect the rider from wind or small particles such as dusts, insects, or rocks, when driving or while doing any activities. Moreover, shield 102 can be used to screen out ultraviolet radiations (UV). In one embodiment, shield 102 can be removable from body 101 . In such embodiment, shield 102 can be removed and can be replaced with another shield. In another embodiment, shield 102 can be permanently attached to body 101 . Shield 102 can comprise a hologram 103 , which can enhance or personalize the look of motorcycle helmet 100 . Hologram 103 can be a three dimensional (3D) graphical image projected on shield 102 .
Further, shield 102 can comprise a first layer 104 and a second layer 105 . First layer 104 can be the innermost layer of shield 102 . First layer 104 can comprise a photochromic material that allows shield 102 to change color upon and depending on the exposure of light. Second layer 105 can be the outermost layer of shield 102 covering first layer 104 . Second layer 105 can comprise a holographic material that enables any graphical images to be seen in three dimensional (or 3D) forms. In one embodiment, hologram can be substantially transparent. As seen in FIG. 1 , hologram 103 can be placed on second layer 105 of shield 102 . The layer structure described herein can aid in strengthening the image of any holographic images when shield 102 is exposed to light by causing reflection. Inversely, when shield 102 is hidden from light the holographic image on second layer 105 can fade. In one embodiment, hologram 103 can be etched into photochromic material. As such, first layer 104 and second layer 105 are combined into one continuous object. In another embodiment, hologram 103 can be a combination of photochromic and non-photochromic material to cause reflection in a darkened state and non-reflection in a lightened state as discussed below.
Further, for purposes of this disclosure, the light mentioned herein can be light comprising ultraviolet (UV) radiations such as sunlight. Since photochromic material reacts with ultraviolet (UV) radiations, shield 102 and hologram 103 can react differently or may not have any reactive response when exposed to room lights that does not contain ultraviolet (UV) rays. Moreover, hologram 103 and any holographic image placed on second layer 105 do not affect the vision of the user.
FIG. 2 illustrates a pair of goggles 200 with hologram 103 . For purpose of this disclosure, goggles 200 can be a type of eyewear that can either be used to protect the eye, or to enhance vision. Moreover, goggles 200 can also comprise body 101 and shield 102 . In this embodiment, body 101 can be the frame that encloses or surrounds shield 102 . Goggles 200 can be worn around the head and fit snuggly in the eye area. Further, shield 102 of goggles 200 can comprise hologram 103 .
FIG. 3 illustrates a motorcycle 300 with hologram 103 . For the purpose of this disclosure, motorcycle 300 can be a type of motor vehicle that can be used for transportation. Motorcycle 300 can be a two or three wheeled motorized vehicle such as ATVs, scooters, or dirt bikes. Motorcycle 300 can comprise body 101 and shield 102 . Body 101 can be the main structure of motorcycle 300 wherein shield 102 can be attached. In this embodiment, shield 102 can be a windshield of motorcycle 300 placed at the front portion of motorcycle 300 . Shield 102 can be used to personalize the look of motorcycle 300 . As such, hologram 103 can be applied to shield 102 to enhance the appearance of motorcycle 300 .
FIG. 4 illustrates the integration of hologram 103 with a design 401 of motorcycle helmet 100 . Design 401 can be any two dimensional (2D) decoration that can be implemented through drawing, printing, painting, engraving, and/or embossing. As such, design 401 can complement the appearance of any structure or material. Design 401 can be used in body 101 of motorcycle helmet 100 . In this embodiment, hologram 103 on shield 102 can be integrated with design 401 . Hologram 103 can add to the interesting look of motorcycle helmet 100 especially when exposed or concealed from light. In a scenario wherein motorcycle helmet 100 is worn outdoor at day time, hologram 103 can appear and blend with design 401 of motorcycle helmet 100 . Conversely, hologram 103 can fade out at night thus only design 401 can be visible during this time.
FIG. 5 illustrates motorcycle 300 that integrates hologram 103 with the motorcycle's design 401 . In this embodiment, design 401 can be placed on body 101 of motorcycle 300 . Hologram 103 employed on shield 102 can complement design 401 applied on body 101 of motorcycle 300 . When motorcycle 300 is used at day time wherein motorcycle 300 is exposed to direct sunlight, hologram 103 can be visible therefore improving the overall appearance of motorcycle 300 during this time. Contrarily, at dusk or at night hologram 103 on shield 102 can disappear or can be barely visible to onlookers.
FIG. 6 illustrates an embodiment of second layer 105 , wherein second layer 105 can be removable from motorcycle helmet 100 . Second layer 105 can comprise a top surface 601 and a bottom surface 602 . Top surface 601 can be the portion of second layer 105 that comprises hologram 103 . Bottom surface 602 can be the portion of second layer 105 that connects with the top surface of first layer 104 . In one embodiment, second layer 105 can be attached to first layer 104 with a clear adhesive. In such embodiment, second layer 105 can self-adhere with first layer 104 . Moreover, second layer 105 in this embodiment can utilize peel and stick method wherein second layer 105 can be removed and reapplied on top of first layer 104 numerous times. In another embodiment, second layer 105 can be printed on a statically connectable material and placed on top of first layer 104 . In such embodiment, second layer can be positioned and connect to first layer without the use of adhesives. Such embodiment has the added benefit of being easier to remove and reattach. In such embodiment a different second layer 105 that comprises a different holographic design can be placed on first layer 104 .
FIG. 7 illustrates an embodiment of second layer 105 , wherein second layer 105 can be removable from goggles 200 . Second layer 105 of shield 102 on goggles 200 can be interchangeable. As such, a different hologram 103 design can be used on another second layer 105 . In one embodiment, second layer 105 can be removed and reapplied at the top of first layer 104 through peel and stick method. In such embodiment, bottom portion 602 of second layer 105 can comprise of clear adhesive. As such second layer 105 can be removed and reapplied on top of first layer 104 numerous times. In another embodiment, second layer 105 can be printed on a statically connectable material and placed on top of first layer 104 . Further in another embodiment, shield 102 can be interchangeable. In this embodiment, the whole shield 102 can be replaced instead of just the second layer 105 . As such, second layer 105 can be permanently attached to first layer 104 .
FIG. 8A illustrates hologram 103 on goggles 200 when first layer 104 is more opaque. The projection of hologram 103 can adjust depending on the amount of exposure of goggles 200 from sunlight. When goggles 200 are exposed or placed in direct sunlight, first layer 104 becomes darker or more opaque. First layer 104 or photochromic materials rely on organic photochromic molecules, wherein at the exposure of sunlight, first layer 104 can absorb ultraviolet radiation causing first layer 104 to darken. Therefore, as first layer 104 becomes darker, hologram 103 on second layer 105 can appear more vibrant due to the reflective nature of the dark background.
FIG. 8B illustrates hologram 103 on goggles 200 when first layer 104 is clear. At a similar pattern, when goggles 200 are concealed from sunlight, the absence of ultraviolet radiation can cause first layer 104 to lighten and fade. Therefore, as ultraviolet on first layer 104 clears or fades out, hologram 103 on second layer 105 can lighten.
FIG. 9A illustrates hologram 103 on motorcycle helmet 100 when first layer 104 is more opaque. In a scenario wherein motorcycle helmet 100 are exposed or placed in direct sunlight, first layer 104 of shield 102 becomes more opaque. First layer 104 becomes darker as ultraviolet light is absorbed. Therefore as first layer 104 becomes darker, hologram 103 on second layer 105 can appear more vibrant.
FIG. 9B illustrates hologram 103 on motorcycle helmet 100 when first layer 104 is clear. Hologram 103 on second layer 105 can lighten when there is an absence of sunlight or ultraviolet rays. Therefore, hologram 103 can be barely visible during night time or when the weather is cloudy. This can be the result of the absence of ultraviolet radiation, which causes first layer 104 to lighten and fade.
Various changes in the details of the illustrated operational methods are possible without departing from the scope of the following claims. Some embodiments may combine the activities described herein as being separate steps. Similarly, one or more of the described steps may be omitted, depending upon the specific operational environment the method is being implemented in. It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments may be used in combination with each other. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.”
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A system and method for varying hologram visibility is disclosed herein. Specifically the system can comprise a shield. The shield can comprise a first layer and a second layer. The first layer can comprise a photochromic material having a dark state and a light state. The second layer can comprise a hologram that is less visible the first layer is in the light state. The method can comprise attaching a second layer to a first layer. The first layer can comprise a photochromic material having a dark state and a light state. The second layer can comprise a hologram. The hologram can be less visible when the first layer is in the light state than when the first layer is in the dark state.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of ventilation and air conditioning apparatus, and particularly to air conditioning apparatus which is commonly used in connection with dampers or damper assemblies used to control the flow of air in the air conditioning system.
2. Description of the Prior Art
A damper typically is a flat blade disposed at the ingress or egress of a ventilation duct to control the amount of air flowing past a given point. The damper typically functions as a throttle plate. One or more dampers may be combined by means of levers, gears and other mechanical linkages to cooperatively operate as a damper assembly. Typically, the entire damper assembly is driven by rotating a single axis or rod which in turn is coupled to the assembly. Given the combined frictional resistance and air pressure, against which a damper assembly must operate, a significant amount of torque is required to efficiently drive the damper assembly. On the other hand the speed in which the damper assembly is driven or activated is usually not of consequence since the limiting time factor is the thermal time constant of the overall ventilation system. Therefore, the prior art has typically coupled various types of electric motors to the driving axis of the damper assembly by means of various types of torque convertors, usually gear reduction boxes. This combination is: (1) relatively expensive; (2) prone to mechanical failure due to the large number of mechanical parts and due to their complexity; and (3) tends to require relatively large amounts of electrical power to activate the dampers. What is needed then is a damper actuator which is capable of delivering large forces or torques without undue mechanical complexity, with high reliability, and small power requirements.
Summary of the Invention
The present invention comprises an actuator for activating a damper or damper assembly in a ventilation system, which actuator has: (1) a frame assembly; (2) an engine means rotatably coupled at one of its ends to the frame assembly; and (3) a lever means rotatably coupled to the frame assembly. The other end of the engine means is rotatably coupled to the lever means such that the engine means is doubly pivoted in order to substantially eliminate all stresses applied to the engine means which are perpendicular to the longitudinal axis of the engine means. The longitudinal axis is defined by a line through the point of rotatable coupling between the engine means and the frame assembly and the point of rotatable coupling between the engine means and lever means. In appropriate embodiments a spring means may be added which is coupled between the lever means and the frame assembly such that a force is exerted on the lever assembly to return it to its initial position or configuration when the engine means is not activated.
More particularly, the present invention is a damper actuator having a doubly pivoted heat motor. One end of the heat motor is rotatably coupled or pivoted by a mounting to the frame assembly. The other end of the heat motor is rotatably coupled or pivoted to the lever which is also rotatably coupled to the frame assembly. The point of coupling between the heat motor and the lever swings through an arc as the lever is rotated. Due to the rotatable couplings, the heat motor is free to change its inclination with respect to the frame assembly. As a result of this feature the amount of stress applied to the heat motor in a direction perpendicular to an axis, defined by the points of the coupling between the heat motor and the lever, and the heat motor and frame assembly, is substantially eliminated. A coil spring may likewise be coupled between the lever and the frame assembly to provide a return force causing the lever to return to an initial position when the heat motor is not activated.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a plan view of the damper actuator showing the engine means, the lever means, the frame assembly and the spring means.
FIG. 2 is a cross sectional view of the lever means taken through Section 2--2 of FIG. 1. FIG. 2 illustrates one way in which the rotational couplings may be made between the heat engine and the lever.
FIG. 3 is a cross sectional view taken through Section 3--3 of FIG. 1 showing one embodiment of the coupling between the engine means and the lever means.
FIG. 4 is a cross sectional view taken through Section 4--4 of FIG. 1 showing the rotational coupling between the mounting and the frame assembly.
FIG. 5 is a cross sectional view taken through Section 5--5 of FIG. 4 showing one embodiment of the rotational coupling between the mounting and the frame assembly.
FIG. 6 is a diagramatic view of the damper actuator illustrating a typical method of linking the actuator with a damper assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is a damper actuator for use in a ventilating system comprising a frame assembly, an engine means for applying a force in response to a signal activating the engine means, and a lever means rotatably coupled to the frame assembly for delivering the force from the engine means to a damper or damper assembly. In addition there is a spring means for providing a force to return the lever assembly to its initial position or configuration when the engine means is not activated. The engine means is rotatably coupled at one of its ends to the frame assembly and at the other of its ends to the lever means. The spring means is coupled between the lever means and frame assembly while the lever means is rotatably coupled to the frame assembly. The present invention may be better understood, together with its various embodiments, by referring to FIGS. 1 through 6.
The lever means, the engine means, the frame assembly, and the spring means is illustrated in plan view in FIG. 1.
In the embodiment illustrated, a frame assembly 10 serves as the structural basis to which the various elements of the actuator are referenced. A lever means 12 is illustrated in FIG. 1 as a simple lever rotatably coupled at one end 14 to frame assembly 10. In particular, rotatable coupling 14 may be a simple pivot pin. An engine means 16 is illustrated as rotatably coupled to lever 12 by a coupling 18 and as rotatably coupled to frame assembly 10 by a coupling 20. Engine means 16 in turn is comprised of a heat motor 22 and a mounting 24. Heat motor 22 is a thermal expansion engine well known to the art and may be of the type described in U.S. Pat. Nos. 3,193,600; 3,194,911; 3,029,595; and 3,376,631. In general, such heat motors operate on the principal that when a material is heated or changes state it undergoes a volume expansion. Heat motor 22 has an internal structure similar to an ordinary thermometer, i.e. a relatively large reservoir holding a material which is free to expand into an elongated cylindrical cavity. In particular, the working material within heat motor 22 may be paraffin which is induced to change state in response to an electrical heating element thermally coupled to a reservoir holding the paraffin. When the paraffin is heated and changes state from a solid to a liquid, the expanding paraffin enters an elongated and generally cylindrical cavity in which a piston has been disposed. The piston provides a tight seal between the walls of the elongated cylindrical cavity and the piston body. As a result the piston is forced along the elongated cylindrical cavity with considerable force by means of the expanding paraffin. In FIG. 1 only the exterior of heat motor 22 is illustrated and a portion of the piston rod 26 which extends into heat motor 22. It is to be understood that any heat motor may be used in the present invention, and that a paraffin heat motor is referred to only for the purposes of illustration.
In many instances a spring means 28 is coupled between frame assembly 10 and lever means 12. In many applications the area of the piston within the heat motor 22 is relatively small while the torque required to move lever means 12 in either direction is relatively large. Therefore in many cases, as the working material within the heat motor 22 cools and contracts, the atmospheric pressure exerted against the piston of heat motor 22 is insufficient to develop enough force to return lever means 12 to its initial position. Therefore, spring means 28 is provided to produce a return force which urges lever means 12 to its initial position or configuration. Lever means 12 is shown in FIG. 1 in its initial position. Its most extreme final position is illustrated in FIG. 1 in phantom outline. A microswitch 30 is attached to frame assembly 10 to provide a limit stop to lever means 12. Microswitch 30 is electrically coupled to the heating element within heat motor 22 in such a manner that when lever means 12 activates microswitch 30, the heating element within heat motor 22 is disabled.
In a typical embodiment incorporating a paraffin based heat motor 22 the diameter of the piston within heat motor 22 is approximately 5/16th of an inch. With this type of heat motor, a force of 250 lbs. can be exerted on lever means 12 at the point of rotatable coupling 18. When approximately 24 volts AC or DC (30 watts) is applied to the heating element of heat motor 22, the actuator illustrated in FIG. 1 may completely open within 5 minutes or less. Using a relatively stiff coil spring for spring means 28, lever means 12 returns to its initial position within 5 to 15 minutes. It can readily be appreciated that the nature of the opening and closing cycles of the actuator illustrated in FIG. 1 can be varied by choosing various types of heat motors utilizing various power inputs as well as chosing various types of springs possessing different spring constants.
It is to be particularly noted that heat motor 22 is pivoted at both of its ends 18 and 20. Therefore, as lever means 12 rotates from the initial to its final position, rotatable coupling 18 will travel through an arcuous path. If heat motor 22 were not rotatably coupled by means of rotatable coupling 20 a substantial transverse stress would be applied to piston rod 26. In cases where heat motor 22 has been rigidly coupled to frame assembly 10 the transverse stresses have ruptured the seal between the piston and the elongated cylindrical (piston) cavity within heat motor 22, even for relatively small amounts of lever rotation. When heat motor 22 is doubly pivoted, as disclosed herein, the only transverse stress applied to piston rod 26 is that due to the very slight frictional drag present at rotatable couplings 18 and 20. Therefore, the present invention substantially eliminates all transverse stresses to piston rod 26. The transverse force applied to piston rod 26 by means of the arcuous path followed by rotatable coupling 18, serves only to rotate heat motor 22 about rotatable coupling 20. Further detail in regard to rotatable couplings 18 and 20 may be understood by viewing FIGS. 2 through 5.
For example, FIG. 2 is a cross section through Section 2--2 of FIG. 1 and shows the nature of the rotatable coupling to lever means 12. Rotatable coupling 14 is a simple pivot pin disposed through lever means 12 in frame assembly 10. The pivot pin may be of any type well known to the art such as a smooth pin fixed at each end with a cotter pin or simply a nut, lock washer and bolt. Similarly, rotatable coupling 18 is a simple pivot pin extending through a clevis 32 and lever means 12.
FIG. 3 illustrates clevis 32 in greater detail. Clevis 32 is clearly illustrated as coupling piston rod 26 to lever means 12 by means of a simple pivot pin 18. Any rotatable means, well known to the art may be used to couple piston rod 26 to lever means 12, and clevis 32 is illustrated only as one example.
FIG. 4 is a cross sectional view of mounting 24 taken through Lines 4--4 of FIG. 1. In one embodiment heat motor 22 has a substantially cylindrical shape. Therefore, mounting 24 is a cylindrical collar which may be slipfit onto heat motor 22. FIG. 5 illustrates that mounting 24 is split so that it straddles an edge portion of frame assembly 10. Again mounting 24 is coupled to frame assembly 10 by means of rotatable coupling 20 which is a simple pivot pin. FIG. 5 illustrates another feature of mounting 24 by showing a cross sectional view of FIG. 5 taken through Section 5--5. Heat motor 22 is shown as coupled to mounting 24 by means of internal shoulders machined into the inner diameter of mounting 24. A slot 34 is similarly machined into the lower portion of mounting 24 such that mounting 24 may freely rotate about rotatable coupling 20 through all positions obtainable by heat motor 22. Free rotational motion of heat motor 22 may be assured by simply providing sufficient clearance 36 between mounting 24 and frame assembly 10.
Finally by way of illustration only, FIG. 6 shows a diagramatic view of one embodiment of the present invention coupled to a damper assembly 40. The lever means is shown as a simple lever 12a, of the type which is illustrated in FIG. 1, which is rotatably coupled at its free end to a rigid rod 12b by means of a rotatable coupling 36a. The other end of rigid rod 12b is rotatably coupled by means of a rotatable coupling 36b to one end of a damper assembly lever 12c. The other end of a lever 12c is fixed to the driving axis or rod 38 of a damper assembly. Using a 30 watt paraffin based heat engine as in the embodiments disclosed herein and the linkages illustrated in FIG. 6, a torque of approximately 28 ounce-inches may be conveniently delivered to axis 38.
Therefore, a novel damper actuator capable of delivering large amounts of torque without requiring complex mechanical torque converters, having high reliability, and efficiently utilizing electrical power has been disclosed. Such an actuator overcomes the deficiences of prior art devices. It is to be understood that further modifications and alterations may be made in the present invention by one with ordinary skill in the art without departing from its spirit and scope.
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A damper actuator for use in a ventilation system typically used in an air conditioning system to activate the damper or damper assembly in response to an electrical signal. More particularly, a heat motor rotatably coupled at one end to a lever or lever assembly and rotatably coupled at its other end to a stationary frame. A spring may also be coupled to the lever or lever assembly and to the frame when necessary to provide a force to return the lever or lever assembly to its initial position or configuration. By means of a rotatable coupling at each end of the heat motor, stresses transverse to the longitudinal axis of the heat motor, are substantially eliminated and the operational life of the heat motor is significantly increased.
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CROSS REFERENCE TO CO-PENDING APPLICATION
This application is a continuation of Ser. No. 195,262, filed May 18, 1988, now abandoned which is, in turn, a continuation-in-part application of Ser. Nos. 053,046, filed May 22, 1987, now U.S. Pat. No. 4,752,197, granted June 21, 1988.
BACKGROUND OF THE INVENTION
The present invention relates to an improved non-woven fibrous product and more specifically to a non-woven blanket of mineral and man-made fibers to which thermosetting resin and carbon black may be added. The blanket may be formed into sheets, panels and complexly curved and configured products.
Non-woven fibrous products such as sheets and panels as well as other thin-wall products such as insulation and complexly curved and shaped panels formed from such planar products are known in the art.
In U.S. Pat. No. 2,483,405, two distinct types of fibers therein designated non-adhesive and potentially adhesive fibers are utilized to form a non-woven product. The potentially adhesive fibers typically consist of a thermoplastic material which are mixed with non-adhesive fibers to form a blanket, cord or other product such as a hat. The final product is formed by activating the potentially adhesive fibers through the application of heat, pressure or chemical solvents. Such activation binds the fibers together and forms a final product having substantially increased strength over the unactivated product.
U.S. Pat. No. 2,689,199 relates to non-woven porous, flexible fabrics prepared from masses of curled, entangled filaments. The filaments may be various materials such as thermoplastic polymers and refractory fibers of glass, asbestos or steel. A fabric blanket consisting of curly, relatively short filaments is compressed and heat is applied to at least one side to coalesce the fibers into an imperforate film. Thus, a final product having an imperforate film on one or both faces may be provided or this product may be utilized to form multiple laminates. For example, an adhesive may be applied to the film surface of two layers of the product and a third layer of refractory fibers disposed between the film surfaces to form a laminate.
In U.S. Pat. 2,695,855, a felted fibrous structure into which is incorporated a rubber-like elastic material and a thermoplastic or thermosetting resin material is disclosed. The mat or felt includes carrier fibers of long knit staple cotton, rayon, nylon or glass fibers, filler fibers of cotton linter or nappers, natural or synthetic rubber and an appropriate resin. The resulting mat or felted structure of fibers intimately combined with the elastic material and resinous binder is used as a thermal or acoustical insulating material and for similar purposes.
U.S. Pat. No. 4,612,238 discloses and claims a composite laminated sheet consisting of a first layer of blended and extruded thermoplastic polymers, a particulate filler and short glass fibers, a similar, second layer of a synthetic thermoplastic polymer, particulate filler and short glass fibers and a reinforcing layer of a synthetic thermoplastic polymer, a long glass fiber mat and particulate filler. The first and second layers include an embossed surface having a plurality of projections which grip and retain the reinforcing layer to form a laminate.
It is apparent from the foregoing review of non-woven mats, blankets and felted structures that variations and improvements in such prior art products are not only possible but desirable.
SUMMARY OF THE INVENTION
The present invention relates to a non-woven blanket or mat consisting of a matrix of mineral fibers and man-made fibers. The mineral fibers are preferably glass fibers and the man-made fibers may be polyester, rayon, acrylic, vinyl, nylon or similar synthetic fibers. A thermosetting resin bonds the fiber matrix together. A conductive material such as copper or aluminum powder or a conductive/coloring agent such as carbon black assists static dissipation during manufacture resulting in a product with improved surface finish. Alternatively, the conductive material may be in the form of fibers.
The product consists essentially of fiberized glass fibers of three to ten microns in diameter. Such fibers, in an optimum blend, comprise 62% of the resulting product. The synthetic fibers may be selected from a wide variety of materials such as polyesters, nylons, rayons, acrylics, vinyls and similar materials. Larger diameter and/or longer synthetic fibers typically provide more loft to the product whereas smaller diameter and/or shorter fibers produce a denser product. The optimum proportion of synthetic fibers is approximately 21%.
A thermosetting resin is utilized to bond the fibers together. The thermosetting resin preferably includes a conductive material such as copper or aluminum powder or a conductive/coloring agent such as carbon black. The thermosetting resin may be selectively activated to bond primarily only those fibers adjacent one or both faces of the blanket, partially activated throughout the blanket or activated throughout the blanket, if desired. The optimum proportion of the thermosetting resin and conductive material is approximately 17%. If desired, a foraminous or imperforate film or skin may be applied to one or both surfaces of the blanket during its manufacture to provide relatively smooth surfaces to the product.
The density of the product may be adjusted by adjusting the thickness of the blanket which is initially formed and the degree to which this blanket is compressed during subsequent forming processes. Product densities in the range of from 1 to 50 pounds per cubic foot are possible.
It is therefore an object of the present invention to provide a non-woven matrix of glass and synthetic fibers having a conductive material dispersed therethrough and adhered together by a thermosetting resin.
It is a still further object of the present invention to provide a non-woven matrix of glass and synthetic fibers having a conductive material and thermosetting resin dispersed therethrough wherein said thermosetting resin may be differentially activated through the thickness of the matrix to provide layers of distinct rigidity.
It is a still further object of the present invention to provide a non-woven matrix of glass and synthetic fibers having a conductive material and thermosetting resin dispersed therethrough wherein said thermosetting resin may be uniformly partially activated throughout the product.
It is a still further object of the present invention to provide a non-woven matrix of glass and synthetic fibers having a conductive material and thermosetting resin dispersed therethrough and a skin or film on one or both surfaces of the matrix.
It is a still further object of the present invention to provide a non-woven matrix of glass, synthetic fibers, thermosetting resin and conductive material which has its strength and rigidity adjusted by the degree of activation of the thermosetting resin.
Further objects and advantages of the present invention will become apparent by reference to the following description of the preferred and alternate embodiments and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an enlarged, diagrammatic, plan view of a non-woven fiber matrix according to the present invention;
FIG. 2 is an enlarged, diagrammatic, side elevational view of a non-woven fiber matrix according to the present invention with unactivated thermosetting resin;
FIG. 3 is an enlarged, diagrammatic, side elevational view of a non-woven fiber matrix product according to the present invention in which the thermosetting resin is partially differentially activated;
FIG. 4 is an enlarged, diagrammatic, side elevational view of a non-woven fiber matrix product according to the present invention in which the thermosetting resin is partially homogeneously activated;
FIG. 5 is an enlarged, diagrammatic, side elevational view of a non-woven fiber matrix product according to the present invention in which the matrix is significantly compressed and the thermosetting resin is fully activated;
FIG. 6 is an enlarged, fragmentary, diagrammatic, side elevational view of a non-woven fiber matrix product according to the present invention having a film disposed on one surface thereof;
FIG. 7 is an enlarged, fragmentary diagrammatic, side elevational view of a non-woven fiber matrix product according to the present invention having a film disposed on both surfaces thereof; and
FIG. 8 is an enlarged, fragmentary diagrammatic, side elevational view of a first alternate embodiment of a non-woven fiber matrix product according to the present invention in which the conductive material is in the form of fibers and which includes a film dispersed on a surface thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a non-woven fibrous blanket which comprises a matrix of mineral and man-made fibers according to the present invention is illustrated and generally designated by the reference numeral 10. The non-woven fibrous blanket 10 comprises a plurality of first fibers homogeneously blended and dispersed through a plurality of second fibers 14 to form a generally interlinked matrix. The first fibers 12 are preferably mineral fibers, i.e., glass fibers. Preferably, such fibers 12 are substantially conventional virgin, rotary spun, fiberized glass fibers having a diameter in the range of from 3 to 10 microns. The fibers are utilized in a dry, i.e., non-resinated, condition. The length of the individual fibers 12 may vary widely over a range of from approximately one half inch or less to approximately 3 inches and depends upon the shredding and processing the fibers 12 undergo which is in turn dependent upon the desired characteristics of the final product as will be more fully described subsequently.
The second fibers 14 are man-made, i.e., synthetic, and may be selected from a broad range of appropriate materials. For example, polyesters, nylons, Kevlar or Nomex may be utilized. Kevlar and Nomex are trademarks of the E. I. duPont Co. for their organic aramid fibers which are members of the aromatic polyamide family. The second fibers 14 preferably define individual fiber lengths of from approximately one quarter inch to four inches. The loft/density of the blanket 10 may be adjusted by appropriate selection of the diameter and/or length of the synthetic, second fibers 14. Larger and/or longer fibers in the range of from 5 to 15 denier (approximately 25 to 40 microns) and one to four inches in length provide more loft to the blanket 10 and final product whereas smaller and/or shorter fibers in the range of from 1 to 5 denier (approximately 10 to 25 microns) and one quarter to one inch in length provide a final product having less loft and greater density. The second fibers 14 may likewise be either straight or crimped, straight fibers providing a final product having less loft and greater density and crimped fibers providing the opposite characteristics.
The first, glass fibers 12 and second, synthetic fibers 14 are shredded and blended sufficiently to produce a highly homogeneous mixture of the two fibers. A uniform mat or blanket 10 having a uniform thickness is then formed and the product appears as illustrated in FIG. 1. Typically, the blanket will have a thickness of between about 1 and 3 inches although a thinner or thicker blanket 10 may be produced if desired.
Referring now to FIG. 2, the blanket 10 also includes particles of a thermosetting resin 16 dispersed uniformly throughout the matrix comprising the first, glass fibers 12 and the second, synthetic fibers 14. The thermosetting resin 16 may be one of a broad range of general purpose, engineering or specialty thermosetting resins such as phenolics, aminos, epoxies and polyesters. The thermosetting resin 16 functions as a heat activatable adhesive to bond the fibers 12 and 14 together at their points of contact thereby providing structural integrity, and rigidity as well as a desired degree of resiliency and flexibility as will be more fully described below. While the quantity of thermosetting resin 16 in the blanket 10 directly affects the maximum obtainable rigidity, the portion of such resin which is activated affects the density and loft as well.
The control of density and loft in this manner is a feature of the present invention and the choice of thermosetting resins 16 is one parameter affecting such characteristics. For example, shorter flowing thermosetting resins such as epoxy modified phenolic resins which, upon the application of heat, quickly liquify, generally rapidly bond the fibers 12 and 14 together throughout the thickness of the blanket 10. Conversely, longer flowing, unmodified phenolic resins liquify more slowly and facilitate differential curing of the resin through the thickness of the blanket 10 as will be described more fully below.
The blanket 10 also includes a conductive material 18 dispersed uniformly throughout the matrix comprising the first, glass fibers 12 and the second, synthetic fibers 14. The conductive material 18 may be in either fibrous or a particulate form. If the conductive material 18 is in particulate, i.e. powder form, the particles of conductive material 18 may be mixed with the fibers 12 and 14, or mixed with the thermosetting resin 16 prior to application to the blanket 10 or the resin 16 and the particles 18 may be applied to the blanket 10 separately. Alternatively, if in the form of fibers, the conductive material 18 may be blended with the first, glass fibers 12 and the second, synthetic fibers 14 at the time the fibers are blended and formed into the blanket 10 as illustrated in FIG. 8 and described below.
The particles of conductive material 18 may be powdered aluminum or copper or carbon black. Other finely divided or powdered conductive materials, primarily metals, are also suitable. The carbon black may be like or similar to Vulcan P or Vulcan XC--72 fluffy carbon black manufactured by the Cabot Corporation. Vulcan is a trademark of the Cabot Corporation. Pelletized carbon black may also be utilized but must, of course, be pulverized before its application to the blanket 10 or mixing with the thermosetting resin 16 and application to the blanket 10.
The conductive material 18, if in particulate form and especially if it is carbon black, changes the appearance of an improved product 20, illustrated in FIG. 3, from its natural tan color through grey to silvery black and black depending upon the relative amount of carbon black added to the product 20. This color shading and particularly the choice of the degree of shading is advantageous in the automotive product market and in applications where the product 20 must be inobtrusive and/or blend with dark surroundings. Automobile hood liners and similar products are ideal applications for the product 20 which has been darkened by the inclusion of carbon black.
The incorporation of conductive material 18 into the blanket 20 also improves the surface uniformity and thus appearance of the product 20. This is apparently the result of the draining off or dissipating of static electrical charges generated during the mixing of the fibers 12 and 14 and forming of the blanket 10. The improved product 20 containing conductive material 18 exhibits greatly reduced wrinkles and other surface imperfections.
The following Table I delineates various ranges as well as an optimal mixture of the two fibers 12 and 14, the thermosetting resin 16 and the conductive material 18 discussed above. The table sets forth weight percentages.
TABLE I______________________________________ Functional Preferred Optimal______________________________________Glass Fibers (12) 33-90 50-75 62Synthetic Fibers (14) 30-50 10-30 21Thermosetting Resin (16) 5-50 9-25 16.5Conductive Material (18) .1-2.0 .25-1.0 .5______________________________________
Referring now to FIG. 3, one manner and result of partial activation of the thermosetting resin 16 is illustrated. Here differential activation that is, activation of the thermosetting resin 16 in relation to the distance from one face of the blanket 10 will be described. As noted, one of the features of the present invention is the adjustability of the rigidity, density and thickness of the product 20 to either match the requirements of a given application or match, i.e., anticipate, those of secondary processing associated with the production of modified, final products.
In FIG. 3, the product 20 illustrated includes the first fibers 12, the second fibers 14 and the conductive material 18. The fibers 12 and 14 have been bonded together in the lower portion 20A of the product 20 by activation of the thermosetting resin 16 as illustrated by the bonded junctions 22. In contrast to the lower portion 20A, is the upper portion 20B of the product 20, wherein the thermosetting resin 16 has not been activated. Such partial differential activation of the thermosetting resin 16 is accomplished by the application of heat, radio frequency energy or other appropriate resin related activating means such as a chemical solvent only to the lower surface 24 of the product 20.
The resulting product exhibits substantially maximum obtainable rigidity and strength in one portion (20A) of its thickness and minimum rigidity and strength in the remaining portion (20B) of its thickness. Thus the lower, activated portion 20A serves as a substrate of controlled rigidity which lends structural integrity to the product and facilitates intermediate handling prior to secondary forming of the product 20 into a final product having fully activated thermosetting resin 16 and concomitant increased structural integrity. It will be appreciated that the relative thicknesses of the initially activated portion 20A and unactivated portion 20B of the blanket 10 may be varied in a complementary fashion from virtually nothing to the full thickness of the blanket 10, as desired.
Referring now to FIG. 4, a second manner and result of partial activation of the thermosetting resin 16 is illustrated. In this product 20', partial homogeneous activation of the thermosetting resin 16, that is, partial activation of the thermosetting resin 16 throughout the blanket 10, will be discussed. The product 20' likewise includes first, glass fibers 12, second, synthetic fibers 14 and the conductive material 18. The fibers 12 and 14 have been partially bonded together by substantially uniform, though partial, activation of the thermosetting resin 16 throughout the blanket 10. Such partial, homogeneous activation is preferably and more readily accomplished with longer flowing resins and careful control of heat or other resin activating agents. The portion of thermosetting resin initially activated in this manner may be varied as desired. The portion of the thermosetting resin 16 activated will be determined by considerations of required or permitted structural integrity of the product 20', for example.
The products 20 and 20' so produced exhibit several unique characteristics. First of all, their strength and rigidity are related to the strength and rigidity of a fully cured (thermosetting resin fully activated) product in direct proportion to the percentage of activated thermosetting resin 16. Thus, a desired rigidity may be achieved by selective application of heat or other means to activate a desired proportion of the thermosetting resin 16 to provide a desired proportion of bonded junctions 22 within the product 20. Secondly, both the products 20 and 20' facilitate secondary processing and final forming of the products 20 and 20' into complexly curved and shaped panels and other similar products. That is, the activated thermosetting resin 16 and junctions 22 provide interim, minimal strength whereas the unactivated regions are still flexible, thereby not rendering the products 20 and 20' overly rigid and creating difficulties with inserting the products 20 and 20' into a final mold while still providing necessary material and bulk for the final product. For example, automobile headliners and other sound and heat insulating complexly shaped panels may be readily formed from the product 20 or 20'.
Referring now to FIG. 5, a product 30 including the first, glass fibers 12, second, synthetic fibers 14 and particles of conductive material 18 is illustrated. Here, all of the thermosetting resin 16 has been activated by heat or other suitable agents. Thus, the bonded junctions 22 appear throughout the thickness of the product 30. Since the thermosetting resin 16 is fully activated in the product 30 illustrated in FIG. 5, it is generally considered that the product 30 is finished and will likely be utilized in this form. The product 30 typically will be planar and could be utilized as a sound absorbing panel in thicknesses from one sixteenth to one and one half inches for acoustical treatment of living spaces or other similar heat or sound insulating or absorbing functions.
It should be understood that when the product 20 illustrated in FIG. 3 or the product 20' in FIG. 4 are subsequently processed by heat, molding or other appropriate steps to fully activate the previously unactivated portion of the thermosetting resin 16, they will appear substantially the same as or identical to the product 30 illustrated in FIG. 5.
Another variant of the product according to the present invention is illustrated in FIG. 6. Here, a product 34 including first, glass fibers 12, second, synthetic fibers 14, the particles of conductive material 18 and the thermosetting resin 16, further includes a thin skin or film 36. Preferably, though not necessarily, the film 36 is adhered to one surface of the product 34 by a suitable adhesive layer 38. The film 36 preferably has a thickness of from about 2 to 10 mils and may be any suitable material such as spunbonded polyester, spunbonded nylon as well as a scrim, fabric or mesh material of such substances. The skin or film 36 may be either foraminous or imperforate as desired. The prime characteristics of the film 36 are that it provides both a supporting substrate and a relatively smooth face for the product 34, which is particularly advantageous if it undergoes primary and secondary activation of the thermosetting resin 16 as discussed above with regard to FIG. 3. It is preferable that the skin or film 36 not melt or become unstable when subjected to the activation temperatures or chemical solvents associated with curing the thermosetting resin 16 into the junctions 22. It should be well understood that the skin or film 36, though illustrated on a product 34 having fully activated thermosetting resin 16, is suitable, appropriate and desirable for use with a product such as the products 20 and 20' illustrated in FIGS. 3 and 4 which are intended to and undergo primary and secondary processing and activation of the thermosetting resin 16 as described above.
With reference now to FIG. 7, another product 34' is illustrated. Here, a non-woven matrix of first, glass fibers 12, second, synthetic fibers 14, the thermosetting resin 16 and the conductive material 18 is covered on both faces with thin skins or films 36. The films 36 are identical to those described directly above with regard to FIG. 6. Adhesive layers 38 may be utilized to ensure a bond between the fiber matrix, as also described above. The thermosetting resin 16 has been cured to form the junctions 22. It will be appreciated that either of the products 34 or 34' having one or two surface films 36, respectively are intended to be and are fully suitable and appropriate for partial differential or partial homogeneous activation of the thermosetting resin 16, as described above with reference to FIGS. 3 and 4, respectively.
Referring now to FIG. 8, a first alternate embodiment product 40 of the product 20 and variants 20', 34 and 34', described above, is illustrated. The alternate embodiment product 40 includes first, glass fibers 12, second, synthetic fibers 14, the thermosetting resin 16 which has been activated to form the junctions 22 and the conductive material 18. In the first alternate embodiment 40, the conductive material 18 is in the form of fibers 42. The fibers of conductive material 18 may be carbon or graphite fibers or metals such as copper or aluminum capable of being drawn or formed into small diameter fibers. Typically, the fibers 42 will be blended with the first, glass fibers 12 and second, synthetic fibers 14 such that they become an integral part of the matrix as illustrated in FIG. 8 and are thus uniformly dispersed throughout the alternate embodiment product 40. As illustrated in FIG. 8, the alternate embodiment product 40 also includes a film or skin 36 disposed on one surface. Preferably, though not necessarily, the film 36 is adhered to the product 40 by a suitable adhesive layer 38.
It should be understood that the alternate embodiment product 40 containing conductive fibers 42 may also include a second skin or film 36 (not illustrated) such that the product will appear quite similar to the product 34' illustrated in FIG. 7 or have no skin or film and thus appear quite similar to the products 20, 20' and 34. Likewise, it should be understood that the various resin activation schemes described above in relation to the products 20, 20', 34 and 34' are fully applicable to and functional with the alternate embodiment product 40 with no, one or two skins or films 36.
The activation of the thermosetting resin 16, as generally described in relation to FIGS. 3, 4, 5, 6, 7 and 8 is preferably accomplished by heat inasmuch as partial activation of the thermosetting resin 16 is more readily and simply accomplished thereby. However, as noted, activation means such as radio frequency energy, chemical solvents and the like functioning to cure various types of thermosetting resins 16 are suitable and within the scope of the present invention. With regard to temperature activation of the thermosetting resins, fast curing resins typically are activated at relatively high temperatures of about 300-400° Fahrenheit and above. In situations where partial activation of the thermosetting resin is desired such as that illustrated in FIGS. 3 and 4, slower curing, unmodified phenolic resins typically require temperatures of between about 200° and 300° Fahrenheit applied to one or both faces of the product 20, as desired.
In summation, it will be appreciated that the present invention provides a non-woven fibrous product consisting of a matrix of glass and synthetic fibers having a thermosetting resin and particles of a conductive material dispersed therethrough. The conductive material provides a surface finish which is significantly smoother when compared to similar products which do not include it. If the conductive material is carbon black or other material having significant coloring effect, the appearance of the product may be altered. As indicated above, carbon black, depending upon its mixed proportion, will alter the color of the product from tan, through grey to black. One surface of the product may include and be defined by a film such as a foraminous or imperforate film or plastic mesh or fabric. In a product which either includes or excludes the film, the thermosetting resin may be partially activated through the thickness of the product to provide in a initial product having minimal rigidity and structural integrity but which is not so rigid as to inhibit placement and subsequent final forming in a complexly curved mold. During the final forming, the remainder of the thermosetting resin is activated and the product takes on increased rigidity. The proportion of thermosetting resin initially activated may be varied as desired. Furthermore, the thermosetting resin in surface adjacent regions of both faces of the product may be activated with the appropriate application of heat to render a medial, i.e. center, section unactivated, if desired.
The product in its final form, which will typically include fully activated thermosetting resin such as those products illustrated in FIGS. 5, 6, 7 and 8, though relatively rigid, exhibits sufficient resiliency and flexibility that it may be relatively sharply bent without damaging the fiber matrix. The product will thus return undamaged to its original position and condition. This feature is a function of the interlinked fiber matrix and the flexibility provided primarily by the synthetic fibers. Flexibility of the final product is increased by increasing the proportion of a synthetic fibers and increasing the length of the synthetic fibers as well. On the other hand, the rigidity of the final product is increased by increasing the proportion of the thermosetting resin, the proportion of glass fibers and compressing the final product to have relatively high density. The density of the final product may be adjusted by such means to between 1 and 50 pounds per cubic foot.
The foregoing disclosure is the best mode devised by the inventors for practicing this invention. It is apparent, however, that products incorporating modifications and variations will be obvious to one skilled in the art of fiber matrix products. Inasmuch as the foregoing disclosure is intended to enable one skilled in the pertinent art to practice the instant invention, it should not be construed to be limited thereby but should be construed to include such aforementioned obvious variations and be limited only by the spirit and scope of the following claims.
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A non-woven matrix of glass and synthetic fibers provides a rigid but resilient product having good strength and insulating characteristics. The matrix consists of glass fibers and synthetic fibers such as polyester, nylon or Kevlar which have been shredded and intimately combined with a thermosetting resin into a homogeneous mixture. A conductive material in either particulate or fibrous form is added to improve surface finish and, if desired and depending upon the choice of conductive material, darken the appearance of the product. This mixture is dispersed to form a blanket. The product may be utilized in a planar configuration or be further formed into complexely curved and shaped configurations. A variety of products having varying thickness and rigidity may be produced by controlling the compressed thickness and the degree of activation of the thermosetting resin. The product may also include a skin or film on one or both faces thereof.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 62/312,647, filed Mar. 24, 2016, the entire contents of which are incorporated by reference, as if fully set forth herein.
FIELD OF THE INVENTION
[0002] The present invention generally relates to hosiery, and more specifically, to fashion tights with cushioned areas that are seamless.
BACKGROUND OF THE INVENTION
[0003] Hosiery, such as fashion tights, are often uncomfortable due to the fact that they are constructed at a fine gauge, and do not provide adequate cushioning. For example, most fashion tights do not provide adequate padding in the heel and toe regions.
[0004] In order to address this comfort issue, most existing hosiery have used “sewn-in” socks whereby two products (e.g., a tight and a sock) are sewn together. In many cases, tights and socks are constructed using two separate machines, making this process complicated. Tights with “sewn-in” socks also have many drawbacks. For one, there is a seamline where the tight-portion and the sock-portion come together. This seamline is uncomfortable for the user and is not aesthetically pleasing. Additionally, because tights with “sewn-in” socks require the use of at least two separate knitting machines, there is often a break in the manufacturing process (between the knitting of the tight and the sewing-in of the sock), resulting in wasted material, higher cost, added labor, longer development process and potentially causing delays in production. Moreover, because tights are typically made of fine gauge material, the process by which a sock is sewn into the tight may cause greater defects during the manufacturing process.
[0005] Accordingly, there is presently a need for hosiery which provides comfort through a cushioned sock area, while also providing a fashionable look which is free from seamlines between the cushioned sock area and the rest of the hosiery. There is also a need for an efficient and streamlined process for producing such hosiery, which reduces the amount of wasted material, decreases labor and machine costs, and generates less defects.
SUMMARY OF THE INVENTION
[0006] An exemplary embodiment of the present invention comprises a garment including at least one non-cushioned portion comprising a first stitch technique, and at least one cushioned portion comprising a second stitch technique such that the at least one non-cushioned portion and the at least one cushioned portion are seamlessly separated. The first stitch technique may be distinct from the second stitch technique and both the first stitch technique and the second stitch technique may be manufactured by a knitting machine having one or more cylinders.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The invention will be better understood with reference to the following detailed description, of which the following drawings form an integral part.
[0008] FIG. 1A illustrates tights according to a first exemplary embodiment of the present invention.
[0009] FIG. 1B illustrates tights according to a second exemplary embodiment of the present invention.
[0010] FIG. 1C illustrates tights according to a third exemplary embodiment of the present invention.
[0011] FIG. 2 illustrates a first cross section view of the tights shown in FIG. 1B .
[0012] FIG. 3 illustrates a second cross section view of the tights shown in FIG. 1B .
[0013] FIGS. 4A-4D illustrate a needle and sinker diagram for a terry loop stitch used in connection with an exemplary embodiment of the present invention.
[0014] FIG. 5 illustrates a stitch diagram for a terry loop stitch used in connection with an exemplary embodiment of the present invention.
[0015] FIG. 6A illustrates a stitch diagram for a tuck loop stitch used in connection with an exemplary embodiment of the present invention.
[0016] FIG. 6B illustrates a needle diagram for a tuck loop stitch used in connection with an exemplary embodiment of the present invention.
[0017] FIG. 7A illustrates a stitch diagram for a float loop stitch used in connection with an exemplary embodiment of the present invention.
[0018] FIG. 7B illustrates a needle diagram for a float loop stitch used in connection with an exemplary embodiment of the present invention.
[0019] FIG. 8A illustrates a detail view of a float loop stitch knitting technique for tights according to an exemplary embodiment of the present invention.
[0020] FIG. 8B illustrates a detail view of the float loop stitch knitting technique shown in FIG. 8A in a relaxed state.
DETAILED DESCRIPTION
[0021] The present invention relates to hosiery and methods for making the same. In one exemplary embodiment, the hosiery includes a cushioned portion and a non-cushioned portion, each made using the same, or different, stitches. The cushioned and non-cushioned portions are preferably constructed so as to appear seamless. The cushioned are may be created by knitting a cushion pile in specific areas of the hosiery.
[0022] FIG. 1A illustrates a garment 100 according to a first exemplary embodiment of the present invention. In this embodiment, the garment 100 comprises hosiery (tights). This embodiment of the invention may be described as “ankle height” or “low bootie.” The garment 100 includes a non-cushioned portion 103 A, and a cushioned portion 101 A. As depicted the cushioned portion 103 A may extend from the user's toes to approximately the user's ankle. At the ankle the cushioned portion 103 A may meet the non-cushioned portion 101 A in a seamless transition.
[0023] FIG. 1B illustrates a garment 100 ′ according to a second exemplary embodiment of the present invention. In this embodiment, the garment 100 ′ comprises hosiery (tights). This embodiment of the invention may be described as “knee height” or “high boot.” The garment 100 ′ includes a cushioned portion 103 B, and a non-cushioned portion 101 B. As depicted the cushioned portion 103 B may extend from the user's toes to approximately the user's calf at a position below the knee. At the calf, the cushioned portion 103 B may meet the non-cushioned portion 101 B in a seamless transition.
[0024] FIG. 1C illustrates a garment 100 ″ according to a third exemplary embodiment of the present invention. In this embodiment, the garment 100 ″ comprises hosiery (tights). This embodiment of the invention may be described as a “foot bed.” The garment 100 includes a non-cushioned portion 101 C, and a cushioned portion 103 C. As depicted, the cushioned portion 103 C may extend along the sole of the user's foot. The cushioned portion 103 C may meet the non-cushioned portion 101 C in a seamless transition. In this exemplary embodiment, the cushioned portion 103 C may or may not be visible when the user is wearing shoes.
[0025] FIG. 2 illustrates a first cross section view of a garment 200 according to a fourth exemplary embodiment of the present invention. In this embodiment the garment 200 comprises hosiery (tights). The garment 200 includes a non-cushioned portion 201 , and a cushioned portion 203 . As depicted, the cushioned portion 203 extends from the portion of the garment configured to cover a user's toes towards the user's upper legs until it meets the non-cushioned portion 201 of the garment positioned near the user's upper legs. In one exemplary embodiment, the materials (e.g., yarns) forming the cushioned 203 and non-cushioned 201 portions of the garment 200 have a fiber size up to 400 denier.
[0026] FIG. 3 illustrates a cross section of the garment 200 shown in FIG. 2 , taken along line A-A. As illustrated, the garment 200 has an interior side 301 , and an exterior side 303 . The interior side 301 faces the skin of the user and includes cushioned portion 203 and non-cushioned portion 201 . The exterior side 303 faces away from the user. From the exterior side 303 , the garment appears to be uniform with no visible delineation between the cushioned portion 203 and the non-cushioned portion 201 (i.e., seamless). This creates a garment 200 with a seamless, comfort transition (between the non-cushioned portion 201 and cushion portions 203 ) while using a continuous knitting process. As illustrated in FIG. 3 , and as will be explained further below, the cushioned portion 203 of the garment may have a higher fabric ‘pile’ than the non-cushioned portion 201 of the garment.
[0027] The cushioned and non-cushioned portions of the garments 100 , 100 ′, 100 ″ and 200 may be constructed by a circular knitting machine of fine gauge. For example, fine gauge could be knitting machine with three hundred needles or more (i.e., 300N and above). Such a circular knitting machine may include one or more cylinders, as will be understood by those of ordinary skill in the art. The same circular knitting machine can be used to produce all parts of the garments 100 , 100 ′, 100 ″ and 200 , including the cushioned ( 203 , 103 A, 103 B, 103 C) and non-cushioned ( 201 , 101 A, 101 B, 101 C) portions. Those of ordinary skill in the art will understand that while the exemplary embodiments described herein reference a circular knitting machine, any type of knitting machine may be utilized.
[0028] The non-cushioned portion 201 of the garment 200 may be constructed using a flat knit stitch. In one exemplary embodiment, a circular knitting machine may have approximately four hundred (400) latch needles and a sinker configured for radial movement between the latch needles in order to form knit stitches. The cushioned portion 203 may be constructed using one of various types of cushioned stitches discussed further below. For example, the cushioned portion 203 may be formed using a terry loop stich ( 500 ; FIG. 5 ), a tuck loop stitch ( 600 ; FIG. 6A ), or a float loop stitch ( 700 ; FIG. 7A ). In order to produce these two different stitches, the circular knitting machine may be programmed to transition from a regular knit stitch for the non-cushioned portion 201 , to one of the cushioned stitches for the cushioned portion 203 . In this way, a single machine may be used to manufacture the garment 200 .
[0029] The circular knitting machine used to manufacture the garments 100 , 100 ′, 100 ″ and 200 may have adjustable settings and/or be programmed to be able to transition from constructing the cushioned and non-cushioned portions of the garment. In one exemplary embodiment, the circular knitting machine does not have to be stopped while transitioning from constructing the cushioned to the non-cushioned portion of the garment. The needles and/or sinker may be adjusted in order to knit portions with various pile heights (and amount of cushion). The pile height may be increased by adjusting the knitting method, fiber type, additional brushing of the pile fibers post-knitting and the like. The cushioned portions ( 203 , 103 A, 103 B, 103 C) of the garments ( 200 , 100 , 100 ′, 100 ″) may be constructed using elongated sinker loops or terry loop stitches, tuck loop stiches, and/or float loop stitches. Those of ordinary skill in the art will understand how to make various pile heights and cushioning for the cushioned portion of the garment 200 using the above-referenced techniques. The following U.S. Patents generally describing knitting techniques, circular knitting machines and the generation of piles are incorporated by reference herein: (1) U.S. Pat. No. 3,226,952; (2) U.S. Pat. No. 3,293,887; (3) U.S. Pat. No. 3,576,115; (4) U.S. Pat. No. 4,020,653; (5) U.S. Pat. No. 4,103,518; (6) U.S. Pat. No. 4,580,419; (7) U.S. Pat. No. 4,633,683; (8) U.S. Pat. No. 5,186,025; (9) U.S. Pat. No. 5,862,681, and (10) U.S. Pat. No. 6,089,047.
[0030] To produce elongated sinker loop stitches or terry loop stitches, a body thread is knit into stiches in successive course, producing needle wales. The needle loops in each course are connected by sinker loops in turn producing sinker wales between the needle wales. A second thread of same size, composed of the body thread, is knitted into needle loops in each course. In one exemplary embodiment, the sinker loops for the second thread are elongated when compared to the sinker loops for the first thread. The elongated sinker threads protrude from the plane formed by the knitted item by forming a cushioned region on the face of the knitted item. More elongated sinker loops may be associated with longer terry loop stitches, in order to create the elongated sinker loops.
[0031] FIGS. 4A-4D show a needle and sinker diagram for an elongated sinker loop stitch including a first sinker 401 , and a second sinker 403 . One of the sinkers (e.g., 401 ) may be configured to catch the main thread, and the other sinker (e.g., 403 ) may be configured to catch a secondary thread. As illustrated, the first sinker 401 engages with a needle 407 . In one embodiment, the needle 407 may be a latch needle with a latch 409 and hook 413 . The hook 413 of the needle 407 may be operable to engage fibers 411 A of a base yarn, as shown in FIG. 4B . The needle 407 also engages a needle loop 415 of a secondary yarn (as opposed to the base thread). The first sinker 401 may move in lateral directions 417 , 419 towards and away from the needle 407 . The second sinker 403 may also move in a lateral direction 405 , 406 towards and away from the needle 407 . When the two sinkers 401 , 403 are moved in a lateral direction away from the needle 407 (i.e., ‘pulled back’), the shape of the second sinker 403 allows for an elongated loop thus creating a terry effect. The needle loops of the secondary yarn are connected by sinker loops as well. In one exemplary embodiment, the terry loops may be knit to only face one side of knit fabric, thereby creating a cushioned portion on only one side of the hosiery that is seamless from the opposite side.
[0032] As shown in FIG. 4B , the knitting process begins with the first and second sinkers 401 , 403 relatively aligned in a horizontal direction (i.e., overlapping). Before the process begins, the second sinker 403 is moved laterally in a direction 405 away from the needle 407 . The fibers 411 A of the base yarn have yet to be contacted by the hook 413 of the needle 407 . As shown in FIG. 4C , as the needle 407 moves down it catches the fibers 411 A of the base yarn in the hook 413 . At the same time, the first and second 401 , 403 sinkers move laterally forward (in directions 417 and 406 , respectively) thereby allowing the fibers 411 A of the base yarn to catch on the protrusions of the sinkers, thus creating a base yarn loop 411 B. The needle loop 415 of a secondary yarn slides up the shaft of the needle 407 as the needle is moved downward, and engages with the base yarn loop 411 B, thereby creating a needle loop stitch 411 C (i.e., sinker loop stitch). As shown in FIG. 4D , this needle loop stitch 411 C is removed from the first and second sinkers 401 , 403 by the lateral movement of the first sinker 401 in a direction 419 away from the needle 407 . This process is repeated over and over again to create a sinker loop stitch which may be used to form the cushioned portion 203 of the garment 200 . As discussed further below, and as will be understood by those of ordinary skill in the art, various types of stitches may be used to form the cushioned portion 203 of the garment 200 , such as terry loop stitches, tuck loop stitches, and float loop stitches.
[0033] FIG. 5 illustrates an stitch diagram for an exemplary terry loop stitch 500 formed by two sinkers. As depicted, the terry loop stitch 500 includes a needle loop 501 , a regular sinker loop 503 , and an elongated sinker loop 505 . The elongated sinker loop 505 may be longer than the regular sinker loop 503 and used to create a cushioned region for the garment 200 .
[0034] The terry loop stitch 500 may be formed in much the same way as described above for the elongated sinker loop stitch ( FIGS. 4A-4D ). For example, a body thread/base yarn is knit into stitches in successive course, producing needle wales. The needle loops in each course are connected by sinker loops in turn producing sinker wales between the needle wales. A secondary yarn of the same size as the body thread/base yarn is knitted into needle loops in each course. These sinker loops for secondary yarn are elongated in correlation to body thread/base yarn sinker loops. Elongated sinker threads allow for thread to protrude from the plain of the fabric, in turn forming a cushioning on the face of the knitted item. The more the sinker loops elongate, the longer the loop you will have (in the form of terry loop stitches). To create elongated loops, there are two sinkers, one catching the main thread and the other catches the second thread and allows for longer loop. When the two sinkers pull back, the shape of the second sinker allows for a larger loop than typical sinker loops when creating another stitch, in turn creating the terry effect. The needle loops of the secondary yarn are connected by sinker loops as well. The terry loop stitches are knit to only face one side of the knit fabric, creating cushion that is seamless from the opposite side.
[0035] FIG. 6A illustrates an stitch diagram for an exemplary tuck loop stitch 600 . FIG. 6B illustrates a needle and sinker diagram for the tuck loop stitch 600 . As illustrated in FIGS. 6A and 6B , the cushioned portion 203 of the garment 200 may also utilize a tuck loop stitch 600 . In such a tuck loop stitch 600 , specific needles may be configured to hold more than one stitch at a time, as shown in FIG. 6B .
[0036] As illustrated in FIG. 6B , a needle 601 that is holding a loop 603 may receive a new loop 605 as the thread passes. The new loop 605 and the held loop 603 do not intermesh. Rather, the held loop 603 is tucked behind the new loop 605 on the reverse side of the stitch. When the held loop 603 is tucked behind the new loop 605 it creates double the thickness of a single loop, in turn creating extra thickness at the point of the stitch. The extra thickness may be used to provide the cushioning for the cushioned portion 203 of the garment 200 .
[0037] FIG. 7A illustrates a stitch diagram for an exemplary float loop stitch 700 . FIG. 7B illustrates a needle and sinker diagram for the float loop stitch 700 . In the exemplary float loop stitch 700 , a knitting stitch is composed of a held loop 703 , one or more float loops 701 , and knitted loops. The needle holding the held loop 703 does not receive a new loop as the thread passes. The float loop 701 falls to the back of the needle on the reverse side of the stitch and joins together the two nearest needle loops knitted from it. The float loops 701 may be composed of fiber types and filament yarn that is configured to create cushioning when the float stitch is allowed to return to its natural wavy shape, as is depicted in FIGS. 8A and 8B .
[0038] FIGS. 8A and 8B illustrate further details of the float loop stitch 700 . In FIG. 8A , a ‘2 by 2’ stitch pattern of float loop stitches 700 is illustrated. FIG. 7A above shows a ‘1 by 1’ stitch pattern of float loop stitches 700 . Those of ordinary skill in the art will realize that any pattern of float loop stitches 700 may be used to create the cushioned area 203 of the garment 200 , without departing from the scope of the present invention.
[0039] FIG. 8A shows the pattern of float loop stitches 700 in a ‘stretched’ state. When the fabric is allowed to ‘relax,’ the long strand of yarn 801 which stretches across each set of double loops bunches up a shown in FIG. 8B . This bunching of the yarn fibers creates a cushion effect, by allowing the fibers of yarn to return to their natural state. The longer strands 801 are created when specific needles are allowed to rest in an inactive state during the knitting process. In the relaxed state, the yarn fibers of the longer strands 801 revert back to the ‘wavy’ nature shown in FIG. 8B , and lose their ‘smooth’ appearance (as shown in FIG. 8A ). The fibers of the longer strands 801 are knit with allowance to remain in a relaxed state, and thus create a fleece-like finish in the cushioned area 203 of the garment 200 .
[0040] Although the invention has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly to include other variants and embodiments of the invention which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention. This disclosure is intended to cover any adaptations or variations of the embodiments discussed herein.
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A garment constructed by a cylinder knitting machine with a comfort quality area on or near the foot area, created by a different method of knitting from the rest of the tight. The difference between the quality of the leg and comfort portion of the garment (i.e., tights) consists of the use of a different needle movement and/or knitting tool, but is not limited to just that. Additionally, the fiber may also differ in the comfort area as compared to the leg area of the tights in order to reach different end results.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is concerned with the breaking or resolution of oil-in-water (O/W) bituminous emulsions by treatment with polymers of quaternary ammonium monomers.
2. Description of the Related Art
A great volume of hydrocarbons exist in known deposits of tar sands. These deposits occur at various places, the Athabasca tar sands in Canada being an example. The petroleum in a tar sand deposit is an asphaltic bitumen of a highly viscous nature ranging from a liquid to a semisolid. These bituminous hydrocarbons are usually characterized in being very viscous or even non-flowable under reservoir conditions by the application of driving fluid pressure.
Where surface mining is not feasible, the bitumen must be recovered by rendering the tar material mobile in-situ and producing it through a well penetrating the tar sand deposit. These in-situ methods of recovery include thermal, both steam and in-situ combustion and solvent techniques. Where steam or hot water methods are used, a problem results which aggravates the recovery of the bitumen. The difficulty encountered is emulsions produced by the in-situ operations. These emulsions are highly stable O/W emulsions which are made even more stable by the usual presence of clays. Most liquid petroleum emulsions are water-in-oil (W/O) types. These normal W/O emulsions are broken by methods known in the art. However, the bitumen emulsions which are O/W types present a much different problem, and the same demulsifiers used in W/O emulsions will not resolve the O/W bitumen emulsions. The uniqueness of these O/W bitumen emulsions is described in C. W. W. Gewers, J. Canad. Petrol. Tech., 7(2), 85-90 (1968). (Prior art Reference A.) There is much prior art concerning the resolution of normal W/O emulsions. Some of the art even mistakenly equates bitumen W/O emulsions with these W/O emulsions. The following is a list of several art references.
B. Texaco Canada was granted a recent patent, U.S. Pat. No. 4,058,453, for breaking bitumen emulsions using high molecular weight poly(ethylene oxides) of >1,000,000 molecular weight with optional addition of alkaline earth metal halide.
C. U.S. Pat. No. 4,141,854 claims the use of quaternary ammonium salts of co-polymers of acrylamide and dialkylaminoethylmethacrylate compounds (5-50 wt.% amino monomer units present) for breaking W/O emulsions encountered in uranium ore solvent extraction. To break O/W emulsions, it was necessary to first adjust the pH to 9 with NH 3 and invert the emulsions with a surfactant (U.S. Pat. No. 4,154,698).
D. In U.S. Pat. No. 4,120,815 a 50:50 wt.% copolymer of acrylamide (or acrylic acid) with diallyl dialkylammonium chloride was used to brek O/W emulsions encountered in refineries or waste treatment streams.
E. In U.S. Pat. No. 4,160,742 co-polymers of acrylamide and methacrylamidopropyltrimethylammonium chloride (MAPTAC) (at least 50 wt.% acrylamide present) were used to break O/W oil refinery waste stream emulsions.
F. U.S. Pat. No. 3,585,148 claims the use of acrylamide co-polymers with diallyl (or dimethallyl) dialkylammonium salts (containing no more than 25 wt.% quaternary salt) to break O/W emulsions.
G. U.S. Pat. No. 4,224,150 describes a process for clarifying water containing oil or suspended solids by treatment with polymers of a quaternary ammonium monomer which has a structure different from that claimed by our invention. Further, the breaking of bitumen emulsions with the use of these polymers is not mentioned. The structure for the monomer in U.S. Pat. No. 4,224,150 is as follows: ##STR1##
SUMMARY OF THE INVENTION
The invention is a method for recovering petroleum from O/W bitumen emulsions by resolving or breaking these emulsions by contacting the emulsions at a temperature of between 25° and 160° C. with polymers greater than about 50,000 molecular weight of compounds having the general structure ##STR2## where R=H or lower alkyl, X=NH or O, n=>1, R 1 and R 2 =alkyl, R 3 =alkyl, alkenyl, alkylaryl, or hydroxyalkyl, and Y=an anion such as chloride, acetate, bromide, sulfate, etc. Also included in this invention are co-polymers of these monomers with other monomers such as acrylamide wherein the weight percent of the monomers of the above structure is present in amounts equal to or greater than about 60% of the total co-polymer composition.
Also included in our invention is a method for recovering oil or bitumen from subterranean formations by use of reclaimed water from broken bitumen emulsions obtained in the method described above. This method comprises adding to the water separated from bitumen emulsions using the above mentioned technique enough anionic compound to remove the demulsifying chemical from the solution. The reclaimed waters are then recycled to subsequent steam or hot water floods of tar sands deposits without hindering the desirable in situ emulsification processes from taking place.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Especially useful and preferred in the process of this invention are polymers of the quaternary ammonium monomer whose structure is found in the Summary of the Invention wherein R is CH 3 , n has a value of from 2 to 3, and R 1 and R 2 are CH 3 . The other substituents and ranges are as they appear in the description in the Summary of the Invention.
Also, where co-polymers of these quaternary ammonium monomers are used, it is preferable that the co-polymer contain greater than 80 wt.% of the quaternary ammonium monomer described in the Summary of the Invention.
The produced bitumen emulsions may be treated by the process of our invention in a conventional manner, for example, in a conventional horizontal treater operated, for example, from about 25° to 160° C. and, preferably, above 60° C. at atmospheric or slightly higher pressures. The concentration of the chemical demulsifier described above used in treating the bitumen in water emulsions may range from about 1 to 200 parts per million and, preferably, from about 30 to 100 parts per million with the optional addition of an organic diluent and/or inorganic salt as well as standard flocculants and mechanical or electrical means of demulsification.
After the bitumen emulsion is broken there is a water phase which must be disposed of. The most efficient way to dispose of this water phase is to use it to recover more bitumen or other hydrocarbons by reinjecting it into a suitable formation. However, since the water phase contains the demulsifying chemicals used to break the emulsion, it will have a deleterious effect on the recovery of additional bitumen if injected into the formation. In the recovery of bitumen and heavy oils, it is generally the object of injecting an aqueous fluid to emulsify the bitumen and, therefore, make it more mobile so that it may be recovered. Therefore, the demulsifying chemicals contained in the aqueous phase must be removed prior to reinjection into the bitumen containing formation.
Therefore, another embodiment of this invention is a process for recovering bitumen from a tar sand formation comprising injecting into the tar sand a fluid containing hot water and/or steam in order to emulsify the bitumen in the tar sand and recovering the emulsified bitumen, demulsifying the emulsion by adding thereto at a temperature of between 25° and 160° C. polymers greater than about 50,000 molecular weight of compounds having the general structure ##STR3## where R=H or lower alkyl, X=NH or O, n=>1, R 1 and R 2 =alkyl, R 3 =alkyl, alkenyl, alkyl aryl, or hydroxy alkyl, and Y=an anion such as chloride, acetate, bromide and sulfate. Thereafter, the demulsifying chemicals are removed by precipitation from solution by addition of enough anionic chemicals such as surfactants or anionic polymers to precipitate the demulsifying chemicals from solution. Then the aqueous phase is reinjected into a bitumen containing formation to recover additional bitumen.
The following examples describe more fully the present process. However, these examples are given for illustration and are not intended to limit the scope of the invention.
EXAMPLE 1
A methacrylamidopropyltrimethylammonium chloride (MAPTAC)* polymer was prepared as follows: To a one-liter glass reactor were charged 200 g MAPTAC (50% solids, 50% water); 134 g deionized water; 0.1 g sodium salicylate; and 0.5 g 2,2'-azobis(2-amidinopropane)hydrochloride. The reactor contents were deoxygenated by passing a stream of nitrogen through for one hour at the rate of 14 liters/hour. The nitrogen padded reactor was then heated for 5.7 hours at 50° C. The viscosity of the resulting polymer solution was ca. 1300 cp. The viscosity of a 0.5% solution of the polymer in water was 10 cp. Monomer conversion was 98% (viscosities were measured with the Nameter Vibrating Sphere Viscometer at 25° C.).
EXAMPLE 2
An example similar to that above was carried out, but the sodium salicylate was omitted. The viscosity of a 0.5% solution in water was 10.3 cp. The monomer conversion was 99+%.
EXAMPLE 3
An experiment similar to Example 1 was performed but only 100 g deionized water was added and 100 g of isopropanol was added. The sodium salicylate was omitted. The conversion of monomer was 92% and a 0.5% solution of the polymer had a viscosity of 5.6 cp.
EXAMPLE 4
To a glass kettle were charged 100 g of a 61.3% solution of methacrylamidopropylhydroxyethyldimethyl ammonium acetate (MAPHDA)*; 400 g deionized water, and 0.5 g 2,2'-azobis(2-amidinopropane)hydrochloride. Following one hour deaeration with nitrogen, the solution was heated to 50° C. for five hours, then at 60° C. for 1.5 hours. Conversion of the monomer was 99%. The viscosity of a 0.5% polymer solution was 8.45 cp.
EXAMPLE 5
A co-polymer of MAPTAC and acrylamide was prepared as follows: to a glass reactor were charged 160 g MAPTAC (50% aqueous solution); 80 g acrylamide (50% aqueous solution); 340 g deionized water; 20 g isopropanol; 0.5 g 2,2'-azobis(2-amidinopropane)hydrochloride; and 0.2 g ethylenediamine tetraacetic acid, disodium salt. After nitrogen purging, the reactor was immersed in a 50° water bath for four hours to provide the polymer product. The viscosity of a 0.5% solution of the polymer at 25° was 11.8 cp.
EXAMPLE 6
An experiment identical to Example 5 was performed, except the isopropanol was replaced with deionized water. The viscosity of a 0.5% solution of the polymer was 14.2 cp at 25° C.
Relative molecular weights were obtained on the polymers prepared in Examples 1-6 by size exclusion liquid chromatography. The column material was silica with an average pore size of 1,000 angstroms. The silica was treated with an amino-organosilane. Elution solvent was 0.1 N nitric acid. Polyacrylamide standards were used. The approximate molecular weights are shown below for the instant polymers.
______________________________________Polymer of Example Molecular Weight______________________________________1 1 million2 --3 0.5 million4 1.7 million5 1.3 million6 1.7 million______________________________________
EXAMPLE 7
Acrylamide-MAPTAC Co-polymer
Using standard emulsion polymerization techniques, such as those found in U.S. Pat. No. 4,152,200, comparative example A, a>1,000,000 molecular weight co-polymer was prepared from a mixture of 74 wt.% acrylamide and 26 wt.% MAPTAC. The product emulsion contained 27.6 wt.% polymer.
To a solution of 0.25 g TWEEN®80 in 96 g H 2 O was added 3.62 g of the above emulsion with stirring to invert the emulsion and prepare a 1 percent aqueous polymer solution (product a).
The procedure above was repeated in the absence of TWEEN 80 to prepare solution b.
EXAMPLE 8
Demulsifier Testing
The following basic testing procedure was employed:
a. A 1 weight percent solution (on an amines charged basis where aminopolymers were used, rather than on an amines salts basis) of each chemical was prepared in water.
b. A 30 ml PYREX® test tube equipped with screw top was charged with 23 ml emulsion of 11.5 weight percent bitumen content obtained by in-situ steam flooding in tar sand pattern located at Ft. McMurray, Alberta, Canada.
c. 2 ml Wizard Lake crude oil was added as diluent and the contents of the test tube were mixed.
d. The contents of the test tube were equilibrated in a 80° C. oven for 1-2 hours and mixed again.
e. Chemical was added to the hot, dilute emulsion at the following concentrations: 30, 60, 120 ppm.
f. Contents of the test tubes were mixed, re-equilibrated in an oven at 80° C. for 1 hour and mixed again.
g. After 20 hours of standing at 80° C., measurements were made on the volume of top and middle layers, and the appearance of the aqueous phase was noted. Samples of some top layers were carefully removed by pipetting and subjected to Karl-Fischer analysis for determination of the water content.
Comparative examples 8d, 8h and 8i are given to show the relative ineffectiveness of compounds cited in Prior Art reference B.
Comparative examples 8b and 8c are given to show the relative ineffectiveness of co-polymers containing less than 50 wt.% cationic character. Better results are seen for co-polymers with 66 wt.% cationic present (Example 8p-8u). And even better results are seen for cationic homopolymers.
In most of the examples given, the required demulsifier dosage for best results is seen to be >60 ppm.
Some effect of molecular weight can be seen in these examples, with >1,000,000 molecular weight polymers giving better results than a 500,000 molecular weight polymer (compare 8a, e, f and g with 8m, n and o).
Successful examples are given for claimed chemicals having Y=Cl and R 3 =CH 3 and having Y=CH 3 CO 2 and R 3 =CH 2 CH 2 OH.
Example 8a represents the first successful reduction to practice of this invention.
Specific test results are summarized in Table I on the following pages.
TABLE I__________________________________________________________________________Demulsifier Testing Oil Phase Emulsion Concentration, Volume in Phase Volume Aqueous PhaseExample 8 Candidate Demulsifier (ppm) ml (% H.sub.2 O) in ml (% H.sub.2 O) Appearance__________________________________________________________________________a Product of Example 1 60 8 (15.2) 0 Dark, translucentb Product a of Example 7 60 2 5 Muddyc Product b of Example 7 60 1.5 3 Muddyd POLYOX ® WSR-301** 60 9 (53.2) 0 Light translucente Product of Example 2 30 ˜6 0 Muddyf* Product of Example 2 60 8 (21.9) 0 Clear, colorlessg* Product of Example 2 120 10 (1.43) 0 Clear, colorlessh POLYOX WSR-301** 60 6 (49.1) 0.5 Brown, translucenti POLYOX WSR-301** 120 7 (34.3) 2 Brown, translucentj Product of Example 4 30 8.5 0 Muddyk Product of Example 4 60 4 (6.34) 3.5 Dark, translucentl* Product of Example 4 120 4 (1.74) 3 Yellow, transparentm Product of Example 3 30 5 2.5 Muddyn Product of Example 3 60 5.5 (17.9) 1.5 Dark, translucento* Product of Example 3 120 4 (2.64) 6(72.3) Yellow, transparentp Product of Example 5 30 9 (86.9) 0 Muddyq Product of Example 5 60 4.5 (98.6) 4 Brown, transparentr* Product of Example 5 120 4 (2.16) 11 Yellow, transparents Product of Example 6 30 9 (33.5) 0 Muddyt* Product of Example 6 60 10 (26.7) 0 Yellow, transparentu* Product of Example 6 120 1 22.5(80.3) Yellow, transparent__________________________________________________________________________ Note: Horizontal lines denote emulsions treated on same day *Clear water layer formed immediately after addition of demulsifier. **A commercial 4,000,000 molecular weight poly(ethylene oxide).
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A process for recovering bitumen from oil-in-water (O/W) emulsions is disclosed wherein water soluble demulsifiers are used. These demulsifiers are polymers of specific quaternary ammonium monomers or co-polymers of these quaternary ammonium monomers wth other types of monomers wherein the greater portion of the co-polymer is comprised of the quaternary ammonium monomers. To resolve the bituminous petroleum emulsions, the process is carried out between 25° and 160° C. wherein the demulsifier of the invention is contacted with the bituminous emulsion.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an improved version of the standard game of chess.
2. State of the Prior Art
The game of chess has a long and proud history. By many accounts it originated in the ranks of royalty during the early middle ages. However, some believe it may have actually derived from a game played several thousand years before the birth of Christ. In any event, the standard game of chess is well known to many aficionados around the world. The World Chess Federation regulates tournaments and publishes a set of rules by which tournament play is regulated.
Chess is a game of strategy and intellect. Successful play requires a knowledge of strategy and an ability to plan and foresee an opponent's strategy as a game develops. This attribute of a standard chess game produces a game of high intellectual satisfaction.
The standard game of chess is not without its drawbacks, however. The original game of chess, as played several hundred years ago, did not encompass plays such as promoting the rank of pawns, capturing en passant and castling. These features were added over time to limit the number of games ending in a draw. Even with these modifications to the original game of chess, checkmate often cannot be achieved due to ineffective play resulting in a total depletion of forces capable of attaining the goal of checkmate.
A typical game of chess starts with one of several standard openings designed to quickly establish positions of power on the chess board. The game quickly transitions into a middle game in which the object is to reduce the opponent's forces while continuing to establish positions of power upon the board. The end game typically involves one of the players gaining a more powerful position and more remaining forces to chase the opponent's king into checkmate. With evenly matched experienced players, games often end in a draw with neither player having sufficient forces remaining to force their opponent's king into checkmate.
SUMMARY OF THE INVENTION
A method for playing a game of chess according to the present invention incorporates the essential characteristics of standard chess, including the original ingenious way of moving the pieces and the object of the game to check mate an opponent, while enhancing strategies of play directed toward capturing the King and reducing strategies of play directed to reducing opponent's forces. With a tendency toward a greater number of pieces on the board, the game according to the present invention provides greater complexities in offensive and defensive tactics while nearly eliminating the possibility that a game can end in a draw.
According to the invention, a method for playing a game of chess between a first player and a second player uses pieces comprising pawns and major pieces wherein the major pieces comprise kings, queens, rooks, bishops, and knights, with the first player's pieces being of a first color and the second player's pieces being of a second color. The game is played on a board comprising a matrix of squares arranged into ranks and files and the steps include each of the first and second players moving a piece in turn with each move comprising the relocation of one of the player's pieces from one square to another square on the board. An improvement comprises the step, at the option of the second player, of placing an additional pawn of a second color onto an unoccupied square selected by the second player in the second player's second, third or fourth rank and in a file which contains no other pawn of the second color upon the capture of one of the second player's major pieces by one of the major pieces of the first player.
Preferably, the method according to the invention further comprises the step of the second player selectively moving one of the pieces of the second color in the same turn, immediately after the step of placing the additional pawn. Preferably, the method comprises the step of commencing the game with no more than four pawns of the first color and four pawns of the second color on the board. Preferably, pawns of the first color are placed on the Rook 4, Queen 4, and King 3 squares of the first player and pawns of the second color are placed on the Rook 4, Queen 4, and King 3 squares of the second player. Further, pawns selectively move one or two squares in sideways direction or one square forward, with an option from the second rank only to advance two squares forward. The maximum number of pawns of either color on the board at any one time is eight.
Preferably, the method further comprises, replacing, at the option of the moving player, a pawn with a previously captured major piece of the same color, if any, when the pawn is moved to the fifth rank of the moving player without capturing a pawn in the same move.
Further, the method comprises a step of creating a protected pawn, protected by capture by major pieces of the opposite color. The protected pawn is created by positioning a protector piece of the same color as the protected pawn on a first square and positioning the protected pawn on a second square with the protector piece in position to move to the second square in a single move without placing the King of the same color as the protected pawn into check.
After moving a first color pawn to a square in the first player's eighth rank and prior to the second player making a move, the method further comprises the step of the first player moving the pawn from the eighth rank square to an unoccupied square in the first players's second rank and in a file not occupied by another first color pawn. After making a move to create a first arrangement of pieces on the board, it is not a legal move for a player to later make the same move to create the same arrangement of pieces on the board, whereby repetitious cycles of moves are eliminated from the game.
Preferably, the Rook 4, Queen 4, and King 3 squares of each player are marked for a correct initial placement of the pawns upon the board. The board can be divided into a first and second half between the fourth and fifth rank, with light squares in the first half being of a different color from light squares in the second half.
A game assembly according to the invention comprises two sets of differently colored movable pieces. Each set of pieces includes pawns and major pieces, the major pieces comprising kings, queens, bishops, knights, and rooks. A board is provided having a matrix of squares arranged into ranks and files. A set of instructions is provided for playing the game wherein the instructions include the steps of a method for playing a game of chess between a first player and a second player. The steps include each of the first and second players moving a piece in turn, each move comprising the relocation of one of the player's pieces from one square to another square on the board. Also, the instructions include the step of, at the option of the second player, placing an additional pawn of a second color onto an unoccupied square selected by the second player in the second player's second, third, or fourth rank and in a file which contains no other pawns of the second color upon the capture of one of the second player's major pieces by one of the major pieces of the first player.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described with reference to the accompanying drawing in which:
FIG. 1 illustrates a plan view of a chess board according to the invention and illustrates the starting arrangement of pieces.
DETAILED DESCRIPTION
The game according to the present invention incorporates the basic rules of standard chess with modifications as described herein. It employs standard chess pieces and can be played on a standard chessboard comprising a grid of 64 squares having eight squares along each edge with alternating light and dark colored squares. Preferably, the present game is played on a game board 10, as illustrated in FIG. 1, representing a modified version of a standard chessboard. On a chessboard, squares are often identified in terms of their rank and file. A rank 12 is a line of squares extending laterally across the board relative to the edge facing the player, with the player's first rank 14 being that rank closest to the player. Each rank 12 is identified numerically. A file 16 is a line of squares running perpendicular to a rank and extending from one edge facing a player toward the opposing edge on the other side of the board. A file 16 is identified by the name of a major piece in the first rank 14 at the start of the game. As in standard chess, a player's major pieces 29 include a King 18, a Queen 20, two Rooks 22, two Knights 24, and two Bishops 26. Thus, for example, the file 16 in which the King 18 is located is termed the King file or King's file. The file in which the rook 22 closest to the King 18 is located is termed the King's Rook file. Individual squares are identified in the same fashion. Thus, for example, the square located in a player's third rank 12 and in the King' s Rook file is termed King's Rook 3.
Major pieces 29, including the King 18, the Queen 20, the Rooks 22, the Bishops 26, and the Knights 24, move in the same manner as in standard chess. However, castling is not permitted. Thus, the King 18 can move one square in any direction, forward, backward, sideways or diagonally. The Queen 20 can move an unlimited number of unobstructed squares in any direction. The Rooks 22 can move an unlimited number of unobstructed squares either forwards, backwards, or laterally. The Bishops 26 can move an unlimited number of unobstructed squares diagonally. The Knights 24 move in their traditional L-shaped pattern, that is one square forwards, backwards, or laterally followed by one square diagonally. As in standard chess, if the path of a King 18, Queen 20, Rook 22 or Bishop 26 is blocked by another piece the movement of the King, Queen, Rook or Bishop is thus limited. However, the movement of the Knight 24 is not so hindered.
According to the invention, Pawns 28 move in the same manner as in standard chess. However, Pawns 28 are also permitted to move one or two squares to either side at the player's option. Each file 16 may contain no more than one Pawn 28 for each player, except where a piece is captured by a Pawn 28. The capturing Pawn 28 may be moved into a file 16 occupied by another Pawn 28 of the same player. Additionally, Pawns 28 can capture en passant as in the standard game of chess.
FIG. 1 illustrates the opening arrangement of the players upon the board. The major pieces 29 are arranged as in the standard game of chess. Each player has either light or dark pieces, commonly termed white and black pieces. FIG. 1 illustrates the game board 10 from the viewpoint of the player having the white pieces. The white Queen 20 is placed upon the most centrally located white square in the first rank 14. The white King 18 is placed upon the most centrally located dark square in the first rank 14. The Bishops 26 are placed in the home rank 14 immediately adjacent the King and Queen 18 and 20. The Knights 24 are placed in the first rank 14 immediately adjacent the Bishops 26. Finally, the Rooks 22 are placed in the corner squares of the first rank 14 immediately adjacent the Knights 24.
Each player has only four Pawns 28 which are placed on the board as illustrated in FIG. 1. One Pawn 28 is placed in the third rank 12 in the King file 16, which position is otherwise termed King 3. A second Pawn 28 is placed at Queen 4 and the third and fourth Pawns are placed at Rook 4. The Queen and Rook files 16 can be considered power lanes and the Pawns 28 in these files 16 are placed in the fourth rank 12 to eliminate first move advantages for the Queen 20 and Rooks 22.
Whenever a major piece 29 is captured by an opponent's major piece, the player whose major piece was captured receives a sided Pawn 28 to be placed, at the player's discretion on an unoccupied square in that player's second, third or fourth rank 12 without doubling Pawns 28 in a file 16. Sided Pawns 28 are not received for capture of a major piece 29 by a Pawn 28. The sided Pawn 28 is placed immediately after the capture, and is not considered a move. Thus, the player receiving the sided Pawn 28 may immediately move the newly-received sided Pawn 28. Also, in the event the capture of a major piece 29 results in an apparent checkmate, the sided Pawn 28 is playable if it can be used to create a flight square or make a counter-capture that will negate the checkmate. If a major piece 29 captures an opponent's major piece 29 and a sided Pawn is placed on the board 10 to put the King 18 into check, of course, the newly-placed sided Pawn 28 cannot be moved to capture the King 18. However, another piece may be moved. If a player has all eight Pawns 28 on the board, then no additional sided Pawns 28 can be obtained even upon capture of a major piece 29. Also, in the event that a major piece 29 is captured and there are no legitimate squares for placement of a sided Pawn 28, no Pawns 28 can be received. A sided Pawn 28 can be declined.
Pawns 28 can be promoted upon being moved to a player's fifth rank 12. However, Pawns 28 can only be promoted from a captured major piece 29. Therefore, a player can never have more than one Queen 20, two Rooks 22, two Bishops 26 or two Knights 24 on the board 10 at any one time. A Pawn 28 can capture a major piece 29 on a fifth rank 12 and promote, but a sided Pawn 28 cannot be received via the promotion. A Pawn 28 can capture an opponent's Pawn 28 on a fifth rank but cannot be promoted. Pawns 28 do not have to be promoted when advanced to, or by capturing a major piece 29 to, a fifth rank 12. A Bishop 26 cannot be promoted to the same color square as the same player's other Bishop 26. A player can place his or her Pawn 28 on the fourth rank 12, then advance to or capture a major piece in the fifth rank and then promote. Pawns cannot jump other pieces, but can capture en passant.
To enhance the strength of each player's position on the board, protected Pawns 28 cannot be captured by a major piece 29. A protected Pawn 28 is a Pawn 28 on the controlling square of any piece, Pawn or major, i.e., a square which can be attacked by an opponent's piece. An unprotected Pawn 28 can be stolen, meaning the major piece 29 stealing the Pawn 28 cannot be recaptured in any way by the opposing player's next move. Pawns 28, however, can capture other Pawns 28 regardless of any protection. The King 18 alone cannot protect a Pawn 28 from two or more attacking majors 29. A piece which is pinned on the King 18 cannot protect a Pawn 28. A major piece 29 which is moved in a discover check or a double check may steal a Pawn 28 regardless of any protection if the capturing major cannot be recaptured by the King 18.
In standard chess, captures of protected Pawns 28 are a major type of play in which forces of both players are reduced. Typically, a player captures a Pawn 28 with a major piece 29, the opponent captures the major piece 29 with another major piece 29 and the first player captures the capturing major piece 29 of the opponent. In all, two major pieces 29 and a Pawn 28 are removed from play. By preventing captures of protected Pawns 28 by major pieces 29, these force reducing exchanges are eliminated and major pieces 29 are kept on the board 10 for more strategic play.
The rules of the present game greatly enhances the complexity of the game and its playing strategies by encouraging players to retain pieces on the board. The resulting game has few captures and is thus significantly different than standard chess. Not only is there more power on the board but the complexity of the game is greatly enhanced over standard chess. For instance, the illustrated set-up eliminates a first move check with the Queen 20 at King's Rook 5. The position also removes the centerline Pawn 28 positioning factor which supports the major piece development theme. The set-up and also eliminates a first move Pawn 28 exchange at Queen 4 which is contrary to the goal of the present game to retain as much power on the board throughout the course of the game as possible. The King 3 Pawn eliminates an effective first move Bishop check at Queen Knight 5. If the first player were to make this move, the second player would be able to counter by blocking with the Knight 24 at the Queen's Bishop 3 square. While the Knight 24 would appear unprotected and susceptible to capture by the first player's Bishop 26, its capture would result in a sided pawn being given to the second player who would then be able to place the sided pawn and capture the Bishop 26. The captured Bishop 26 of course would not be replaced by a sided Pawn 28, leaving the first player who initiated the exchange worse off, and leaving the second player with an additional Pawn 28 for possible promotion back to a Knight 24. Thus, the first player is discouraged from making this senseless exchange. It also protects the Queen Pawn 28 and serves as an effective defensive Pawn 28 on the third rank 12.
In the set-up illustrated, it is very difficult to advance one of the four initially set Pawns 28. This encourages players to develop their major pieces 29 foremost to create more complex and unpredictable opening moves and to allow for equal opportunity offense and defense. Having only four Pawns 28 at the start enables for an equal and significant number of open files 16 to accommodate effective placement of sided Pawns 28.
When a Pawn 28 reaches the eighth rank 12 it can be repositioned to any unoccupied square on the player's respective second rank 12 without placing more than one Pawn 28 into a single file 16. Pawns 28 can only be repositioned to the second rank 12. A Pawn 28 can capture to the eighth rank 12 and be repositioned to the second rank 12. If a legitimate square is not available for repositioning to the second rank 12, a Pawn cannot advance to or capture to the eighth rank 12.
In standard chess, games sometimes devolve into a repetitive loop of moves from which the players seem unable or unwilling to extricate themselves. In the present game, when a particular situation exists on the board, it is illegal to commit the same move that will recreate that exact same situation.
A King 18 cannot move onto or capture onto a square that will put the King 18 into check. This will not prevent a sided Pawn 28 from being placed to put a King 18 into check. A move is defined as being the specific beginning position of a piece to the specific end position. Therefore, neither the beginning nor the end position is the sole determining factor in whether a move is illegal.
The board 10 is provided with several additional features to enhance playability of the game according to the rules. Several of the rules of the game revolve around the fourth and fifth ranks 12, and thus it improves the playability of the game to clearly divide the board 10 between the fourth and fifth ranks 12. To this end, a differently colored dividing line 30 is provided between the fourth and fifth ranks 12 to divide the board 10 into a first half 32 and second half 34. The dividing line 30 is preferably a dark green color. The dark colored squares in the first half 32 are also preferably of a different but visually compatible color to the dark squares in the second half 34. The differently colored dark squares visually divides the board 10 and by making the squares visually compatible the light and dark square combination of the chess board 10 remains clear. Along each player's left lateral side 36 of the board 10, a stripe 38 of the same color as the dark colored squares on their half 32 or 34 of the board 10 is provided. Reference numerals 40 are provided to designate the number of each of that player's ranks 12. Lateral of the stripes 38, color coordinated spaces 42 and 44 are provided for storing captured majors 29 and sided Pawns 28 which are to be used throughout the course of the game. Of course, alternatively, the light colored squares could be made of compatible colors with the dark squares being black or another dark color. To avoid confusion at the initial set-up, tiny dots 46 are preferably placed on the squares upon which the Pawns 28 are to be initially set.
For illustrative purposes, a short game according to the present invention is illustrated along with comments. The notation generally follows standard chess movement notation familiar to those skilled in the art of chess and specifically comprises:
K=King,
Q=Queen,
R=Rook,
B=Bishop,
N=Knight, P1=Pawn.
(-)=move to,
(×)=capture,
(+)=check,
(/) indicates placement and move,
(. . . ) indicates a black move,
PP=Sided Pawn Placement,
re.=Repositioned Pawn,
() indicates promotion or specific piece.
______________________________________White Black______________________________________ 1. Q-B2, [strong position/diagonal] P(Q)-KB4, [defending Q-N6+] 2. Q-KN2 Q-N3, [for flight square] 3. Q-N6+ K-Q1 4. N-KB3 B-N5+ 5. N-B3, [if . . . BxN, PP-QN2/ N-QB3 PxB white gains a pawn] 6. N-K5 B-Q2 7. Q-N7 K-B2, [error, should have N-B3] 8. QxB+ PP-QN2/K-N1 9. QxP N(1)-K210. K-Q1, [freeing the N] R-N111. N-N5 Q-Q112. N-Q7+ K-B113. P-Q5 Q-B114. N-N6+, [NxQ+ is bad; . . . PP-Q2/ K-N1 PxQ]15. P-Q6 N-Q416. P-Q7 P-B217. Q-K8+, [very complex; strong K-N2 check, if . . . QxQ, PP-QB4/PxQ/ re. Q2, N-? , P-BS(Q) and black looses the Q]18. Q-B8+ RxQ19. PP-QB4/PxN(Q) R-Q120. QxN+, [forcing the K up] PP-K4/KxQ21. PP-QB3/PxB Q-Q3+, [big error]22. N-Q4+, [ff . . . PxN, P-N5(Q)+ K-N2 trouble]23. P-N5(Q) P(2)xN24. Q-R6+ K-N125. P-N7 K-B226. P-N8/re. Q2 PxN(N)27. Q-R7+ K-B3, [. . . K-B1 is bad, B-R6 mate]28. B-N5 + K-Q429. PxN Q-K330. Q-Q7+, [if . . . RxQ or QxQ, P-Q3 PP-K4/P-K5(Q) mate]31. Q-B6+ KxP32. B-N2 mate______________________________________
While particular embodiments of the invention have been shown, it will be understood that the invention is not limited thereto since modification can be made by those skilled in the art, particularly in light of the foregoing teachings. Reasonable variation and modification are possible within the foregoing disclosure of the invention without departing from its true spirit and scope. It is to be understood that the description of the particular embodiment contained herein is by way of illustration and not limitation, and that the scope of the appending claim should be construed as broadly as the prior art will permit.
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An improved game of chess is disclosed in which capture as a strategy is weakened and major pieces are subsequently kept on the board to enhance strategic play. Captured major pieces are replaced with pawns, the game starts with each player having only four pawns on the board, each player is limited to one pawn per file, and pawns promote at the fifth rank, but only from captured major pieces. A protected pawn cannot be captured by a major piece. A chess board is disclosed for enhancing playability of the game. The board is divided into two halves representing the player's representative sides of the board, by a colored dividing line and differently colored light squares representing the two halves. In the initial setup, each player has pawns on Rook 4, Queen 4 and King 3, and these squares are marked on the board to facilitate correct initial positioning of the pawns.
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FIELD OF THE INVENTION
This invention relates to steam turbine systems, and more particularly, to a spray cooled regenerator intended for use in such systems.
BACKGROUND OF THE INVENTION
Various means have been utilized to provide propulsion for torpedoes. Desirably, such systems should be quiet in operation to prevent or minimize the possibility of premature detection.
Further, the system should not be depth-sensitive, that is, should be capable of operating in a single, specified fashion whether located just below the surface or substantially below the surface.
Many systems that have been proposed, particularly those utilizing steam turbines, have not met the above criteria. Typically, such systems are open cycle systems where spent or exhaust steam is vented from the torpedo during its operation. Such venting not only increases the noise level of operation, but renders the torpedo sensitive to the depth at which it is running since the back pressure resisting venting will vary proportionally to depth.
To avoid these difficulties, it is proposed to provide a closed cycle steam turbine system particularly suited as a source of propulsion for torpedoes. As implied by the term "closed cycle", the working fluid, namely water, after it exhausts from the turbine as steam, is condensed and subsequently evaporated to form additional steam for driving the turbine wheel. As a consequence, the working fluid flows throughout the closed cycle, eliminating any need for venting the same, in turn, eliminating the source of noise associated with venting and sensitivity to depth.
The difficulty with such a system is that it necessarily requires more components than an open cycle system, including at a bare minimum, a condenser for condensing the exhaust steam from the turbine wheel and a pump for delivering the condensate to the boiler.
In addition, a regenerator is desirably incorporated in the system to maximize its efficiency.
To incorporate such additional components in a torpedo without unduly enlarging its size over and above that of an otherwise identical open cycle torpedo is a considerable task.
The present invention is directed to accomplishing that task.
SUMMARY OF THE INVENTION
It is the principal object of the invention to provide a new and improved steam turbine with a regenerator. More specifically, it is an object of the invention to provide such a turbine and regenerator which is extremely compact and which may interact with a condenser in such a way as to be ideally suited for utilization in a close-cycle steam turbine system such as may be employed in a torpedo.
An exemplary embodiment of the invention achieves the foregoing objects in a steam turbine comprising a rotatable turbine wheel. An annular heat exchanger is disposed just radially outwardly of the wheel and has a first fluid flow path including an annular outlet and an inlet in fluid communication with the turbine wheel to receive exhaust steam therefrom. The annular heat exchanger further has a second fluid flow path in heat exchange relation with the first path, the second path being adapted to receive make-up water for the steam turbine. Means are provided for generating an annular spray across the first flow path at the outlet thereof.
As a consequence of this construction, any superheat remaining in exhaust steam from the turbine wheel after it has passed through the first flow path is dissipated by the cooling spray at the outlet of the first flow path before the steam passes through a condenser which may be connected to such outlet. This, in turn, reduces the size of the condenser required to effect condensation of the working fluid prior to re-evaporation of the same. At the same time, the disposition of the regenerator annularly about the turbine wheel provides for considerable compactness, particularly in the axial direction.
According to the invention, the inlet for the first flow path is on the radially inner side of the heat exchanger and the outlet is on the radially outer side. Means are provided to define a condenser radially outwardly of the outlet and in fluid communication therewith. In the case where the system is employed in the torpedo, the condenser will be a so-called hull condenser which relies on the relatively cool temperature of the water in which the torpedo is operating, to create a temperature differential across the hull of the torpedo to effect condensation.
The invention contemplates, as alluded to previously, that the spray generating means be at the interface of the outlet and the condenser.
According to a preferred embodiment of the invention, the first flow path of the heat exchanger is radially directed and the turbine wheel is an axial flow turbine wheel. The inlet to the first flow path includes a flow director for receiving axially flowing exhaust steam from the turbine wheel and for redirecting the exhaust steam radially to the first flow path.
The invention contemplates that the first flow path be defined by axially spaced, generally radially directed walls, each terminating in an annular conduit. The spray generating means comprise nozzles in the conduits, each nozzle being directed at the opposite conduit to thereby create an annular spray pattern across the entirety of the outlet.
In a preferred embodiment, the radially outwardly opening grooves are located on the walls adjacent the conduits and seals are disposed in the grooves. The seals are adapted to seal the outlet to a hull condenser in a closed cycle torpedo or the like.
The invention also contemplates use in a closed cycle steam turbine system including a turbine and heat exchanger with spray cooling as mentioned above, and further including a condenser connected to the outlet along with a boiler interposed between the condenser and the turbine wheel. A pump is provided for pumping water from the condenser to both the boiler via the heat exchanger and to the spray generating means.
Other objects and advantages will become apparent from the following specifications taken in connection with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a turbine wheel and heat exchanger assembly made according to the invention;
FIG. 2 is an elevational view of the turbine wheel and heat exchanger assembly with parts broken away for clarity;
FIG. 3 is an enlarged, fragmentary sectional view of the interface of the heat exchanger and a condenser;
FIG. 4 is a further enlarged, fragmentary sectional view showing a typical nozzle configuration; and
FIG. 5 is a block diagram illustrating the closed-cycle steam turbine system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An exemplary embodiment of a turbine and regenerator made according to the invention is illustrated in the drawings and with reference to FIG. 1, is seen to include a turbine wheel, generally designated 10, have a hub 12 mounted on a shaft 14 suitably journalled by bearings (not shown). The shaft 14 serves as the output for the turbine wheel 10.
At its radially outer periphery, the turbine wheel 10 includes a series of blades 16 defining an axial flow turbine, that is, one where the working fluid flows primarily in the axial direction parallel to the shaft 14 as opposed to the radial direction transverse to the shaft 14.
Suitable nozzles of any conventional construction (not shown) are utilized for directing steam at the blades 16 to rotate the wheel 10. Such nozzles would, of course, be located on the right-hand side of the blades 16 as viewed in FIG. 1. On the left-hand side of the blades 16 is a flow director, generally designated 18 which, by means of a curved wall 20, one or more curved baffles 22, and a further curved wall 24 serves to direct the exhaust steam from the turbine wheel 10, after it has flowed therethrough in the axial direction, in the radial direction.
Radially outwardly of the perimeter of the turbine wheel 16 is a heat exchanger, generally designated 26, which serves as a regenerator. The heat exchanger 26 generally surrounds the entirety of the periphery of the turbine wheel 10 save for an approximately 60 degree gap, shown generally at 28 in FIG. 2, which may be employed for routing fluid lines, electrical control systems, etc., from one side of the turbine wheel 10 to the other when the apparatus is employed in a confined space, as for example, a torpedo.
As seen in FIGS. 1 and 2, the heat exchanger is made up of a radially outwardly extending continuation 30 of the wall 20 and an axially spaced, generally radially outwardly directed wall 32 mounted on the wall 24 in any suitable fashion. The walls 30 and 32 define a first flow path through the heat exchanger 26 which is generally radially directed about the entire periphery of the turbine wheel 10 save for the gap 28. The inlet to such first flow path is radially inwardly on the heat exchanger 28 and is defined by the portions of the walls 20 and 24 adjacent the plate 16. The outlet from the heat exchanger 26 is radially outwardly and is defined generally by the radially outer perimeters of the walls 30 and 32 as will be described in greater detail hereinafter.
Within the space between the walls 30 and 32 are six rows of ring-shaped tubes 34. Each of the tubes 34, for enhanced heat exchange, is provided with a series of ring fins 36.
As best seen in FIG. 2, opposite ends of each of the tubes 32 terminate in headers 38 and 40 flanking the space 28. Though not shown in FIG. 2, it is preferred that one of the headers 38 and 40 be closed by a baffle or cap including an outlet whereby two rows of the tubes 34 are placed in fluid communication within adjacent two rows of the tubes 34 and the remaining two rows connected to the outlet. A similar baffle cap is utilized in connection with the other header 38 and 40 to provide an inlet as well as to connect sets of two rows of the tubes 34 in series to define a second flow path within heat exchanger 26. The second flow path having such a connection will be a triple pass flow path and is adapted to be provided with feed water prior to evaporation thereof in a boiler downstream in the system before the evaporated water is provided to the turbine wheel 10 to drive the same.
Thus, the heat of the exhaust steam from the turbine wheel flowing through the first path will brought into good heat exchange relation with relatively cool make-up water flowing within the tubes 34 to elevate the temperature of the same. Waste heat is then recaptured to maximize system efficiency and the size of the boiler utilized to evaporate the feed water may be commensurately reduced.
The radially outer periphery of each of the walls 30 and 32 terminates in an annular conduit 50 and 52 respectively. The conduits 50 and 52 are mirror images of each other so that only the conduit 50 will be described. An enlarged illustration of the same is illustrated in FIG. 4 and it is seen to include a generally ring-shaped plate 54 having an inverted L-shaped cross-section. At periodic intervals around the length of the plate 54, apertures 56 are disposed therein and spray nozzles 58 are secured to the plate 54 over such apertures. A second ring-shaped plate 60 having an annular flange 62 is suitably secured to the plate 54 as by brazing (not shown) in such a way as to define an annular space 64 at the interface of the plates 62 and 54 which acts as the conduit 50. As can be appreciated from FIG. 4, the space 64 is in fluid communication with the apertures 56, and thus the nozzles 58. Each nozzle 58 has a flat opening 66 therein which acts as the nozzle orifice. Preferably, the orifice 66 is configured to provide a flat spray which diverges about 30 degrees to each side of the center line of the orifice 66 to provide a fan-shaped spray extending over an arc of approximately 60 degrees.
The nozzles 58 on each of the plates 54 may then be angularly spaced from each other by about 60 degrees with the nozzles 58 associated with the conduit 50 being staggered approximately 30 degrees from the nozzles associated with the conduit 58. As a consequence of this, a ring-like annular spray covering the entirety of the outlet of the first flow path through the heat exchanger 58 is provided.
FIG. 3 also illustrates the provision of radially outwardly opening grooves 70 adjacent the conduits 50 and 52. The grooves 70 are adapted to receive seals such as O-rings 72 which in turn are adapted to seal against the radially inner wall, shown schematically at 74, of a hull condenser shown schematically at 76, when the apparatus is employed as part of a closed cycle torpedo. The hull condenser 76 is thus placed in fluid communication with the heat exchanger 26 with the spray nozzles 58 being disposed at the interface of the two.
The apparatus may be employed in a system such as that shown in block form in FIG. 5. In this instance, the heat exchanger 26 acts as a regenerator receiving exhaust steam from the turbine wheel 10 as indicated by an arrow 80. Feed water for the system flows through the tubes 34 to be heated by the exhaust steam and the same is then fed to a boiler 82 as shown by an arrow 84. The feed water is evaporated in the boiler 82 and fed, as shown by an arrow 86, to the turbine wheel 10 to drive the same.
The exhaust steam passing through the regenerator to heat the feed water is directed to the hull condenser 76 as shown by an arrow 88 where it is condensed and then pumped by a pump 90 to the tubes 34 in the regenerator 26 as shown by an arrow 92. At a junction 94, part of the stream from the pump 90 is split and directed to the conduits 50 and 52 as indicated by an arrow 96. As alluded to previously, the spraying of water across the outlet of the heat exchanger 26 removes all superheat from the emerging exhaust steam stream allowing the size of the hull condenser to be minimized.
At the same time, the provision of the regenerator in the system, minimizes the size of the boiler 82 and the configuration of the regenerator about the turbine wheel 10 provides for an extreme degree of axial compactness.
Thus, the apparatus, while it may be used in any application involving a steam turbine and a regenerator, is ideally suited for use in a closed-cycle torpedo.
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Component size difficulties in a closed-cycle steam turbine system are eliminated by disposing an annular regenerator about a turbine wheel and providing spray nozzles at the outlet of the regenerator for eliminating superheat in the exhaust steam passing through the regenerator prior to its condensation in a condenser.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to United Kingdom Application No. 0509919.7 filed on May 16, 2005 by inventors Christine Isobel Schofield and Peter James Howard Rodgers.
FIELD OF INVENTION
[0002] The invention to which this application relates is to improvements to a door closure system of the type which is particularly, although not necessarily exclusively, of use to be movable between an open and closed position with respect to an environment, on one side, which is held in chilled or freezing temperatures for the storage of goods therein and, on the other side an environment which is substantially at ambient temperature.
BACKGROUND OF INVENTION
[0003] A problem which is often experienced with openings between environments which are required to be held at different temperatures, is the need to provide a closure in the form of a door for the opening, which door is operable to move between opened and closed positions and in particular, once opened, to return to a closed condition as quickly as possible so as to be able to maintain the temperature in the cooler environment and thereby allow the maintenance of the goods in the cooler environment at the required temperature.
[0004] The applicant, in their co-pending application GB2385659, disclose such a door system which incorporates a first wall or curtain which forms an external surface facing into one of the environments and a second, opposing, spaced, wall or curtain which forms the external surface facing into the second environment.
[0005] A further problem which is experienced is the creation of condensation on the door itself which can lead to, firstly, the gathering of water or liquid in the vicinity of the door and, if frost forms, the malfunction or poor operation of the door structure.
[0006] The applicant's co-pending application discloses the ability to pump air, which is required to have a relatively low humidity, through the cavity defined between the first and second walls of the door and said air, which may also be heated but need not necessarily be so, serves to reduce the tendency of moisture or frost being created on the door.
SUMMARY OF INVENTION
[0007] The aim of the present invention is to ensure that the air is uniformly passed through said cavity and to provide an airflow system and a structure whereby this problem is overcome.
[0008] In a first aspect of the invention, there is provided a door structure, said door structure including a door selectively movable between open and closed conditions, a frame formed from spaced side members and a top member which, in combination with the floor, define the opening in which the door is positioned, the door when closed, formed by a first wall forming an external surface at a first side of the opening and a second, spaced wall defining an external surface to the second side of the opening, said first and second walls defining a cavity between the same which extends substantially across the area of the opening and air movement means are provided to cause the movement of air into and through the said cavity and wherein the air is introduced into the cavity from a port located on one of the side members of the door frame and towards the lower edge of the door when the door is closed.
[0009] Preferably an opening is provided in each side frame member so that air is introduced into the door cavity from each side member and further preferably, the ports are located so that air enters the cavity at or adjacent to the lowest edge thereof.
[0010] In one embodiment the lower edge of the door joins the first and second wall and is formed by a plate. In one embodiment the plate can be a flexible membrane.
[0011] In one embodiment a perforated layer is provided adjacent the lower edge of the door, spaced inwardly from said plate such that said layer and lower edge plate form a channel into which air passes from the side member ports rather than directly into the cavity. The air then passes into the remainder of the cavity by passing through the perforated layer apertures. In one embodiment the size of the apertures increases from the edges of the layer towards the middle of the same.
[0012] In one embodiment the configuration of the apertures also changes.
[0013] In one embodiment the perforated layer is formed of foam.
[0014] In one embodiment, deflector plates or vanes are located in the side frame members adjacent the ports so as to induce the entry of air into the cavity in a preferred flow path.
[0015] In one embodiment, the cavity includes plates or vanes mounted therein to further control the movement of air through the cavity and, in one embodiment, plates or vanes are provided towards the lowest edge of the cavity, depending into the cavity and at a location centrally of said lower edge.
[0016] In a further embodiment, adjustment means are provided along the flow channels to allow “fine tuning” of the flow to suit particular environments and/or dimensions of the door. The adjustment means can be any, or any combination of, flaps, valves or the like.
[0017] Typically, the air movement means is a pump which is located in the door frame or above the same such that the air from the air movement means passes along channels provided in the said door flame top and side members to reach the ports into the cavity.
[0018] Typically the air is checked with respect to predetermined parameters with regard to the humidity of the same and, if necessary, can be conditioned to “dry” the same prior to entering the door cavity. In one embodiment heaters are also provided, typically in the door frame to heat the air prior to it entering the door cavity.
[0019] Typically, the door is movable between open and closed conditions by raising and lowering the same respectively with regard to the door frame.
[0020] This movement can be achieved quickly and efficiently in accordance with the applicant's co-pending patent application and thereby ensures that the environments on each side of the door are exposed to each other through the opening for a minimum period of time.
[0021] In one embodiment the temperature of the environment on one side of the door is lower than the temperature of the environment on the opposing side of the door and the door is provided to maintain the differential in temperature. In one embodiment the environment in which the temperature is lower is a chilled or frozen storage facility.
[0022] It is found by controlling the flow of air through the cavity in the door as herein described, so the air is found to act more substantially uniformly across the area of the walls of the door and thereby further minimising or indeed eliminating the creation of frost on the walls or in the vicinity thereof.
[0023] In a further aspect of the invention there is provided a door, said door formed from first and second walls held in a spaced configuration so as to define a cavity therebetween, said walls formed of a flexible material to allow the same to be selectively rolled and unrolled to move the door between open and closed conditions, said door having a lower edge formed by a plate joining the lower edges of the first and second walls and wherein spaced inwardly of the plate there is provided a perforated or porous layer, said layer and plate forming a channel or passage into which a fluid is supplied prior to passing through the perforated or porous layer and into the cavity.
[0024] In one embodiment the perforated or porous layer includes a series of apertures formed therein to allow the passage of the fluid from the channel or passage and into the cavity. Typically the apertures increase in size from opposing edges of the layer towards the middle axis of the layer said edges and middle axis being perpendicular to the longitudinal axis of the layer.
BRIEF DESCRIPTION OF DRAWINGS
[0025] The foregoing summary as well as the following detailed description of the preferred embodiment of the invention will be better understood when read in conjunction with the appended drawings. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown herein. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
[0026] The invention may take physical form in certain parts and arrangement of parts. 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:
[0027] FIG. 1 illustrates an elevation of a door structure in accordance with the invention;
[0028] FIG. 2 illustrates the elevation of FIG. 1 with portions of the structure removed for ease of reference;
[0029] FIG. 3 illustrates a cross sectional elevation through the door structure;
[0030] FIGS. 4-5 illustrate a further embodiment of the invention with portions of the structure removed for ease of reference; and
[0031] FIGS. 6-8 illustrate embodiments of the perforated layers to be positioned towards the lower edge of the door.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Referring now to the drawings, there is illustrated a door structure in accordance with one embodiment of the invention. The door structure 2 comprises a door frame 4 formed of side members 6 , 8 and top member 10 which in conjunction with the floor on which the frame is mounted define an opening in which the door 12 is provided. The door 12 is formed by a first wall 14 and a spaced, second wall 16 which together, in conjunction with a bottom beam or layer 18 form a cavity 30 . The door structure is shown in a closed condition but can be moved to an open condition by a mechanical drive means of rollers 21 , 23 to move the door in direction 20 whereupon the walls of the door, which are flexible to a degree, can be wound and stored at or above the top door frame member 10 in a rolled up form on respective rollers 21 , 23 . In the open position, persons and/or objects can be moved between the environments on either side of the door and it is found that doors of this type are of particular advantage when one of the environments is a chilled or frozen storage facility. To unroll the walls to again close the door, the drive of the rollers can be reversed which causes each of the walls to unroll from the respective roller such that the leading or bottom edge beam or layer 18 of the walls moves down towards the floor. Preferably, and especially where the environment on at least one side of the door is a chilled or frozen environment, the time during which the door is open is kept to a minimum to ensure that the chilled temperature is kept as low as is required and warmer air passing from the other side of the door is kept to a minimum. Because of the speed of the movement of the door from closed to open and back to a closed condition, sensors can be provided on or adjacent to the door to detect the presence of a person, object or vehicle in the door opening. If a detection is made then the door is prevented from moving back down to the closed position until the detected person or object leaves the door opening and it is then safe for the door to be moved back to the closed position.
[0033] The structure further includes air movement means 22 which typically can be in the form of a pump and the air movement means may also include means to allow “dry” or low humidity air to be created and then moved through the door structure and into the door cavity particularly when the door is in the closed position. In one embodiment, heating means can also be provided to heat the air which is to be moved through the structure.
[0034] The movement of the air is illustrated in detail in FIG. 2 which shows the door frame in section and the wall 14 removed. It is shown that the air which leaves the air movement means 22 passes in two paths 26 , 28 through channels or ducts formed in the side door frame members as indicated by arrows 31 , 32 such that the air passes down and along the side frame members until it reaches ports 34 , 36 in the respective side frame members. It should also be appreciated that the side walls of the cavity are in fact formed by the inner facing surfaces 39 , 41 of the side frame members with which the side edges of the walls locate.
[0035] In the channels in the side wall members, there are provided deflection plates 40 , 42 which are shaped so as to induce the flow of the air in a desired manner and such that the air enters the cavity 30 in the door in a desired manner and with a reduction in turbulence as the aim is to ensure that the air passes uniformly across the cavity. Once the air has entered the cavity 30 then the same begins to move through the cavity and further deflector plates 50 , 52 are located within the cavity and depend upwardly from the bottom edge of the cavity at a central location on said bottom beam 18 so as to further induce the movement of the air upwardly and uniformly through the cavity.
[0036] Referring now to FIGS. 4 and 5 , there is illustrated a further embodiment of the invention in which the same reference numerals are used for common features. In this embodiment the bottom beam or plate 18 of the cavity has a layer of perforated or porous material 54 , offset therefrom to form a channel 55 into which air enters from the side members through ports 34 , 36 and the layer 54 forms the internal surface facing towards the cavity. One suitable material is a unicellular foam layer placed above the bottom beam or plate 18 .
[0037] In one embodiment, as shown in FIG. 6 , the material is provided with holes 56 , which increase in size towards the middle axis 58 of the layer of the beam. In practise, this layer 54 is found to improve the subsequent dispersion of air within the cavity 20 from the deflector plates 40 . 42 and distribute the air more evenly upwardly and across the whole width of the cavity. If required the vanes 50 , 52 can still be provided in the channel 55 , although not shown in this example.
[0038] FIGS. 7 and 8 illustrate a variation in the configuration of the apertures 56 and in this case, only one half of the layer 54 is shown with the edge 58 to be located at the centre of the cavity where the apertures 56 are to be at their longest and the edges 60 located adjacent one edge of the cavity where the apertures are at their smallest. Two of the layers in reverse configuration will therefore be fitted end to end across the cavity of the door. FIG. 8 illustrates the layer 54 fitted in position in end elevation.
[0039] By providing the layer 54 with the apertures configured as illustrated so the reduction in air flow which typically occurs towards the centre line 58 of the cavity can be offset as the apertures 56 are larger than at the edge of the cavity thereby allowing more air flow through and the smaller apertures at the edge prevent greater air flow and cause more of the air to pass to the centre.
[0040] In whichever embodiment the air will over time, escape from the cavity, as the cavity is not necessarily airtight and so the continual flow of the dry air is required when the door is in the closed position shown. The flow of this dry and possibly heated air is found to reduce the condensation effect across the door structure substantially uniformly and hence prevents or minimise the creation of frost at cold spots if, for example, the door structure is used to selectively close an opening between a chilled or frozen temperature environment on one side of the opening and door and an ambient environment on the other side of the opening and door.
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A door structure, said structure for use particularly, although not necessarily exclusively, to selectively close an opening between a first environment which is at a temperature which is lower than the temperature of the environment on the opposing side of the opening. The door is provided with a structure so as to define a cavity-therein into which air is caused to flow. The door has formations and a structure so as to encourage uniform air flow through the cavity and hence prevent or minimise the creation of condensation and/or frost on the door structure.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a new and improved tire including a tread surface or portion.
In its more specific aspects, the present invention particularly relates to an improved tire including a tread surface or portion which comprises profile elements such as blocks, ribs and the like extending in circumferential direction. These profile elements are provided with lamella fine cut-outs or incisions defining wall regions of a non-planar configuration.
The present invention further relates to improved tire mold lamellae for producing lamella fine cut-outs or incisions in tire tread surfaces.
2. Discussion of Background and Material Information
It is known in the art that the sliding friction which occurs between the tire and the ground during normal rolling and upon braking and accelerating, plays an essential role with respect to the gripping characteristics or properties of a tire. There is always present a certain amount of skid or slip between the ground and the tire of a travelling vehicle. During braking and accelerating as well as during travel through curves the amount of skid or slip is substantially greater than during normal rolling or travel of the tire.
It is also known that reducing the skid will assist in improving the gripping and adhesion characteristics as well as the handling characteristics of the tires. Therefore, maintaining the skid at a minimum is a central aspect of tire development. The measures heretofore undertaken for this purpose, on the one hand, were carried out on with respect to the mixture composition for the tread surfaces and, on the other hand, from the standpoint of tread construction, i.e. by correspondingly structuring the tread surface profile. The contribution made thereto by the mixture composition, can be briefly summarized in that the tread surface rubber must be capable of permitting cyclic deformations during sliding of the tire upon ground irregularities in order to thereby consume part of the kinetic energy. As a constructional measure it has heretofore proven useful to form lamella fine cut-outs or incisions of a width in the range of 0.4 to about 0.8 mm. in the profile elements in order to provide additional gripping edges which contribute to reducing skid or slip. The skid reducing effect of fine cut-outs or incisions in the tire, however, is not merely the result of additional gripping edges. Above all, particularly on a dry roadway and in the presence of strong tire deformations, which also are the conditions present during a tire handling test, the mutually facing walls of the tire fine cut-outs or incisions are subject to high frictional engagement. The thus produced friction losses are taken from the kinetic energy of the tire and thus likewise act in a skid reducing manner.
However, it has been found that conventional lamella formation in the tread surface profile nevertheless causes some deterioration in handling. The reason therefore is that tire fine cut-outs or incisions always tend to render more labile or unsteady the contact geometry of the tire. At high travelling speeds this unsteadiness will be more dominant than the positive effects due to the additional gripping edges or the dissipated friction energy.
Further disadvantages which may result from tire fine cut-outs or incisions, reside in their tendency to capture stones or gravel, promoting break-outs which start from the base of the tire fine cut-outs or incisions, and irregular wear.
In order to moderate the disadvantages of fine cut-outs or incisions, it is known in the art and a frequent practice to reduce the depth of the fine cut-outs or incisions, either across the entire width of the fine cut-out or incision or only in sections thereof. This means, however, that during the service life of the tire such raised fine cut-outs or incisions are sooner or later entirely or partially lost, as a result of which there will surely result a more or less abrupt deterioration in the gripping characteristics or properties of the tires.
Furthermore, it is known in the art to use, instead of totally planar tire fine cut-outs or incisions, cut-outs or incisions which are wave or zig-zag shaped as seen in radial top plan view. In this manner, the slippage or sliding past one another of mutually facing wall halves of the fine cut-outs or incisions in lateral direction is rendered substantially more difficult. In comparison with entirely planar tire fine cut-outs or incisions there is thus obtained, above all, a handling advantage.
There are, however, also known fine cut-outs or incisions where the zig-zag or wave configuration extends into the depth of the tire. In this manner there are formed transversely oriented edges within the fine cut-outs or incisions and these are used, for example, according to German Published Patent Application No. 1,480,932 for preventing stones from penetrating or further migrating toward the radial-ply construction. Furthermore, as described, for example, in European Published Patent Application No. 0,282,765, there have been proposed mirror-image pairs of fine cut-outs or incisions containing a zig-zag configuration extending in the depth direction. The thus resulting, always mutually opposed inclination of pairs of fine cut-outs or incisions are intended to particularly improve upon the tire grip at a wet, snowy or icy roadway. Additionally, the in-depth extending zig-zag configuration further has the effect that the relative movements of the adjoining walls with respect to each other progressively decrease toward the base of the tire fine cut-outs or incisions. The risk of fissure formation at the base of the tire cut-outs or incisions is thereby suppressed and there is also diminished the tendency of irregular wear.
All heretofore existing wave or zig-zag shaped and non-planar tire fine cut-outs or incisions restrict the relative movement of the adjoining walls with respect to each other only in the direction of extent of the wave or zig-zag configuration. In a direction perpendicular thereto the walls of the fine cut-outs or incisions can be described as continuous straight wall extents.
SUMMARY OF THE INVENTION
Therefore, with the foregoing in mind, it is a primary object of the present invention to achieve, in a tire of the initially mentioned type, an improvement in handling, in the resistance to the formation of fissures which extend from the base of the fine cut-outs or incisions, as well as suppression of irregular wear.
A further important object of the present invention resides in providing a tire of the initially mentioned type in which the friction is increased between the adjoining walls of the fine cut-outs or incisions due to deformations which are produced as a result of braking, accelerating or curve travel.
It is another important object of the present invention to provide a tire of the initially mentioned type in which the friction between the adjoining walls of the fine cut-outs or incisions is increased in order to thereby use this energy-dissipating component for reducing the tire skid.
Now in order to implement these and still further objects of the present invention, which will become more readily apparent as the description proceeds, the present development is manifested, among other things, by lamella fine cut-outs or incisions which at least partially comprise mutually associated three-dimensionally structured wall regions having edges as well as protruding or salient and receding surfaces. It is thus ensured that the wall regions of the fine cut-outs or incisions do not contain continuous straight portions in any direction. Preferably, the edges of the structured wall regions are arcuately curved and/or form a network and/or are branched with respect to each other.
Thus, the invention renders possible, in a relatively simple manner, maintaining small the relative movements of the adjoining walls of tire fine cut-outs or incisions in lateral and in radial direction, and additionally, effectively converts part of the kinetic energy of the skidding tire into heat via friction. The structure of the wall regions of the lamella fine cut-outs or incisions leaves unaffected their primary purpose, namely forming additional gripping edges in the profile or profiled tread surface.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above, will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1a shows a top plan view of part of a first exemplary embodiment of the inventive tire mold lamella in the form of a planar lamella sheet blank with indicated bending lines;
FIG. 1b shows an axonometric view of a section of the tire mold lamella formed by embossing the planar lamella sheet blank shown in FIG. 1a;
FIG. 2a shows a top plan view of part of a second exemplary embodiment of the inventive tire mold lamella in the form of a planar lamella sheet blank with indicated bending lines;
FIG. 2b shows an axonometric view of a section of the tire mold lamella formed by embossing the planar lamella sheet blank shown in FIG. 2a;
FIG. 3a shows a top plan view of part of a third exemplary embodiment of the inventive tire mold lamella in the form of a planar lamella sheet blank with indicated bending lines;
FIG. 3b shows an axonometric view of a section of the tire mold lamella formed by embossing the planar lamella sheet blank shown in FIG. 3a;
FIG. 4a shows a top plan view of part of a fourth exemplary embodiment of the inventive tire mold lamella in the form of a planar lamella sheet blank with indicated bending lines;
FIG. 4b shows an axonometric view of a section of the tire mold lamella formed by embossing the planar lamella sheet blank shown in FIG. 4a;
FIG. 5a shows a top plan view of part of a fifth exemplary embodiment of the inventive tire mold lamella in the form of a planar lamella sheet blank with indicated bending lines;
FIG. 5b shows an axonometric view of a section of the tire mold lamella formed by embossing the planar lamella sheet blank shown in FIG. 5a;
FIG. 6a shows a top plan view of part of a sixth exemplary embodiment of the inventive tire mold lamella in the form of a planar lamella sheet blank with indicated bending lines;
FIG. 6b shows an axonometric view of a section of the tire mold lamella formed by embossing the planar lamella sheet blank shown in FIG. 6a;
FIG. 7a shows a top plan view of part of a seventh exemplary embodiment of the inventive tire mold lamella in the form of a planar lamella sheet blank with indicated bending lines;
FIG. 7b shows an axonometric view of a section of the tire mold lamella formed by embossing the planar lamella sheet blank shown in FIG. 7a;
FIG. 8a shows a top plan view of part of an eighth exemplary embodiment of the inventive tire mold lamella in the form of a planar lamella sheet blank with indicated bending lines;
FIG. 8b shows an axonometric view of a section of the tire mold lamella formed by embossing the planar lamella sheet blank shown in FIG. 8a ; and
FIG. 9 is an inclined view of a section of a tread surface profile of a pneumatic vehicle tire provided with the inventive lamella fine cut-outs.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
All of the exemplary embodiments of the tire mold lamellae or the fine cut-outs or incisions structured according to the invention and illustrated in the drawings can be manufactured by embossing the lamella sheet blanks and thus can be produced in a very simple manner.
In the drawings, the illustration has been selected such that the top end region of the respective lamella sheet corresponds to the end region of the fine cut-out or incision which is associated with the road surface in the final tire. The anchoring of the lamella sheets in the tire mold need not be here described in any greater detail because this operation can be carried out in conventional manner. It is also possible, for example, to cast the lamella sheets into the tire mold and, in this manner, the entire lamella may contain the embossed structure according to the present invention. Lamella sheets which are constructed according to the invention, may also be inserted into eroded molds. In such case, the contact location at the mold must be constructed correspondingly in order to permit its insertion into the tire mold.
FIG. 1b shows an exemplary embodiment of a lamella 2 which includes wave-shaped or sinusoidal bending lines 3 extending substantially parallel to each other and associated with a substantially transverse direction. Across the width of the lamella 2, a number of maxima and minima of the wave form are shown. As will be seen in FIG. 1a, the wave forms are displaced relative to each other by an amount C. The minimum mutual spacing B resulting therefrom between adjacent wave forms is selected in the range of 0.5 mm. to 3 mm. and preferably amounts to about 1.2 mm. The amplitude A of the wave forms in the lamella sheet 1 should not be smaller than C/2 and not greater than 3C. The length D corresponds to one-quarter of the wavelength.
During forming or embossing the lamella 2, the sheet metal blank 1 is bent along the bending lines 3 to obtain a predetermined bending angle γ. Preferred bending angles γ are in the range of 150° to 90°. In the axonometric illustration of lamella 2 shown in FIG. 1b, the angle γ is selected to be 120°. During the forming operation, the length D is decreased and the amplitude A is increased and there are formed non-planar surfaces 13a and 13b. The embossing depth p which is also evident from FIG. 1b, is selected in the range of 0.5 mm. to 3 mm. and preferably amounts to 1.8 mm. The lamella sheet metal itself is selected to have a thickness of about 0.4 mm. to 0.8 mm.
In the event that hereinafter in the description of the following exemplary embodiments, nothing different is mentioned, then, the aforementioned dimensions regarding the spacing between adjacent bending lines, the embossing depth and the thickness of the lamella sheet are also valid for these variants.
In the exemplary embodiment shown in FIGS. 2a and 2b, a system of arcuately curved bending lines 3'a to 3'h is led, starting from the lamella base, across the lamella 2' in a fan-shaped manner. It will be evident from FIG. 2b that the embossing depth p' of the lamella 2' is not uniform. The maximum embossing depth p' max may here amount up to about 7 mm.
In the exemplary embodiment illustrated in FIGS. 3a and 3b, there are shown in the lamella sheet 1" two systems of predetermined bending lines which extend substantially parallel to each other in each system. The lines which extend in a zig-zag shape in substantially transverse direction, are transformed, during the embossing operation, into zig-zag shaped bending lines 3" which remain in their plane which is substantially parallel to a primary plane defined by the embossed lamella 2". The radially disposed straight lines in the lamella sheet blank 1" are also transformed, during the embossing operation, into zig-zag shaped bending lines 4" which, however, come to lie in their planes substantially perpendicular to the primary plane defined by the embossed lamella 2". The two systems of bending lines 3" and 4" conjointly result in a network of bending lines. In this embodiment, the network of bending lines or edges constitute respective pluralities of four lines or edges which branch from a common area or point in a respective different direction. The individual embossed surfaces which are produced by the embossing operation to form the lamella 2", correspond to parallelograms or rhombi. These surfaces preferably have substantially equal sizes, when considering the entire lamella 2".
In this variant, as illustrated, it is furthermore advantageous if the bending lines 3" which are associated with the transverse direction, as viewed in the transverse direction of the lamella 2", overlap with the next and the next following adjacent bending lines 3". Such overlap may be promoted by reducing the parallelogram angle α" but also by more intensely embossing, resulting in smaller bending angles γ", or by a smaller ratio B"/D". The usefulness of the here described overlap resides in that upon wear of the tire there is no abrupt change in the performance of the lamella 2".
In FIG. 3b, there are shown further angles in addition to the angles α" and γ". The angle δ" is the bending angle about the bending line 4" and the angle φ' is the zig-zag angle of the bending line 3". The following relationships hold with respect thereto: ##EQU1##
FIGS. 4a and 4b depict a lamella 2'" which differs from the lamella shown in FIG. 3b in two respects. In one respect there has been undertaken a rotation through an angle of about 90°; the bending lines 4'" extend horizontally and an overlap of the bending lines 3'", as illustrated in FIG. 3b, is no longer required. In the other respect there now appear two different types of radially oriented bending lines 3'"a and 3'"b which differ with respect to their zig-zag angles.
As will be further evident from FIG. 4a and 4b, the embossed surfaces thereby degenerate to trapezoids and the lamella 2'" thereby acquires, as viewed in top plan, a curvature which increases with increasing difference between the angles α'" and β'" and with decreasing bending angle δ'". By providing a corresponding sequence of the bending lines 3'"a and 3'"b, a wave configuration, for example, in top plan view may be imparted to the lamella 2'", which wave configuration is advantageous in certain variants of the fine cut-outs or incisions in the tread surface profile. For the axonometric illustration, there has been selected an angle δ'" of 120°. (It is simpler in this case to operate with the angle δ instead of the angle γ because the bending lines 3a'" and 3b'" cause two different angles γ).
In the exemplary embodiment illustrated in FIGS. 5a and 5b, a specific embossing structure results for the lamella 2 IV due to the fact that the network consists of non-zig-zag shaped bending lines 5 IV which extend normally to the plane of the lamella 2 IV and which are combined with zig-zag shaped bending lines 6 IV extending at an inclination relative to the plane of the lamella 2 IV , in order to form a network of bending lines. In this structure, the bending lines 6 IV appear in substantially parallel-extending pairs and adjacent pairs are present in a mirror-image relationship. The embossed structure contains surfaces in the form of substantially equal-sided trapezoids and parallelograms or rhombi. The lamella 2 IV shows a marked "waviness" in transverse direction which also becomes effective in a relatively great embossing depth p IV which may amount to as much as about 6 mm. In contrast therewith, the structuring in radial direction is relatively small. The bending angle ε IV which is formed by the bending lines 5 IV , has been selected as 60° for the axonometric illustration.
FIGS. 6a and 6b show a modification relative to FIGS. 5a and 5b. Herein the mirror-image relationship is such that the zig-zag shaped bending lines 6 V contact each other and the embossed structure now is formed by rhombi and triangles. Additionally the network of bending lines has been rotated so that the bending lines 5 V are no longer in orthogonal disposition. An inclination of the plane of the bending lines 5 V relative to the transverse direction of the lamella 2 V in the range of 20° to 70° is preferred. While in FIGS. 4a and 4b the lamella 2 V abruptly changes its inclination relative to the road upon wear of the tread surface or tread surface strip, this is prevented by the described inclined positioning of the lamella 2 V . Such inclined positioning also may be advantageous with respect to handling, particularly when used in the region of the tire shoulder. The angle ε V is 60°.
In the exemplary embodiment of the lamella 2 VI illustrated in FIGS. 7a and 7b, this lamella is provided, as seen in top plan view, with a simple zig-zag or wave-shaped structure such that there are present therein edges and corner regions which extend in the direction of the depth of the fine cut-out or incision. Along such corner regions or edges there are provided receding noses or lugs 11 VI which are formed by means of a punching operation. Each nose or lug 11 VI causes a hole or aperture 12 VI into which a branched bending line 7 VI or an arcuately curved bending line opens or terminates. During the operation of forming or molding the tire or the heating procedure to which the tire is subjected, the rubber mixture of the tread surface penetrates through the holes or apertures 12 VI . Since the noses or lugs are oriented in radial direction, the tread surface rubber is severed in the region of the holes or apertures 12 VI during the de-molding operation and the wall structure which is formed thereby in the lamella fine cut-outs or incisions, ensures that the effect to be achieved by the invention is accomplished. The holes or apertures 12 VI which are formed as a result of the punching operation, should be dimensioned such that there is again present an embossing depth of up to about 2 mm., particularly about 1 mm.
FIGS. 8a and 8b, finally, show an exemplary embodiment of a lamella 2 VII in which a network of branched bending or kink lines 7 VII are used and comprise straight and arcuately shaped elements. The a network of branched bending lines 7 VII are radially disposed and adjacent ones of the branched bending lines 7 VII are mutually oppositely oriented. It can been seen that there are three edges or lines 7 VII which branch from a common area or point in a respective different direction. In FIGS. 8a and 8b there also appear isolated bending lines 8 VII which, however, may also be avoided by correspondingly rounding this section or region of the lamella.
In all of the illustrated exemplary embodiments described hereinbefore, the embossing dimensions can be adapted to each other in a manner such that no or hardly any strains or stresses appear in the material of the lamella sheet during upward and downward embossing of the respective structure. In particular, it is rendered possible in the exemplary embodiments shown in FIGS. 1b to 8b, to have the described and illustrated embossing structure formed by a folding or bending operation from the plane defined by the lamella along the bending lines. It should be self-evident that it would also be possible to tolerate strains or stresses in the lamella sheet which, however, must be kept small, and have the network of bending lines arise from structures which just can not be folded from the plane.
FIG. 9 shows a partial region of a tread surface profile in a vehicle tire and which profile comprises lamella fine cut-outs or incisions 17 formed by means of tire mold lamellae structured according to FIGS. 8a and 8b, however, in a version having greater "breadth". This region of the tread surface profile is composed of profile elements in the form of blocks or ribs 14 which are bounded by transverse flutes or furrows 15 or the like and recesses or grooves 16 extending in circumferential direction. The lamella fine cut-outs or incisions 17 provided in each one of the blocks 14, extend in generally transverse direction and open or terminate in the circumferential recesses or grooves 16.
Particularly during braking and accelerating the walls of the fine cut-outs or incisions are urged or pressed against each other due to the block deformations which occur in the contact area or shortly prior to the entry of the blocks into the contact surface or shortly after the exit of the blocks from the contact surface. Due to their structure, the walls of the fine cut-outs or incisions can only slide off each other with difficulty which has the consequence that energy is converted into heat through friction and skid is reduced. Reference is made to the fact that the described and illustrated exemplary embodiments can be modified and/or combined with each other.
In the finished tire, the lamella fine cut-outs or incisions may be constructed in a manner such that there are formed island or isolated cut-outs or incisions, blind hole cut-outs or incisions or cut-outs or incisions which completely traverse the respective profile elements.
While there are shown and described present preferred embodiments of the invention, it is distinctly to be understood the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims.
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The lamella fine cut-outs provided in profile elements of the tread surface of a tire, have three-dimensionally structured wall regions. Such wall regions restrict relative movements of the mutually facing wall regions in lateral as well as in radial direction. In such manner there are improved the travel characteristics as well as the wear characteristics like break-outs and irregular wear of such lamella tires.
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FIELD OF THE INVENTION
[0001] This invention relates to a tilt latch mechanism for use in a pivotable sash window, and more particularly to a latch housing designed for ease of installation while ensuring integrity of the latch installation during window deformation accompanying high wind loads.
BACKGROUND OF THE INVENTION
[0002] The traditional style of windows used in the United States, and many other places that had been colonized by the English, is the single-hung and the double-hung sash window. A Double-hung window assembly typically comprises two sash windows each of which slide vertically in a master frame. To enable a user to easily open or close such windows, as well as to enable the window to remain static once it has been opened or closed, a balance assembly is attached to each window. Such balance assemblies were originally just counterweights on either side of the window, where the weights were suspended by a cord or chain across a pulley and attached to the sash window.
[0003] Advances in window construction have been significant, and although contemporary windows may visually resemble their ancestor described above, a resemblance which may even permit its use as a replacement window in historic homes, the technological improvements render them very different as to the materials used, and vastly superior in terms of performance. Many of the changes have been due in part to the demand for greater energy efficiency in both hotter and colder climates, where the savings attributable to reductions in the corresponding air-conditioning or heating expenses can be considerable.
[0004] Increases in thermal efficiency have been made through the use of an Insulating Glass Unit (IGU) or double-paned window, in which two panes of glass are hermetically sealed to form a single glazed unit, with an ‘air-space’ between the two panes of glass. This arrangement, also known as “double-glazing,” generally reduced or eliminated the problem of windows fogging or frosting, and of the windows being uncomfortably cold upon contact. Further improvement were made by filling the ‘air-space’ with inert gases, such as argon and krypton, both of which have a higher resistance to heat flow than does air. Additional thermal resistance of an IGU has also been achieved through the use of low-emissivity coatings, which are typically applied to the non-exposed, interior side of the glass pane or panes. The coatings can be alternatively designed for a high or low solar heat gain coefficient (SHGC), depending on the location's requirements, while simultaneously reducing the window's u-factor, or rate at which the unit conducts infrared radiation (non-solar heat) from a warm pane of glass to a cooler pane of glass.
[0005] Despite these tremendous advances, a further consideration as to the overall energy efficiency of a window is that the window's frame constitutes roughly 25% of its area, making its conductivity a substantial factor in the window's energy performance. Wood frame windows are still widely available, however, the maintenance drawbacks of solid wood windows has led to some of the material upgrades previously mentioned, as frames have become available in the form of vinyl-clad and aluminum-clad wood, and such frames actually comprise a major share of the market. Not surprisingly, the market for energy conductive aluminum frame windows is relatively small. But a large intermediate share is held by insulated vinyl and insulated fiberglass frame windows which are among the best energy performers.
[0006] Advances have similarly been made in the associated window hardware, including the latch which enables a sash window to not only move vertically, but to pivot inwardly as well. One such latch is shown by U.S. Pat. No. 5,139,291 to Schultz. The latch is adapted for installation into a window having a hallow top sash rail. The latch housing has a “side wall rail,” which, in combination with the housing cover edge, forms a groove, where the groove cooperates with the edge of the top wall of the top sash rail to retain the latch. The latch slides into a side opening in the sash window stile, which has a periphery to match the latch profile. A tab on the front face of the latch engages the stile to retain the tilt latch in position.
[0007] However, many if not most coastal areas now mandate that the windows installed be constructed to satisfy very stringent standards. These standard may include a requirement that the window be able to structurally withstand, for a set period of time, a specified design pressure, which would permit the window to maintain its integrity throughout the sustained winds of a category five hurricane. Under such loading, it is not uncommon to see a window convex a couple of inches, but when properly designed, the window will regain its original form. This significant deformation under such high wind loads creates as serious if not fatal problem for the hardware currently available, particularly the tilt latch. The Schultz tilt latch would not be retained by the sash rail as described above, when the window experienced high wind loading and deformation, especially in the case of a vinyl frame window, which lacks the structural rigidity of the energy inefficient aluminum frame window.
[0008] It is possible to utilize the top plate of the latch to restore some of the frame's structural rigidity, and may be accomplished in the approach shown in FIG. 3 of U.S. Pat. No. 7,069,694 to Fullick. The top plate in Fullick widens to permit the installation of mechanical fasteners which connect the top plate to the opposite sides of the top wall of the top rail. Although this approach would help to limit the local window frame deformation which would impair the integrity of the latch installation during loading and deformation occurring in extreme weather conditions, it requires additional parts and manufacturing operations not needed with the Schultz configuration. The Fullick design also affects the aesthetic appearance of the latch, which is a significant factor in a competitive market where such a tradeoff, for the most part, may not enhance overall value to the consumer because statistically speaking, the ability of the latch to satisfy high wind loading conditions of extreme weather phenomena will seldom be utilized.
[0009] Also, the latch in U.S. Pat. No. 5,671,958 to Szapucki has resilient tabs 18, 18′, 20, and 20′, as shown in its FIG. 12, which permit a drop down latch installation into the top rail of the window, rather than an installation endwise through an opening in the stile. These tabs in Szapucki are designed to be resilient so that they snap outwardly under the edges of the top plate. The tabs may assist in keeping the latch in place while the window experiences some minor deformation associated with ordinary use and loading, but the tabs are extremely limited by their design and inherent ability to withstand large scale deformations that accompany the high wind loading conditions.
[0010] The invention disclosed herein provides a more advanced and unique concept for installation than provided by Schultz, and without the inherent drawbacks created by incorporation of the Fullick top plate and fasteners. This invention furthermore overcomes the limitations posed by attempting to use other existing designs represented by the Szapucki patent.
SUMMARY OF THE INVENTION
[0011] The latch of this invention is designed to be able to maintain the integrity of a latch installation and its functionality, even when a window undergoes substantial deformation, which may occur as a result of the high sustained winds experienced during hurricanes, as well as the high winds associated with other extreme weather phenomena. The latch features disclosed herein may be utilized on number of different latch types, but they are particularly useful for a latch to be installed on the sash window of a tiltable single-hung or double hung window assembly.
[0012] The latch of this invention comprises a latch housing, which may comprise a pair of side walls extending down from a top plate, where the top plate extends beyond the side wall and may be used to install the latch onto the top rail of a hung window. Although not required, the housing may further comprise a bottom wall and a back wall, where the bottom and back walls may connect to at least a portion of the side walls. The bottom wall may assist in forming a cavity to retain a latch bolt, however, the latch bolt may also be retained by other means, such as, but not limited to, a lip on the end of the side walls, etc.
[0013] A latch bolt with a tapered nose may be disposed in the housing so that the nose extends out from an opening in one end of the housing, and be biased into an extended position. The nose may be designed and shaped to co-act with a side jamb flange. Biasing may be accomplished by a spring means such as, but not limited to, a compression spring, a tension spring, etc. Protrusions or stops or other such features may be provided on the latch bolt or the housing or both the latch bolt and the housing, to limit the travel of the latch bolt in the extended position. The latch bolt may comprise a top wall, a pair of side walls, a bottom wall, and a rear wall. A raised area on the top wall may protrude through an opening in the latch housing to provide a means of retracting the latch bolt, where the raised area may be in the form of a button. The button may be integral to the latch bolt or may be a separate part that is attached to the latch bolt. The button may be attached to the latch bolt by any number of methods including, but not limited to, bonding, using mechanically fasteners, or, as in the preferred embodiment, using hook-shaped spring clips which are inserted through an opening in the top wall of the latch bolt and thereafter catch upon the underside of the top wall. Also, the top wall may further comprise a recess adjacent to the raised area to provide an increase in the surface area upon which a user may apply a force to toggle the latch bolt.
[0014] The latch of this invention further comprises a cantilevered member that occupies a normal “rest” position at an angle to the housing side walls. The cantilevered member may extend from the housing side wall or alternatively from a housing bottom wall, if a bottom wall is incorporated as part of the latch housing. The cantilevered extension may be an integral part of the housing side or bottom wall, and may be formed so as to normally protrude away from a vertex on the housing, at an angle relative to the side wall. As an alternative to forming the cantilevered member as an integral part, a separate part or wall segment may be connected to the housing to function in the same manner as the integral member.
[0015] Biasing of the cantilevered member may be employed to maintain contact between the cantilevered member of the latch housing and the window structure. With an embodiment where the cantilevered member is integral to the housing side or bottom wall, biasing may be accomplished in a number of ways, including, but not limited to, incorporating a spring to bias the cantilevered member into the angular position, where the connection around the region of the vertex is merely a flexible connection. Another biasing scheme for an integral cantilevered member may involve forming the connection between the cantilevered member and the housing, around the region of the vertex, from a resilient material. With this means of biasing, the forming of the connection around the vertex must be such that the cantilevered extension should normally occupy an unstressed, “rest” position while extended at an angle to the housing, such that deflecting the cantilevered member so as to be pressed up against the housing would created stored elastic strain energy in the resilient connection. Once the force that deflected the cantilevered member up against the housing was released, as the latch is installed in the window, the stored strain energy would seek to return the cantilevered member to the angled position. The restorative force of the resilient connection would enable positive contact between the cantilevered extension and the window's top wall of the top rail.
[0016] The biasing of a separate cantilevered member in the form of a wall segment offers similar as well as other possible configurations of the invention. The wall segment, comparable to the integral cantilevered member, may have either flexible material at the vertex accompanied by biasing with a spring, or it may have resilient material around the vertex which normally biases the cantilevered member to the angled position. The separate cantilevered member in the form of a wall segment may need to be attached to the housing. Attaching a separate side wall segment, while providing either the flexible or the resilient vertex region, may entail having a flange extending away from the vertex and opposite the cantilevered portion, where such a flange may provide an area for accomplishing attachment to either the housing side wall or bottom wall. Attachment of this flange could include, but is not limited to, use of mechanical fasteners, bonding of the flange to the housing, etc. A separate wall segment may alternatively be attached to the housing with a hinged connection. With a hinged connection, the wall segment would be free to rotate and would need a means of biasing the wall segment to the angled position, which may include, but is not limited to, a compression spring.
[0017] The location of the vertex on the housing, as well as the length of the cantilevered member, may vary, and both may be designed to assure positive contact of the cantilevered member with the window structure. The closer to an end of the housing that the vertex is located, the longer may be the length of the cantilevered member. A longer cantilevered member that is properly biased would naturally be able to accommodate greater deformations in the window frame and still maintain contact. Also, locating the vertex of a cantilevered member in close proximity to one end may permit use of a plurality of such cantilevered members on one side of the housing, and in addition, a plurality of cantilevered members may be utilized on both sides of the housing. Furthermore, the cantilevered member may have a vertex and arrangement such that the cantilevered member angles away from the housing, with the displaced end of the cantilevered member disposed towards the interior of the window. Alternatively, as in a preferred embodiment, the vertex and arrangement may be such that the cantilevered member angles away from the housing, with the displaced end of the cantilevered member disposed towards the stile of the window.
[0018] For any of these possible configurations, installation of the latch bolt may be accomplished through an opening in the window stile that matches the end profile of the latch, and with an opening in the top wall of the top rail contoured to match the housing side walls and back wall. When installing the latch in the window by inserting the latch into the opening, the cantilevered member may need to be pushed against the latch housing until it is past the opening, in order to prevent it from catching on the opening. The latch may be retained in the window opening by have a flexible or a resilient retaining tab on the housing side walls or bottom wall that, after insertion of the latch into the window opening, catches on the window stile and prevents the latch from working its way out from the installed position.
[0019] A typical pivotable sash window would include installation of two such latches—one on each of the two stiles. As such, the two latches may be in the form of a left-hand latch, and a mirror image version, or a right-hand latch.
OBJECTS OF THE INVENTION
[0020] It is an object of this invention to provide a latch to be installed in the top rail of a sash window of a single-hung or a double hung window assembly.
[0021] It is an object of this invention to provide a latch which permits a sash window of a single-hung or a double-hung window assembly to tilt inwardly.
[0022] It is a further object of this invention to provide a latch in which the latch may be easily installed in the sash window frame of a hung window.
[0023] It is a further object of this invention to provide a latch in which the latch bolt may be installed in the sash window frame without the use of mechanical fasteners.
[0024] It is another object of this invention to provide a latch that can be retained by the sash window frame under conditions in which the window experiences severe deformation.
[0025] It is another object of this invention to provide a latch that can be retained by the sash window frame during the sustained winds of a hurricane.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a perspective view of a tiltable sash window utilizing the latch of this invention, with part of the master window frame removed to reveal latch details.
[0027] FIG. 2 is an exploded view of the parts comprising a latch embodiment according to the invention.
[0028] FIG. 3 is a top view of the latch according to the invention.
[0029] FIG. 4 is a side view of the latch according to the invention.
[0030] FIG. 5 is a side view of the latch according to the invention.
[0031] FIG. 6 is a bottom view of the latch according to the invention.
[0032] FIG. 7 is a perspective view of an alternative embodiment of the latch being installed into an opening in a sash window stile and top rail.
[0033] FIG. 8 is an enlarged perspective view of an alternate embodiment of the cantilevered member of the latch, as the latch is installed into an opening in a sash window stile and top rail.
[0034] FIG. 9 is an enlarged perspective view of the right-hand latch of this invention with the cantilevered member maintaining the integrity of the latch installation, as the window experiences severe deformation under actual high wind load testing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0035] A left-hand latch assembly 40 may be provided for installation in a single-hung or double-hung window assembly 10 , as shown in FIG. 1 . The tiltable single-hung or double hung window 10 has an upper sash window 21 , lower sash window 22 , and a master frame consisting of a sill portion 11 , a head jamb 12 , and side jambs 13 . Portions of the head jamb 12 and the side jambs 14 have been cut away in the figure in order to illustrate the features of the jamb with which the latch interacts. The lower sash window 22 is comprised of bottom rail 26 , top rail 27 , and stiles 24 and 25 , which support the edge of the glazing, or glass pane 23 . As is common for tiltable single-hung or double-hung sash windows, the lower portion of the window has a connection to the frame (not shown) which is both pivotable and slidable with respect to the frame. The upper portion of the window may have latch 40 with a latch bolt 70 having a nose 76 , where latch 40 is also slidable with respect to the jamb, but where the nose 76 may be retracted to permit the lower sash window 22 to rotate inward.
[0036] The latch bolt 70 , in a preferred embodiment, may be comprised of a top wall 71 , bottom wall 72 , first side wall 73 and second side wall 74 , as shown in FIG. 2 . The latch bolt 70 may have a rear wall 75 connecting at least a portion of the first and second side walls, but in a preferred embodiment, a rear wall 75 is formed only by the thickness of the end of top wall 71 , and has a semi-circular shape. The latch bolt 70 may have a nose 76 which may be angled from the second side wall 74 towards the first side wall 73 to form a pointed edge. The first side wall 73 may, near the pointed edge of the nose 76 , have a step feature which may be specially designed to co-act with the side jamb flange 15 of the window 10 .
[0037] The latch bolt 70 may have a recess 79 in the top wall 71 which may be accessible to the user through an opening 56 in the top plate of the housing 50 . The opening 56 may take many different forms including, but not limited to, a circular opening, a rectangle, an oval, a polygon, etc, and must merely accommodate access to recess 79 . In a preferred embodiment the opening 56 is a race-track shape with two straight sides connected by two semi-circular edges. The recess 79 may permit the user—using a thumb, thumb nail, finger, finger nails, or a tool—to toggle the latch bolt from the extended to the retracted position. To permit easier toggling, the latch bolt may have, in place of or in addition to recess 79 , a protruding or raised portion, which in a preferred embodiment, is in the form of a button 80 . The button 80 of a preferred embodiment may have an exposed portion 81 and a non-exposed portion 82 , where the non-exposed portion 82 may contain features to facilitate attachment of the button to the latch bolt 70 .
[0038] The exposed portion 81 , in a preferred embodiment, may have a front face 83 , a top face 84 , and an angled back face 85 , such that the front face 83 would provide an easily graspable surface to enable the user to toggle the latch bolt.
[0039] The non-exposed portion 82 , in a preferred embodiment, may have first and second hooked extensions or spring clips 86 and 87 , which may be inserted into an opening 78 in the top wall 71 of latch bolt 70 . The spring clips 86 and 87 and the opening 78 may be formed so as to require the spring clips to be deflected towards each other to pass through the width of the opening during installation. Once the underside of top portion 81 of button 80 contacts the top wall 71 of the latch bolt 70 during installation, the spring clips may rebound back to a natural undeflected position so that the hooks catch on the underside of the top wall 71 of the latch bolt 70 to fix the button 80 to the latch bolt 70 . The opening 78 may take many different forms including, but not limited to, a circular opening, a rectangle, an oval, a figure-8, a polygon, etc, and must merely accommodate the hooked extensions 86 and 87 . In a preferred embodiment the opening is square shaped.
[0040] A spring 90 may be used to bias the latch bolt 70 to normally occupy an extended position, such that the nose 76 of the latch bolt 70 protrudes from an opening in the housing 50 . Spring 90 may be a tension spring or a compression spring, depending on its placement relative to latch bolt 70 and housing 50 . In a preferred embodiment, spring 90 is a compression spring. The travel of the latch bolt 70 relative to housing 50 may be limited in a number of ways, but in a preferred embodiment, the housing 50 may have a stop 57 , which may be used to contact a flange 88 that protrudes down from the underside of button 80 and prevent the compression spring from causing excessive travel and disengagement of the latch bolt 70 from the housing 50 .
[0041] The latch 40 may have a housing 50 which may be comprised of a first side wall 51 , and a second side wall 52 , where at least a portion of each side wall is connected to top plate 55 . Although it is not required, a back wall 53 may also connect to at least a portion of the first and second side walls, and may also connect to the top plate 55 . Similarly, opposite the top plate may be a bottom wall connecting to at least a portion of the first and second side walls to provide an enclosure within which a latch bolt 70 may translate. However, instead of a bottom wall creating an enclosure, one of several alternative methods to slidably retain the latch bolt may be used, including, but not limited to, rectangular wings protruding from the side of the latch bolt which may be slidably retained by a slot in the first and second housing sidewalls, a lip extending from the first and second side walls, etc.
[0042] An opening 30 in the top rail 27 of the lower window 22 exposes a top wall of the rail and creates an outer flange 31 of the rail opening and an inner flange 32 of the rail opening, and also creates a side flange 33 of the stile 24 ( FIG. 1 ).
[0043] The top plate 55 may overhang beyond the first side wall 51 and second side wall 52 , as well as the back wall 53 if such a back wall is provided, so that upon installation of latch 40 into opening 30 in the top rail 27 , the overhanging portion would positively retain the latch 40 on the top rail 27 , and prevent the latch from dropping down into the hallow area of the rail.
[0044] The second side wall 52 , may have a protrusion 63 extending outward from the wall so that when the latch 40 is inserted into the rail slot 30 of the window 22 , the inside flange 32 (or the outside flange 33 ) may be trapped between the top plate 55 and the protrusion 63 . Also, where a back wall 53 is incorporated into the housing 50 , a similar protrusion 62 on back wall 53 may cooperate with the housing top plate 55 to trap the wall of the top rail at the point where the inside flange 32 and outside flange 33 meet. The protrusion 62 may, for example, have a rectangular cross-sectional shape and a length running along second side wall 52 , as shown in FIGS. 5 and 6 , but could alternatively comprise other shapes and still be functional. Similarly, protrusion 63 may have a rectangular cross-section and run along a flat or a curved back wall 53 . One possible alternative protrusion 93 may have curved surfaces forming peaks and valleys, as shown in FIG. 7 .
[0045] The first side wall 51 could, in a conventional approach, have a fixed protrusion similar to protrusion 63 on the second side wall, in order to contact the underside of the top plate and cooperate in retaining the latch 40 in the window slot 30 . However, to successfully counter severe deformations accompanying high wind loading, first side wall 51 , in a preferred embodiment, may have flexibly attached to it a cantilevered member 64 which may have a protrusion 67 extending therefrom. Protrusion 67 may also have a rectangular cross-sectional shape and a length running along the cantilevered member, and may also alternatively comprise other shapes and still be functional.
[0046] In a preferred embodiment of the invention (see FIG. 2 ), a protrusion 67 extends from a wall of the cantilevered member 64 , creating a lower portion 65 and an upper portion 66 of the wall of the cantilevered member. With the latch installed in a pivotable window, where the window experiences severe deformation due to high wind loading, such as shown in FIG. 9 , the top area 68 of the protrusion 67 and the upper portion 66 of the cantilevered member 64 will, as a result of biasing, maintain contact with the wall ( 31 or 32 ) of the top rail.
[0047] A cantilevered member 64 may extend only from first side wall 51 , or alternatively cantilevered members may extend from both side walls 51 and 52 , or it may extend from one or more locations of bottom wall 54 . Where such a cantilevered member 64 extends from the housing 50 , it may be configured to have its free end extend a distance beyond the edge of the top plate 55 . Also, as the cantilevered member 64 is flexible attached to the housing 50 , it may be possible to deflect the cantilevered member 64 or members inward to be flush against the respective housing wall. This inwardly deflected position may aid in installing the latch endwise into opening 30 of the lower window 22 , where the opening 30 periphery matches the end profile of the latch, such that the rectangular protrusion 67 may pass through a matching keyway and then be free to expand outward to contact outer flange 31 or inner flange 32 of opening 30 . This inward flexibility of the cantilevered member 64 may even be such that it permits the latch to be installed vertically by dropping it down into the opening 30 , rather than through an endwise installation. A drop down installation as described would eliminate the need for a keyed feature in the portion of opening 30 formed in the stile ( 32 and 33 ) of the window 22 . The configuration for this drop down installation may have a cantilevered member 64 that deflects inward, possibly into an opening or a recess in the housing, but to an extent where such deflection positions the protrusion 67 so as to be clear of the flange ( 31 or 32 ) of the top rail 27 as the latch drops through opening 30 , whereupon the cantilevered member biases outward and contacts the flange.
[0048] The cantilevered member may be a separate wall that is hinged to the side or bottom wall; may be attached—mechanically fastened or bonded or the like—to the side wall or to the bottom wall utilizing a flexible connection at the vertex 91 ; or the cantilevered member may alternatively be an integral portion of the side or bottom wall but with a flexible connection at the vertex 91 . The cantilevered member may generally be free at three sides—the top, the bottom, and the protruding edge, and may be connected to the housing on a fourth side.
[0049] In a preferred embodiment, the cantilevered member 64 is integral to side wall 51 , but normally extends away from side wall 51 at an angle. The connection of the cantilevered member 64 at vertex 91 , in addition to being flexible, may be resilient in nature so as to accomplish biasing, whereby applying a force to deflect the cantilevered member towards the side wall so as to parallel the side wall 51 , creates stored elastic strain energy in the resilient connection. This stored elastic strain energy seeks to return the cantilevered member to its angular position once the force has been removed. This method of biasing may be utilized whether the cantilevered member 64 is integral to the side wall 51 , or if is attached to the side wall.
[0050] As an alternative to having the flexible connection being resilient in nature, a spring means may be utilized to bias either the integral or the attached cantilevered member 64 . Such a spring means may include, but is not limited to, a compression spring, a torsion spring, etc., which may bias the cantilevered member away from the side wall 51 . Where a hinged connection is used to attach a separate wall segment to the housing to serve as a cantilevered member, a spring means may necessarily be used for biasing. During installation of the latch into an opening in the window stile 24 and top rail 27 of the sash window 22 , it may be necessary to manually deflect the cantilevered member 64 into a position parallel to the side wall to prevent the cantilevered member from catching or hanging up on the stile.
[0051] Cantilevered member 64 may also be positioned on the side wall such that the vertex 91 is near back wall 53 , and may have a length equal to the length of the housing, to accommodate severe deformations and still maintain positive contact with the wall of the top rail. Similarly, the first and second side walls 51 and 52 , although shown as having a very shallow depth in a preferred embodiment in FIG. 2 , may actually extend to a greater depth, and may thus be capable of supporting a cantilevered member having a substantial vertical dimension. Also, although not shown in the figure, an embodiment could include having a pair of cantilevered members extending from each side of the latch, whereby a first cantilevered member could maintain contact with outer flange 31 of the top rail and a second cantilevered member could maintain contact with inner flange 32 of the top rail.
[0052] Another possible embodiment may include a plurality of cantilevered members 64 on each side wall ( 51 and 52 ), or on each side of the bottom wall 54 . It should be noted that for any of these possible embodiments, the cantilevered member 64 may have a vertex 91 and orientation such that the cantilevered member 64 angles away from the housing, with the displaced end of the cantilevered member 64 disposed towards the interior of the window 22 . Alternatively, as in a preferred embodiment, the vertex 91 and orientation of the cantilevered member 64 may be such that the cantilevered member 64 angles away from the housing, with the displaced end of the cantilevered member 64 disposed towards the stile 24 of the window 22 .
[0053] It should be apparent from basic geometry that for a given angular deflection of cantilevered member 64 , that the greater the length of the cantilevered member, the greater the distance its end would be positioned away from the housing 50 side wall, and thus be capable of accommodating greater window deformations caused by wind loading, as the member would still be capable of maintaining contact with the wall of the top rail to support the latch.
[0054] Since the cantilevered member 64 would be constructed to normally extend away from the housing 50 at an angle, which would not be ideal for shipping of the product and could lead to damage to the cantilevered member, the lower portion 65 of the cantilevered member 64 may further comprise a small protrusion 67 . Protrusion 67 of the cantilevered member 64 may, with the cantilevered member pushed flush against the housing 50 side wall, fit into an opening 61 in the housing 50 to prevent the cantilevered member from deflecting outward until the protrusion 67 of the cantilevered member is deliberately disengaged, at which point the cantilevered member may swing into its angled position for installation into a slotted opening 30 of a tiltable sash window 10 . To assist in fitting the protrusion 67 of the cantilevered member 64 into the opening 61 , the lower portion 65 of the cantilevered member may have some slight curvature, as seen in FIG. 2 .
[0055] To complete endwise installation of the latch 40 through an opening 30 in the stile 24 , a retaining tab 59 may be formed on bottom wall 54 of housing 50 . The retaining tab 59 may protrude down away from the bottom wall 54 , so that once installed, it would contact side flange 33 of the stile 24 , to prevent the latch 40 from working its way out of the slotted opening 30 . To assist in installing the latch 40 , the retaining tab 59 and even the entire bottom wall 54 may be constructed of resilient material. As an alternative, there may be a gap 58 in the bottom wall 54 around retaining tab 59 , which would permit some flexibility of the retaining tab 59 and allow it to be deflected inward as the latch were slid into the slotted opening 30 .
[0056] Other modifications, substitutions, omissions and changes may be made in the design, size, materials used or proportions, operating conditions, assembly sequence, or arrangement or positioning of elements and members of the preferred embodiment without departing from the spirit of this invention as described in the following claims.
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A latch is provided for use on a pivotable sash window of a single-hung or double-hung sash window assembly to releasably secure the window to the master frame. The latch comprises a latch-bolt slidably mounted within, and biased relative to a housing. The housing is adapted to be installed into the top rail of the sash window through an opening in the stile and top rail, which has a periphery contoured to match the housing end profile. The latch bolt, while maintaining an aesthetically appealing external appearance, is configured to incorporate a cantilevered member which only becomes visible when biased to an angled position where it maintains engagement of the latch housing with the edge of the top wall of the rail during window deformation resulting from high wind loading. The cantilevered member ensures integrity of the latch installation under high wind load conditions typically experienced during extreme weather phenomena.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to computer-aided design and, more particularly, to a method for managing annotations in a computer-aided design drawing.
[0003] 2. Description of the Related Art
[0004] The term computer-aided design (CAD) generally refers to a broad variety of computer-based tools used by architects, engineers, and other construction and design professionals. CAD applications may be used to construct computer models representing virtually any real-world object, e.g., a machine part, a bicycle, a house, a skyscraper, or a stretch of highway complete with bridges and buried utilities.
[0005] Most CAD applications provide an environment for creating models at their real world size. This environment is typically called model space. In model space, everything exists as in the real world, and the model provides a 1:1 scale representation of the real-world objects. If a building is 80 feet by 40 feet, it is created at that size.
[0006] Since the model or portions thereof need to be annotated and output to a sheet of paper, CAD applications often have an environment for composing different views of the model along with annotations that document the model. This environment is known as paper space. In paper space, the sheet of paper is represented in 1:1 scale, and the information contained in model space is presented in paper space by way of one or more viewports that can be scaled, rotated, and arranged in different ways to create the final drawing to be printed or plotted.
[0007] Viewports in paper space are simply bounded views into the model. In order to display a large model on a sheet of paper, viewports can be assigned a viewport scale.
[0008] The display of the model is scaled so that it can be seen on the sheet at the desired size, e.g., ¼″=1′-0″ or 1:100, 2:1, etc. Different parts of the model may be displayed in different viewports in paper scale at different scales. The sheet (paper space) is generally plotted at scale of 1:1.
[0009] While users like to design models at their real-word size, they need to create their annotations at a size that is appropriate for the sheet. Annotations may be created in the paper space environment or in the model space environment. In conventional CAD applications, when the text, dimensions, symbols, and other annotations are drawn in model space (the same environment as the model geometry), these annotations along with the model geometry are scaled down when displayed in a viewport in paper space. The size of such text, dimensions, symbols, and other annotations has to be carefully selected so that they will scale correctly to give the desired appearance in the final printouts and plots that will be generated from paper space. For example, if drawing sheets of a model are to be plotted with the model scaled at 1:100, and the user wants the plotted text size to be ⅛″, the text must be drawn 100/8″ in model space.
[0010] When working with a few viewports in paper space or with a single paper space scale, the planning that is required for correct annotation scaling may be manageable. However, when the same geometry and annotations need to be plotted multiple times at different scales, the user has to create duplicate annotations on different layers, in different positions, and adjust the visibility of each layer to create the desired effect. This, of course, not only takes a significant amount of time, but results in potential out-of-sync problems, making the drawing environment more complex and difficult to manage.
SUMMARY OF THE INVENTION
[0011] The present invention provides a method for managing annotations in CAD drawings, and a computer readable storage medium containing instructions for a computer system to carry out such a method. With the present invention, the CAD designer can specify a fixed paper size for the annotations and the CAD application will generate the annotations at the specified fixed size even though modeled objects within the CAD drawing are scaled in accordance with a paper space scale selected by the CAD designer.
[0012] A method for managing annotations in a CAD drawing according to a first embodiment of the present invention includes the steps of receiving a user input that specifies an annotation scale and generating annotations having a size that is equal to a fixed size relative to the sheet of paper on which they are intended to be displayed. The annotations comprise one or more of text, dimensions, hatch patterns, and symbols, and are represented as annotation objects having multiple properties, such as size, visibility, position and rotation.
[0013] The annotation objects can support one or more scales. When the scale of the model is changed (e.g., when plotting or creating a sheet that contains views of the model), the size of the annotations will change (relative to the geometry of the model) to remain at a specified size relative to the sheet. The same annotation object can display at different sizes (relative to the geometry of the model) in different views of different scales so it appears at the same size on the sheet.
[0014] A method for managing annotations in a CAD drawing according to a second embodiment of the present invention includes the steps of annotating the CAD drawing with text, specifying a fixed size for the text, preparing a first workspace in which the CAD drawing is generated in accordance with a first scale, and preparing a second workspace in which the CAD drawing is to be generated in accordance with a second scale. When the CAD drawing is generated in accordance with either the first scale or the second scale, the size of the text that is generated is the same and is equal to the specified fixed size.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a conceptual block diagram of a computer system with which embodiments of the present invention can be practiced.
[0016] FIGS. 2A-2D are schematic representations of graphical user interfaces that illustrate the process for managing annotations.
[0017] FIGS. 3A-3D are schematic representations of graphical user interfaces that illustrate the size, position and orientation of annotations in relation to the modeled object.
[0018] FIGS. 4A-4B are schematic representations of graphical user interfaces that illustrate the size of graphic annotations in relation to the modeled object.
[0019] FIG. 5 is a flow diagram that illustrates the process for generating annotations according to an embodiment of the present invention.
[0020] FIG. 6 is a flow diagram that illustrates the process for generating multiple viewports with different viewport scales.
DETAILED DESCRIPTION
[0021] FIG. 1 is a conceptual block diagram of a computer system 100 with which embodiments of the present invention can be practiced. The components of the computer system 100 illustrated in FIG. 1 include CAD application 105 , graphical user interface (GUI) 110 , CAD drawing 120 , user input devices 130 , and a display device 115 . CAD application 105 is a software application that is stored in memory and executed by the processor of the computer system 100 . It includes software program routines or instructions that allow a user interacting with GUI 110 to create, view, modify and save CAD drawing 120 . In the examples provided herein, the CAD application 105 is the AutoCAD® software application program available from Autodesk, Inc. and associated utilities. Typically, user input devices 130 include a mouse and a keyboard, and display device 115 includes a CRT monitor or LCD display.
[0022] In accordance with embodiments of the present invention, CAD application 105 enables a user to specify fixed sizes and other properties of the annotations of CAD drawing 120 . FIGS. 2A-2D are schematic representations of GUI 110 that illustrate the process of managing the annotations. FIG. 2A shows a GUI 110 that displays in model space a modeled object 220 , various annotations 230 , 232 associated with the modeled object 220 , and an annotation scale 240 . Each of the annotations 230 , 232 is represented by a software object and has various properties associated with it. The annotation scale 240 indicates the scale at which the existing annotation objects are displayed and the scale that new annotation objects will be defined. Annotation objects have a property that indicates what scales are supported. For each scale supported, the position, rotation, paragraph width, etc. of the same object can vary. When the system is set to scale not supported by the annotation object, the object can be hidden.
[0023] FIG. 2B represents an input dialog window for managing the style of an annotation. It controls the properties of the annotation object and is displayed to the user when the annotation object is created. With the input dialog window of FIG. 2B , the user can specify a custom fixed size for the annotation object by checking the box 261 (which sets its annotative property to be equal to 1) and inputting a paper height size (i.e., text height size in paper space) in input window 262 . The input dialog window of FIG. 2B also allows the user to specify other properties of the annotation object including special display effects, such as “Upside down,” “Backwards,” and “Vertical.” Using a similar dialog window, the user can specify the visibility of the annotation and the rotation of the annotation to any arbitrary angle. Further, the annotation object keeps track of the position of the annotation. When the user moves the annotation to a different position in CAD drawing 120 , the position property of the annotation object is updated to reflect the new position.
[0024] FIG. 2C shows a property control panel that is displayed to the user when an annotation object is selected after it has been created. It shows the paper text height of the object specified by the user and the model text height-the height of the text in model units. It also shows the properties of the same object for different annotation scales. When the annotation scale of the view changes, the scale of the object (and the model text height) changes, but the paper text height remains the same.
[0025] In the embodiments of the present invention illustrated herein, an annotation object is permitted to have different properties for different annotation scales. For example, for an annotation scale of ½″=1′-0″, the user may specify the annotation object associated with annotation 230 to be “not visible” whereas for an annotation scale of ¼″=1′-0″, the user may specify it to be “visible.” To switch amongst different annotation scales, an annotation scale menu 241 , which is shown in FIG. 2D , is provided. The annotation scale menu 241 is displayed when the user selects the menu arrow (▾) on the annotation scale 240 using an input device. FIG. 2D shows a selection of the ¼″=1′-0″ annotation scale by the user. After this selection is made, all user inputs that affect the properties of annotation objects will be valid only for those annotations corresponding to an annotation scale of ¼″=1′-0″.
[0026] FIGS. 3A-3D are schematic representations of GUIs 110 that illustrate the size, position and orientation of annotations 230 , 232 in relation to the modeled object 220 . FIG. 3A illustrates a paper space viewport 302 (on a sheet 301 representing a sheet of paper) at a scale of ¼″=1′-0″. The viewport scale is indicated by reference numeral 270 . The sizes of the annotations 230 , 232 are defined in model space as follows. First, the user selects the annotation scale (¼″=1′-0″) from the annotation scale menu 241 like the one shown in FIG. 2D . Then, the user creates the annotation object using an annotative style (as shown in FIG. 2B ). The user then checks the box 261 and inputs the desired text height size in input window 262 . When the user creates the viewport in paper space shown in FIG. 3A at the scale of ¼″=1′-0″, the annotations 230 , 232 are displayed at their paper text size sizes as defined by the user.
[0027] If the user wishes the annotations to be displayed in a viewport or plotted at a different scale, the user can select the annotations and specify the additional scales to support. When changing the annotation scale of the model, the text will update to the appropriate size and can be repositioned as needed. FIG. 3B represents the same model geometry and annotations displayed in a paper space viewport at a scale of ⅛″=1′-0″. While the model geometry is scaled down based on the viewport scale, the annotations maintain a fixed size relative to the sheet.
[0028] FIG. 3B illustrates a paper space viewport 302 (on a sheet 301 representing a sheet of paper) at a scale of ⅛″=1′-0″. The viewport scale is indicated by reference numeral 270 . The sizes of the annotations 230 , 232 are defined in model space as follows. First, the user selects the annotation scale (⅛″=1′-0″) from the annotation scale menu 241 like the one shown in FIG. 2D . Then, the user selects an annotation (e.g., annotation 230 or annotation 232 ) and accesses a property control panel like the one shown in FIG. 2C to change the properties of the annotation object. When the user creates the paper space viewport shown in FIG. 3B at the scale of ⅛″=1′-0″, the annotations 230 , 232 are not scaled down to the viewport scale but maintain their fixed sizes as defined by the user.
[0029] FIG. 3C shows the same model geometry and annotations displayed in a paper space viewport 302 (on a sheet 301 representing a sheet of paper) at a scale of 1/16″=1′-0″, but the annotation is rotated and repositioned when displayed at this scale. The viewport scale is indicated by reference numeral 270 . The sizes of the annotations 230 ′, 234 are defined in model space as follows. First, the user selects the annotation scale ( 1/16″=1′-0″) from the annotation scale menu 241 like the one shown in FIG. 2D . Then, the user selects an annotation (e.g., annotation 230 or annotation 232 ) and accesses a property control panel like the one shown in FIG. 2C to change the properties of the annotation object. When the user creates the paper space viewport shown in FIG. 3C at the scale of 1/16″=1′-0″, the annotations 230 ′, 232 are not scaled down to the viewport scale but maintain their fixed sizes as defined by the user. The paper space viewport of FIG. 3C also illustrates a different position and an orientation of the annotation 230 ′. The position of the annotation 230 ′ has been moved from its original position that is above the modeled object to a new position that is to the left of the modeled object. Further, the orientation of the annotation 230 ′ has been rotated by 270°. These two new properties of the annotation object 230 ′ are stored as properties of the annotation object 230 ′ associated with the viewport scale of 1/16″=1′-0″.
[0030] FIG. 3D illustrates two paper space viewports 302 A, 302 B (on a sheet 301 representing a sheet of paper). The paper space viewport 302 A is at a scale of ⅛″=1′-0″. The paper space viewport 302 B is at a scale of 1/16″=1′-0″. The scale for viewport 302 A is indicated by reference numeral 270 A. The scale for viewport 302 B is indicated by reference numeral 270 B. The side-by-side view of the two paper space viewports 302 A, 302 B shows that the size of annotation 232 A is the same as the size of annotation 232 B even though the modeled object 220 is scaled down. The side-by-side view of the two paper space viewports 302 A, 302 B also shows that an annotation can be displayed without rotation in one view (annotation 230 A) and with rotation in another view (annotation 230 B).
[0031] FIGS. 4A-4B are schematic representations of GUIs 110 that illustrate the size of graphic annotations such as hatch patterns and symbols in relation to the modeled object 221 . FIG. 4A illustrates a paper space viewport 302 (on a sheet 301 representing a sheet of paper) at a scale of ¼″=1′-0″. The size of the text annotation 236 is defined in model space as described above. The sizes of the graphic annotation 237 (the square with a hatch pattern) and the graphic annotation 238 (tree symbol) are defined in a similar manner. First, the user selects the annotation scale (¼″=1′-0″) from the annotation scale menu 241 like the one shown in FIG. 2D . Then, the user selects an annotation (e.g., annotation 237 or annotation 238 ) and creates the annotation object using an annotative style (as shown in FIG. 2B ). The user then checks the box 261 and inputs the desired graphic annotation height size (e.g., the height of the repeating pattern for the graphic annotation 237 or the height of the tree symbol for the graphic annotation 237 ) in input window 262 . When the user creates the paper space viewport shown in FIG. 4A at the scale of ¼″=1′-0″, the annotations 236 , 237 , 238 are not scaled down to the viewport scale but maintain their fixed sizes as defined by the user. FIG. 4B illustrates a paper space viewport 302 (on a sheet 301 representing a sheet of paper) at a scale of ⅛″=1′-0″. After the user selects the annotation scale (⅛″=1′-0″) from the annotation scale menu 241 like the one shown in FIG. 2D , the sizes of the text annotation 236 and graphic annotations 237 , 238 are defined in model space as described above with reference to FIG. 4A .
[0032] FIG. 5 is a flow diagram that illustrates the process for generating annotations according to an embodiment of the present invention. The illustrated process is carried out by a computer in response to instructions from CAD application 105 . In step 510 , a paper space viewport is created. Then, an annotation scale is assigned to the paper space viewport (step 512 ). Within the paper space viewport, the modeled object is scaled (step 514 ) and the annotation objects are regenerated based on their properties (step 516 ). If an annotation object is not annotative (i.e., annotative property=0), the annotation is scaled just like the modeled object (steps 518 and 520 ). If the annotation object is annotative (i.e., annotative property=1) and supports the assigned scale, the annotation is displayed unscaled relative to the sheet (steps 518 , 522 and 524 ). On the other hand, if the annotation object is annotative but does not support the assigned scale (steps 518 and 522 ), step 520 is carried out and the annotation object is scaled just like the modeled object; alternatively, instead of carrying out step 520 , the annotation object can be hidden.
[0033] FIG. 6 is a flow diagram that illustrates the process for generating multiple viewports with varying scales. The illustrated process is carried out by a computer in response to user inputs made through various GUIs. In step 610 , drawing objects are created in model space. Then, in step 612 , the drawing objects in model space are annotated and the sizes for the annotations are selected. For example, the size of a text annotation to be displayed at a viewport scale of ¼″=1′-0″ may be set as ⅛″, and the size of the same text annotation to be displayed at a viewport scale of ½″=1′-0″ may be also set as ⅛″.
[0034] In steps 614 through 620 , one or more viewports are created from the drawing objects created in model space. The view and the scale associated with the viewport are selected in step 614 . In step 616 , the viewport drawing is generated in accordance with the selected scale. During this step, the drawing objects are scaled down, but the annotations may or may not be scaled down. If the annotative property associated with an annotation is zero, the annotation is scaled down. However, if the annotative property associated with an annotation is one, the annotation is not scaled down and is generated in accordance with the fixed size input by the user. Then, in step 618 , the computer monitors for changes in any of the viewport scales. If it is determined that any of the viewport scales has changed, the process flow returns to step 616 and the viewport drawing associated with the changed viewport scale is regenerated in accordance with the changed viewport scale. The process flow also returns to step 616 if new viewports are created by the user (step 620 ).
[0035] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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Annotations in CAD drawings are given fixed sizes so that CAD application will generate the annotations at the fixed size even though modeled objects within the CAD drawing are scaled in accordance with a paper space scale selected by the CAD designer. The annotations generally comprise text annotations and graphic annotations, including one or more of text, dimensions, hatch patterns, and symbols, and are represented as annotation objects having multiple properties, such as size, visibility, position and rotation.
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FIELD OF THE INVENTION
The present invention pertains to a joint for the movable connection of two components of a motor vehicle, which are movable in relation to one another.
BACKGROUND OF THE INVENTION
Such joints are currently used, e.g., as “sleeve joints” for mounting stabilizers in motor vehicles. The designation “sleeve joint” is derived from the mount body present in the mount, which is designed as a sleeve in prior-art embodiments, so that it has a through hole. The sleeve joints known from the state of the art have a mount body with a spherically shaped bearing surface. This is accommodated in a complementarily shaped bearing shell inner surface of the bearing shell and is guided therein in a slidingly movable manner. For example, a bolt, which is used to fasten the joint to a motor vehicle component, is passed through the through hole of the mount body.
However, the problem arises that the space necessary for introducing and fixing the bolt in the area of the wheel suspension is very limited. Thus, the installation of prior-art joints in the motor vehicle is rather difficult.
Moreover, it was observed that the cross section of the prior-art sleeve joints is weakened due to the through hole prepared in the mount body, and this weakening must be compensated by the application of additional material on the outer circumference of the mount body in order to reach the required strength values of the component. The prior-art joint designs correspondingly have a considerable overall volume and consequently require more space for installation in the area of the wheel suspension than would be desirable.
SUMMARY OF THE INVENTION
The basic object of the present invention is to make available a joint that has a compact design and can be preferably connected to a motor vehicle component from one side, so that its installation is simplified.
Accordingly, a joint according to the present invention for the movable connection of two components of a motor vehicle, which are movable in relation to one another, has a housing and a bearing shell accommodated in the housing for the slidingly movable mounting of a mount body. The mount body is provided with a bearing surface curved complementarily to the bearing shell inner surface and is thus accommodated in the bearing shell in a slidingly movable manner. On at least one side, the mount body has a pin neck, and the bearing surface passes over into the pin neck. The pin neck has a connection area for connecting the mount body to a bearing journal.
Due to a mount body being equipped with a connection area, it becomes possible to connect a bearing journal to be mounted on the mount body to the mount body in a very short time, so that the time needed for installing a joint according to the present invention becomes shorter. In addition, the installation of the joint in the motor vehicle is simplified. The joint has a small overall size and is consequently very compact.
In a preferred embodiment of the present invention, the mount body has two pin necks arranged diametrically to each other, and the curved bearing surface is a joint ball. Thus, the mount body has an outer geometry similar to the prior-art sleeve joint inner parts. Unlike in the prior-art designs of the sleeve joint inner parts, the mount body is not provided with a through hole in the joint according to the present invention, but it has only a connection area for connection to the bearing journal, which is preferably provided on the pin neck.
Both connections by material bonding (to integrate structurally) and positive-locking connections may be selected for connecting the pin neck of the mount body to the bearing journal. Moreover, a combination of connection by material bonding and positive-locking connection is possible and can be embodied in the sense of the present invention.
Thus, corresponding to a variant of the present invention, the connection by material bonding between the pin neck and the bearing journal may be a welded connection or a bonded connection. Processes such as friction welding or resistance pressure welding are possible for preparing the welded connection.
A positive-locking connection between the pin neck and the bearing journal may, moreover, be designed such that at least one pin, which passes through an opening of a flange present at the bearing journal and is placed on the flange on the opposite side of the flange by means of deformation of the material, is made in one piece with the pin neck. A nondetachable connection, which meets very high requirements in terms of fatigue strength, is thus obtained between the bearing journal and the pin neck.
Another possibility of preparing the connection between the pin neck and the bearing journal is to make a connection pin, whose geometry, which deviates from a regular cylindrical shape at least in some sections, is fitted into a complementary recess of the bearing journal, in one piece with the pin neck. The reverse case can also be readily embodied in the sense of the present invention. Thus, a recess may be prepared in the pin neck, and a connection pin having a geometry deviating from the regular cylindrical shape at least in some sections is then introduced into the said recess.
In other words, the pin neck of the mount body is thus connected to the bearing journal by a connection pin being present on the first component and by a corresponding recess being prepared in the other component. Thus, a deformation process may be used as the manner of connecting the components indicated. Furthermore, it is possible to prepare the connections by means of a press fit or, in the simplest case, to provide a thread on the connection pin, which thread can be screwed into a fitting internal thread of the recess. Moreover, combined with the positive-locking connection, a connection by material bonding may be selected for the permanent, nondetachable fixation of the mount body on the bearing journal. This is possible, but not absolutely necessary in the sense of the present invention.
Moreover, a variant of the present invention is seen in that a contour for the action of a tool or a tool engagement contour is provided on the bearing journal and/or the mount body. This tool action contour or tool engagement contour permits the simplified mounting of the joint according to the present invention as well as facilitated installation in the wheel suspension of a motor vehicle. The tool action contour or tool engagement contour is used as a holder for a tool while the bearing journal is being connected to the bearing body. If this connection comprises the above-mentioned threaded connection, the tool engagement contour or tool action contour offers an ideal possibility of holding the components in this case.
Two preferred embodiments of a joint according to the present invention will be described in greater detail below on the basis of the views in the figures.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial sectional view through a first joint according to the present invention;
FIG. 2 is a partially cut-away mount body as an individual part;
FIG. 3 is a partially cut-away view of a bearing journal;
FIG. 4 is a sectional view through another embodiment of a joint according to the present invention;
FIG. 5 is a section through the mount body of a joint according to FIG. 4 ;
FIG. 6 is a partially cut-away bearing journal of the joint shown in FIG. 4 ; and
FIG. 7 shows a partial section through another joint.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings in particular, FIG. 1 shows an embodiment of a joint according to the present invention. This joint comprises a housing 1 and a bearing shell 2 inserted into the housing. The bearing shell accommodates a curved, here spherically shaped bearing surface 4 of a mount body 3 , which said bearing surface is rotatably or tiltably movable. The bearing shell 2 has a bearing shell inner surface curved complementarily to the bearing surface 4 for this purpose.
The housing 1 of the joint shown in FIG. 1 has two housing openings 23 , 24 and is open on both sides. The housing 1 has on one side a collar, which is directed toward the inside of the joint and at which the bearing shell 2 is supported in the axial direction of the joint. On the opposite side, the bearing shell 2 is fixed in the housing 1 by means of a securing ring 17 . The bearing shell 2 is fixed in the known manner by the deformation of an edge of the housing, so that the securing ring is thus locked in a groove of the housing.
The mount body 3 has a pin neck 5 each on both sides of the curved bearing surface 4 designed as a joint ball. As can be recognized in the upper part of FIG. 1 , a tool engagement contour 15 was prepared in the pin neck 5 of the mount body 3 . This tool engagement contour 15 comprises in this case a hexagonal recess or a hexagonal round recess (Torx) for attaching a corresponding tool wrench. In the lower part of the mount body 3 , the mount body is provided with a connection area 6 . In the embodiment of a joint according to the present invention shown in FIG. 1 , the connection area comprises a connection pin 12 , which is made in one piece with the mount body 3 and is made integrally with the mount body 3 and is screwed with a corresponding external thread 20 (see FIG. 2 ) intro a corresponding internal thread 21 (see FIG. 3 ) of the bearing journal 7 . To prepare the internal thread 21 in the bearing journal 7 , a recess 13 is prepared in the bearing journal in advance. To improve the contact between the mount body 3 and the bearing journal 7 , a flange 8 is present in the contact area of the said components. A sealing bellows 14 , on the one hand, and, on the other hand, another sealing bellows 16 are used to seal the sensitive components of the joint. The sealing bellows 14 and 16 are fixed directly on the pin neck 5 by means of respective straining rings 18 and 19 , on the one hand, and in a groove of the housing, on the other hand. The pin necks 5 of the mount body pass through the housing openings 23 and 24 in the axial direction and project from the housing 1 on both sides, so that the tool engagement contour 15 and the connection area 6 can be used here to mount the joint as well as to install it in the motor vehicle.
A mount body 3 of the joint according to the present invention, which is described in FIG. 1 , is shown as an individual part once again in FIG. 2 for better illustration. This mount body 3 has on one side a connection pin 12 , which was provided with an external thread 20 . This connection pin 12 is made integrally with the mount body 3 and is made on one side in one piece with a part of the mount body 3 , which part is designed as a pin neck 5 . On the side of the mount body 3 located opposite the connection pin 12 , the mount body has, moreover, a tool engagement contour 15 for attaching a tool wrench.
Moreover, FIG. 3 shows a partially cut-away view of a bearing journal 7 of the embodiment of a joint shown in FIG. 1 . The partial section clearly shows the blind hole 22 prepared in the bearing journal 7 , in which blind hole an internal thread 21 was prepared. To improve the contact between the pin neck 5 of the mount body 3 and the bearing journal 7 , a flange 8 is made in one piece with the bearing journal 7 . Furthermore, a tool engagement contour 15 , which has a shape similar to that of the tool engagement contour shown in FIG. 2 , is prepared on the side located opposite the flange 8 in the embodiment of a bearing journal 7 shown here.
Another possible embodiment of a joint according to the present invention is shown in a partial sectional view in FIG. 4 . The design of this joint is basically similar to that of the joint shown, and the same reference will therefore also be used to designate identical components.
Unlike in the view in FIG. 1 , the mount body 3 has a recess 13 , which was prepared only to a defined depth in the mount body 3 . This recess 13 , prepared as a blind hole 22 , has, moreover, an internal thread 21 . A connection pin 12 , on which a corresponding external thread 20 is present, can be screwed into this internal thread until the face of the pin neck 5 of the mount body 3 comes into contact with the flange 8 of the bearing journal 7 , on which the connection pin is present and secure locking of the components to be connected is thus made possible as a consequence of the self-locking of the thread.
As is apparent from FIG. 5 , in which a sectional view of the mount body 3 of a joint according to FIG. 4 is shown, the mount body 3 also has a tool engagement contour 15 on the side located opposite the connection area 6 . Since the recess 13 is not a through hole, higher strength values can be obtained with the embodiments being shown here along with reduced dimensions than was hitherto possible in prior-art joints.
FIG. 6 once again shows a bearing journal 7 , which has in the partial section a tool engagement contour 15 , on the one hand, and, located opposite this above the flange 8 , a connection pin 12 , whose external thread 20 can be screwed into the above-described internal thread 21 of the mount body 3 until the face of the pin neck 5 of the mount body 3 comes into contact with the flange 8 . Moreover, the tool engagement contour 15 is used to facilitate the installation of the joint in the wheel suspension of a motor vehicle.
Furthermore, FIG. 7 shows a detail of the connection area between the bearing journal 7 and the mount body 3 , as can also be applied in a meaningful manner. The pin neck 5 has a recess 13 here, into which a connection pin 12 is inserted. The connection pin and the recess have complementary regular cylindrical contours. A plurality of openings 10 , through which pins 9 made in one piece with the pin neck 5 pass, are prepared in the flange 8 on the bearing journal 7 , distributed over its circumference. On the side located opposite the pin neck 5 , these pins 9 have a material deformation 11 , so that they guarantee a permanent connection between the bearing journal 7 and the mount body 3 .
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
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A joint for the movable connection of two components of a motor vehicle, which are movable in relation to one another, with a housing ( 1 ) and with a bearing shell ( 2 ) accommodated in the housing ( 1 ) for the slidingly movable mounting of a mount body ( 3 ) is presented, wherein the mount body ( 3 ) has a bearing surface ( 4 ) curved complementarily to the bearing shell inner surface and passes over at least on one side into a pin neck ( 5 ), which has a connection area ( 6 ) for connection to a bearing journal ( 7 ).
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FIELD
[0001] The invention relates to a method of resetting a safety system of an elevator installation from an actual state to a desired state, particularly to a normal state, in which a normal operation of the elevator installation is released by the safety system, and to an elevator installation for performing the method.
BACKGROUND
[0002] Elevator installations comprise a safety system for ensuring sufficient operational safety. The requirements are fixed by various standards and regulations. These safety systems are usually constructed to be largely independent and superordinate to the rest of the elevator systems. The safety system can influence the elevator installation and is for that purpose connected with, for example, the drive or brake unit of the elevator installation. If sufficient operational safety is not guaranteed, travel operation is interrupted.
[0003] A safety system of that kind can be constructed as a safety circuit in which a plurality of safety elements such as, for example, safety contacts and safety switches are arranged in series connection. The contacts monitor, for example, whether a shaft door or the car door is open. The elevator car can be moved only when the safety circuit and thus also all safety contacts integrated therein are closed. Some of the safety elements are actuated by the doors. Other safety elements such as, for example, an over-travel switch are actuated or triggered by the elevator car. The safety circuit interrupts travel operation if the safety circuit is opened.
[0004] Safety systems with safety circuits of this kind are subject to numerous disadvantages such as, for example, inherent problems of a voltage drop in the safety circuit and a comparatively high susceptibility to fault. In addition, the safety circuit does not allow a specific diagnosis, since if the safety circuit is open it can be established only that at least one safety contact is open.
[0005] It was therefore proposed to equip elevator installations with a safety bus system instead of the mentioned safety circuit. The safety bus system typically comprises a control unit, a safety bus and one or more bus junctions. Various safety elements such as, for example, door contacts, lock contacts or buffer contacts are interrogated by way of the bus junctions. If a report of the safety elements does not correspond with a target magnitude, the safety system can influence the control of the elevator installation and, for example, initiate emergency switching-off. The safety system can in that case pass into an emergency state in which operation of the elevator installation is, for example, blocked or is possible only to reduced extent. Typical emergency states comprise, for example, emergency switching-off, for example as a consequence of the elevator car exceeding a speed or an unclosed door or a maintenance state in which only maintenance journeys are possible. A safety system of that kind is described in, for example, WO 03/024856 A.
[0006] If the safety system passes into an emergency state, it is necessary to reset the safety system to a normal state in which normal operation of the elevator installation is released. The safety system is often set back (‘reset’) to the normal state by a service engineer after successful checking of the elevator installation. Resetting can in that case be carried out, for example, directly at an access point of the safety system. This can be arranged in, for example, a closed maintenance area so as to ensure that only an authorized person can trigger the resetting. However, the safety system is thus often difficult to access, whereby resetting can be time-consuming and, for example, inconvenient for the service engineer. Resetting could in certain cases also be carried out automatically by an elevator control. However, in this case the requisite safety steps for resetting would often not be guaranteed, since an elevator control as an unsafe system is subordinate to the safety system in a safety hierarchy.
SUMMARY
[0007] It is therefore an object of the invention to provide a method and an elevator installation with a safety system, which enable efficient and safe operation of the elevator installation. Moreover, it is an object of the invention to provide a method and an elevator installation with a safety system which will enable convenient and simple resetting of the safety system with sufficient safety against, for example, misuse, vandalism, faulty operation or faulty functions.
[0008] These objects are fulfilled by a method of resetting a safety system of an elevator installation from an actual state, particularly a state in which a normal operation of the elevator installation is not released, to a desired state, particularly to a normal state in which a normal operation of the elevator installation is released by the safety system, wherein the safety system is connected by way of at least one communications interface for data exchange with a control system, which is associated with the elevator installation, but which, in particular, does not belong to the safety system. The method comprises the steps of:
receiving a reset request, which is transmitted from the control system, for resetting from the actual state to the desired state in the safety system; carrying out verification of the reset request by the safety system; evaluating the verification by the safety system; and resetting the safety system from the actual state to the desired state if the verification by the safety system is evaluated as valid.
[0012] It is ensured by means of this method that resetting of the safety system represents an action of intentional processing and takes place securely. In particular, resetting of the safety system by unauthorized personnel or by a faulty function, for example in the case of a randomly generated reset request, can be excluded. Accordingly, the method ensures that when normal operation of the elevator installation is taken up the safety system is reliably placed in operation.
[0013] By “actual state” there is denoted an instantaneous state of the safety system from which it is to be reset to the desired state by the transmitted reset request. The actual state is typically an emergency state in which normal operation of the elevator installation is not released. The actual state can be, for example, a state in which the safety system is disposed as a consequence of, for example, a faulty function or at the time of maintenance of the elevator installation.
[0014] The “desired state” denotes a state to which the safety system is to be transferred as the consequence of the reset request. In particular, the desired state is a normal state in which normal operation of the elevator installation is made possible. In this case, verification of the reset request is particularly important in order to guarantee safety during normal operation. It will be obvious that depending on requirements the actual state can also be a normal state and the desired state an emergency state. In particular, the desired state can also be, for example, a maintenance state in which only maintenance journeys are possible.
[0015] The control system can comprise not only internal components belonging to the elevator installation, but also external components. Internal components can be, for example, locally fixed or mobile control units of the elevator installation. In particular, the control system can comprise, for example, parts of an elevator control of the elevator installation. Mobile control units such as, for example, portable maintenance or diagnostic apparatus or mobile telephones can be connected or connectible by way of, for example, an internal cable-supported or cable-free network. Depending on respective requirements the control units can comprise, for example, means for reading out or representing data, such as, for example, a display, and/or means for input of data, such as, for example, a keypad or a touchscreen.
[0016] External components of the control system can be connected by way of, for example, an external, possibly public, network. For example, a mobile telephone, which is connected by a mobile radio network with the control system, or a computer, which is connected by way of the Internet, can form part of the control system. The control system can for that purpose comprise an interface unit for connection with the corresponding external network.
[0017] The at least one communications interface can comprise, for example, a communications bus led by way of a cable (for example, CAN, i.e. ‘Controller Area Network’, bus). However, the communications interface can equally also comprise an internal cable-free network belonging to the elevator installation (for example WLAN, i.e. ‘Wireless Local Area Network’, network) or a connection to an external public cable-free or cable-supported network. It will be obvious that the control system or components thereof can be connected with the safety system by way of one or several communications interfaces.
[0018] The “reset request” denotes a reset request for resetting from the actual state to the desired state. The transmission of the reset request to the safety system can be triggered by a user or by a system of the elevator installation (denoted in the following in general by “trigger”). In the case of transmission of the reset request it is optionally possible to transmit additional data to the safety system such as, for example, the intended desired state or optionally data of the trigger. The reset request can be transmitted to the safety system by way of an internal or external component of the control system.
[0019] Denoted by “verification” is, fundamentally, any form of confirmation of the validity of the reset request. The verification can in that case advantageously also comprise an authentication, wherein in addition an authorization or identity of, for example, the trigger is checked. According to the invention, resetting of the safety system to the desired state as a rule obviously also takes place in the case of valid verification only when the safety system evaluates resetting to the desired state as safe or the desired state is permitted by the safety system. In specific forms of embodiment it can be advantageous for the verification of the resetting request by the safety system to be carried out only if the desired state is evaluated as safe. Otherwise, the safety system can, for example, trigger an alarm signal in response to the reset request.
[0020] By way of the verification in accordance with the invention it can be ensured that resetting cannot be triggered by faulty functioning of an elevator installation, erroneously by a user or intentionally by an unauthorized party. The control system can therefore also be part of an unsafe system of the elevator installation, i.e. a system which is subordinate to the safety system in hierarchical terms and should not, in particular, form part of the safety system. In the case of a mobile control unit carried by the user the connection with the safety system can, in accordance with the invention, even take place by way of a non-secure public network such as, for example, a mobile radio network.
[0021] Performance of the verification can comprise reading-out of a verification code which is transmitted directly with the reset request to the safety system. The verification code can in that case be input or produced by the trigger of the reset request before or at the time of transmission of the reset request. For verification of the reset request the safety system can compare the verification code with, for example, a target verification code stored in the safety system or generated by this. For example, the verification code can, on triggering or receipt of the reset request, be extracted in the manner of a cross-off list from a stored list. Systems of that kind can require, for example, manual selection from a printed list or be implemented electronically in chip cards, dongles or other mobile release devices, which are connectible with a control system, for example with an interface of a control unit.
[0022] Also conceivable are time-synchronized systems which generate at the trigger and in the safety system verification codes which are valid only in limited, synchronized time windows. However, verification codes can also comprise a simple personal identification number (PIN) or other static codes, which are known only to an authorized trigger. Equally conceivable would be, for example, a fingerprint or iris scan of a user, which is picked up for triggering the reset request and transmitted with the reset request in coded form. Further possibilities for verification in the case of transmission of the reset request are readily apparent to the expert.
[0023] Alternatively, performance of the verification takes place in the manner of a question/answer verification, in which a verification request is transmitted directly or indirectly to a system or a user (collectively termed “receiver” in the following), which or who has to confirm the request by a verification response. In particular, performance of the verification comprises transmission of a verification request, particularly an enquiry code, from the safety system to the control system in response to the received reset request, as well as reception in the safety system of a verification response, particularly response code, transmitted by the control system.
[0024] The verification request can be a simple signal of the safety system such as, for example, illumination of a button, which, for example, has to be pressed by a user as verification response for confirmation, of a keypad in the control system. However, for enhanced safety the verification request preferably comprises an enquiry code and/or the verification response comprises a response code. The enquiry code and/or the response code can have different degrees of complexity depending on the respective requirements and comprise, for example, an alphanumeric or a binary character sequence. Equally, the enquiry code and/or the response code can also comprise a pictorial representation such as, for example, symbols or a barcode or a double-matrix code. Enquiry code and response code can be identical, in which case, for example, the enquiry code, which is transmitted by the safety system, for the verification response is transmitted back by the receiver in identical form to the safety system. Enquiry code and response code are preferably provided in such a way that the correct response code can be transmitted to the safety system only with knowledge of the enquiry code.
[0025] As response codes use can also be made of, for example, verification responses independent of the verification request, such as, for example, authentication by a coded fingerprint or an iris scan of a user.
[0026] It will be obvious that the receiver of the verification request and the trigger can be different from one another, i.e. the verification request does not have to be directed to the trigger of the reset request. The reset request can, for example, be transmitted by a locally fixed control unit of the control system to the safety system (trigger), whereas the verification request is transmitted to a mobile control apparatus, which a service engineer carries, of the control system (receiver). Further variations are immediately evident.
[0027] Evaluation of the verification preferably comprises comparison of the verification response with a target verification response, and evaluation of the verification as valid when the verification response agrees with the target verification response. If the verification response comprises a response code, the target verification response preferably comprises a target response code.
[0028] The verification request is preferably regenerated, in particular randomly, by the safety system for each reset request. In this way verification requests for successive reset requests differ from one another. It is thereby possible to prevent a verification from being associated with a false reset request in the case of, for example, a short sequence of reset requests.
[0029] If the verification request, in particular—in a given case—the enquiry code, is generated randomly a conventional random generator can serve as a basis for the generation. Random generators of that kind can be implemented in the safety system in terms of hardware or software. In variants, the enquiry code can also be based on other factors such as, for example, the current date and clock time. Equally, the verification request and a target verification response for generation can be extracted in the form of a cross-off list from a list stored in the safety system. The verification request can in this case be an appropriate cross-off list with response code filed at the receiver. Cross-off lists of that kind can be updated by a firmware update at, for example, the time of maintenance.
[0030] In order to further increase the safety step the verification request is, with advantage, unique to each reset request. In this way it is ensured that the verification request is uniquely defined for each reset request.
[0031] For preference, exactly one target verification response is then associated with each verification request. In this case a uniquely defined combination of verification request and verification response or target verification response can be used for each reset request. It is thus ensured that previously employed verification requests or verification responses or, in a given case, corresponding enquiry codes or response codes cannot be present in the system, which could lead to erroneous or intentionally invalid verifications.
[0032] In variants it is obviously conceivable for, for example, always the same verification response to be employed and for a respective individual target verification response to be determined in dependence on other factors such as, for example, the current date and/or clock time.
[0033] Advantageously, the target verification response is generated by the safety system in accordance with a rule, particularly a coding, from the verification request. In this instance, the receiver transmitting the response code to the safety system has to use the same rule so as to generate the correct verification response, i.e. the verification response corresponding with the target verification response. The rule can comprise a simple set of rules which, for example, can be employed directly by a user. However, the rule can also comprise a complex coding which is, for example, implemented electronically.
[0034] Depending on the respective use it can be advantageous to generate the target verification response in the safety system from the verification request only after receipt of the verification response. This has the advantage that in the time period between transmission of the reset request and the verification response no target verification response, which could be read out and/or misdirected, is present in the safety system. Alternatively, the target verification response can be generated together with the verification request and filed in a memory of the safety system at least until transmission of the verification response.
[0035] The control system preferably comprises at least one of the following control units:
a locally fixed control unit, particularly an operating unit or a control unit of an elevator control, a mobile control unit which is connected or connectible with the safety system by way of the control system, wherein the control system preferably comprises a connection with an internal or external wire-free network by way of which the mobile control unit is connected or connectible.
[0038] In that case, advantageously
the verification request is transmitted from the safety system to the at least one control unit and the verification response is transmitted from the at least one control unit or from a further control unit of the control system to the safety system.
[0041] The locally fixed control unit can be an internal system of the elevator installation and a part of an elevator control such as, for example, a control unit. However, the locally fixed control unit can also comprise parts of an external system or be provided by an external system. For example, a maintenance system or maintenance center of the installation operator for, for example, several elevator installations is conceivable. If external systems are embraced, the at least one communications interface and/or the control system can comprise an interface for connection with an external network such as, for example, the Internet or a mobile radio network. Here, “locally fixed” designates both a stationary, i.e. non-moved, arrangement and a fixed arrangement at moved components of the elevator installation such as can be the case, for example, with an operating panel in an elevator car.
[0042] The locally fixed control unit can comprise means for automatically generating the verification response in response to transmission of a verification request and for transmitting it to the safety system. This can be advantageous with, for example, control units of the elevator control in order to be able to independently verify the reset request. The locally fixed control units can also comprise means for data exchange with a user and/or for connection of a release device (see below). The locally fixed control unit can comprise, for example, an operating unit arranged in an elevator car. The operating unit can, for example, be arranged as a maintenance unit behind a wall panel or a maintenance window. However, the operating unit can also comprise a freely accessible operating panel in the elevator car. In that case, for example, use can be made of a display, which is present in any case, for representation of the verification request, whilst buttons, which are present in any case, can serve for manual input of the verification response. In this way synergetic use can be made of components of the elevator installation which are present anyway.
[0043] The mobile control unit can, for example, be carried by a user and is constructed for connection with the safety system by way of the control system or by way of the at least one communications interface. For that purpose, the control system and/or the communications interface can comprise, for example, a connection to a wire-free internal network such as, for example, a WLAN network or an external network such as, for example, a mobile radio network. However, the mobile control unit can also be connected or connectible with the control system by way of a plug connection at an appropriately constructed interface (for example, by way of a further, locally fixed control unit). The mobile control unit can comprise means for data exchange with a user or for connection of a release device (see below). The mobile control unit can be, for example, diagnostic or maintenance apparatus of the elevator installation, a mobile telephone or a tablet computer (so-called “tabs” or “pads”).
[0044] The verification request is preferably transmitted from the safety system to the at least one control unit. The verification request can be read out thereat by, for example, a user or a release device connected with the at least one control unit. Transmission of the verification response to the safety system in that case does not necessarily have to take place from the same control unit insofar as the control system comprises more than one control unit. In particular, in this instance basically any combinations of the above-mentioned control units are conceivable in order to receive the verification request from the safety system by way of one of the control units and to transmit it to the safety system by way of a further control unit.
[0045] Advantageously, the at least one control unit comprises at least means for reading out the verification request and the control unit, from which the verification response is transmitted to the safety system, comprises at least means for input of the verification response. The verification request is in that case read out by way of the means for reading out and the verification response is input by way of the means for inputting. It will be obvious that in the case of only one control unit this can comprise not only the means for reading out, but also the means for inputting.
[0046] The means for reading-out of the verification request can then comprise a display for visual representation of the verification request, on which display, for example, the enquiry code can be indicated. The means for inputting can comprise a keypad, by way of which, for example, the response code can be manually input. In this case, the verification request can be read out by a user who generates the verification response and can be input by the user. It will be obvious that the verification response can in that case be generated by the user by way of, for example, an independent external apparatus through input of the verification request. The verification response can then be transferred manually from the external apparatus to the control unit from which the verification response is transmitted to the safety system.
[0047] However, the means for reading out can also comprise an interface by way of which the verification code can be read out by a release device connectible or connected with the interface. In this case, the interface can also provide the means for input of the verification response, which, for example, is automatically generated by the connected release device and transmitted to the safety system. For that purpose the release device comprises means for generating the verification response from the verification request, which can, for example, be implemented in terms of hardware or software in a circuit or a programmable computer unit. Release devices of that kind can comprise, for example, chipcards, dongles, USB sticks or other mobile devices, which can be connected with the interface.
[0048] Depending on the respective kind of control unit the at least one control unit can itself comprise means for generating a verification response from the verification request. These means can comprise, for example, a circuit in which, for example, a rule for generation of the verification response or a list of verification responses can be implemented in terms of hardware or software. For preference, in this case the verification response is automatically generated by the at least one control unit on receipt of the verification request and transmitted to the safety system. This is particularly advantageous if the control unit is a controlling unit which can verify the reset request without interaction with a user. The means for generating the verification response can, however, also advantageously be present in other locally fixed or mobile control units.
[0049] For safety it can additionally be provided that the transmission of the verification response has to be triggered by the user and the transmission can be triggered only by, for example, a key switch or an additional code enquiry. Equally, it is conceivable for the verification response to be produced from the verification request only as a result of an appropriate input.
[0050] Performance of the verification preferably has to take place within a predetermined time period in order to be evaluated by the safety system as valid. The time period can then be triggered by the reset request or only with the transmission of the verification request by the safety system. If the predetermined time period elapses without verification being concluded a new reset request is, as a rule, required. In this way the safety system is prevented from being in an undefined waiting state for a longer period of time.
[0051] The invention also relates to an elevator installation, particularly for carrying out a method according to the invention, comprising a safety system, which is resettable from an actual state, in particular from a state in which a normal operation of the elevator installation is not released, to a desired state, in particular a normal state in which a normal operation of the elevator installation is released by the safety system. In that case the safety system is connected by way of at least one communications interface for data exchange to a control system, which is associated with the elevator installation, but which, in particular, does not belong to the safety system. The elevator installation is distinguished by the fact that the safety system comprises means for receiving a reset request, which is transmitted from the control system, for resetting from the actual state to the desired state and means for carrying out verification of the reset request by way of the control system as well as means for evaluating validity of the verification. The safety system is in that case constructed in such a manner that it resets from the actual state to the desired state as a consequence of a verification evaluated as valid.
[0052] It is readily apparent that the construction of the elevator installation in accordance with the invention can be provided by, for example, appropriate programming of programmable control units of the safety system as well as the control system or the components thereof. In that case use can be made of components of the elevator installation which are present in any case, such as, for example, an operating panel in an elevator car, which is connected with the safety system by way of a conventional communications bus such as, for example, a CAN bus.
[0053] In that case, the means for carrying out the verification preferably comprise transfer means for transmission of a verification request to the control system and receiving means for receiving a verification response from the control system.
[0054] With advantage, the safety system comprises means for generation, in particular for random generation, of a verification request, particularly an enquiry code, and means for generation of a target verification response associated with the verification request, particularly a target response code associated with the enquiry code according to a rule or a list. In that case the means for evaluating validity of the verification are preferably constructed for the purpose of comparing a verification response, which is received from the control system, with the target verification response.
[0055] The control system associated with the elevator installation preferably comprises at least one, preferably several, of the following control units:
[0056] a locally fixed control unit, particularly an operating unit arranged in an elevator car or a control unit of an elevator control,
[0057] a mobile control unit, which is connected or connectible with the safety system by way of the control system, wherein the control system preferably comprises an internal wireless network or an interface for connection with an external wireless network by way of which the mobile control unit is connected or connectible.
[0058] Internal control units are part of an elevator installation, whereas external components of the control system are indeed associated with the elevator installation, but are not comprised therein.
[0059] The at least one control unit preferably comprises:
[0060] means for reading out the verification request, particularly an interface for connection of a further control unit or a mobile release device for reading out the verification response, or a display for visual representation of the verification request, and/or
[0061] means for input of the verification response, particularly an interface for connection of a further control unit or a mobile release device for input of the verification response or a keypad for manual input of the verification response, and/or
[0062] means for generating the verification response, particularly a circuit or a programmable computer unit.
[0063] Possible further required components or synergetic utilizations of already present components of an elevator installation according to the invention are readily apparent from the above description of the method according to the invention.
[0064] In addition, further advantageous forms of embodiment and feature combinations of the invention are evident from the following detailed description and the totality of the patent claims.
DESCRIPTION OF THE DRAWINGS
[0065] The drawings used for explanation of the embodiments schematically show:
[0066] FIG. 1 is a schematic diagram of a safety system and a control system of an elevator installation according to the invention;
[0067] FIG. 2 is a flow chart of a method according to the invention, in which a verification code with a reset request is received from the safety system; and
[0068] FIG. 3 is a flow chart of a method according to the invention, in which in response to a verification request a verification response is received from the safety system.
[0069] Basically, the same parts are provided in the figures with the same reference numerals.
DETAILED DESCRIPTION
[0070] FIG. 1 shows (indicated in dashed lines) an elevator shaft 2 of an elevator installation 1 . The elevator installation 1 comprises a safety system 10 with a central control unit 11 and a safety bus 12 . The control unit 11 can be constructed as a programmable computer unit or comprise a computer unit of that kind, whereby the functionality required for carrying out the method according to the invention (see FIGS. 2 and 3 ) can be provided by, for example, appropriate programming. The safety bus 12 can be implemented as, for example, a controller area network (CAN) bus. Different safety elements of the safety system 10 for monitoring the elevator installation 1 are connected with the safety bus 12 by way of bus junctions (not illustrated). In the present case, door sensors 14 for monitoring shaft doors 3 in the elevator shaft as well as an over-travel switch 16 are illustrated. It will be obvious that these safety elements have been selected purely by way of example and that in practice a plurality of further safety elements can be connected with the safety system 10 .
[0071] As an alternative to the safety bus 12 the safety elements such as door sensors 14 , over-travel switch 16 or further safety elements can be connected in series in a safety circuit. Here the safety circuit is connected with the control unit 11 . In the case of such a solution the safety elements are usually not individually monitored. The safety circuit indicates merely the state of all safety elements. If one safety element adopts an unsafe state, for example in the case of an open shaft door 3 , the safety circuit is interrupted and indicates an unsafe state of the elevator installation 1 .
[0072] The control unit 11 is connected with, for example, a drive 4 or a brake unit of the elevator installation 1 in order to interrupt travel operation. This can be the case if, for example, the safety system 10 passes to an emergency state as a consequence of a faulty function report of the safety elements or an interruption of the safety circuit. In the present instance the control unit 11 is connected with the drive 4 by way of a separate line 18 . The connection can, however, also be provided by way of the safety bus 12 .
[0073] The control unit 11 is connected by way of a communications interface 19 with a control system 20 , which is associated with the elevator installation 1 . The communications interface 19 can, analogously to the safety bus 12 , be implemented as a CAN bus. The control system 20 comprises parts of the elevator installation 1 , but can also comprise external components which are not to be ascribed to the elevator installation 1 . The control system 20 comprises various control units 21 , 22 , 23 , 28 which are connected directly or indirectly with the control unit 11 and thus with the safety system 10 by way of the communications interface 19 .
[0074] One of the control units is constructed as an operating unit 21 (indicated in dashed lines) fixedly arranged in an elevator car 9 . The operating unit 21 comprises a display 21 . 1 as well as a keypad 21 . 2 or, for example, a touchscreen for the reading-out or input of data by a user. The operating unit 21 can also comprise an interface 21 . 3 with which a portable device such as, for example, a dongle or a portable computer is connectible. The interface 21 . 3 can in that case be constructed for the input of data and/or reading-out of data from a connected device. In particular, the interface 21 . 3 can also be constructed as a card reader for a chipcard.
[0075] A further one of the illustrated control units is constructed as control unit 22 of an elevator control. This can be arranged at various locations in the elevator installation 1 such as, for example, in the elevator shaft 2 , in a maintenance area or also, for example, behind a wall panel in the elevator car 9 . The control unit 22 forms a controlling unit which is basically provided for automatic, i.e. carried out by the control unit 22 itself, verification in accordance with the invention. For that purpose the control unit can comprise an appropriate circuit which is provided or appropriately programmed for the verification. However, this does not exclude the possibility of the control unit 22 similarly comprising means for reading out and/or means for inputting as well as an interface (indicated in dashed lines).
[0076] A further one of the illustrated control units is constructed as a mobile control unit 23 . This can be, for example, a portable computer, special maintenance apparatus or a mobile telephone. The mobile control unit 23 can be carried by a user. The control system 20 can comprise an internal wireless network 24 connected with the communications interface 19 and, by way of this, with the safety system 10 . The mobile control unit 23 is, in the case of appropriate construction with wireless communication means, connected or connectible with the safety system 10 by way of the wireless network 24 . The mobile control unit 23 can, however, alternatively or additionally also comprise a terminal 23 . 1 by which it is connected or connectible with the communications interface 19 via the interface 213 or via an appropriate interface in the control system 20 .
[0077] The control system 20 can additionally comprise an interface 25 for an external network. By way of the interface 25 the control system can be connected with, for example, a cable-supported external network 26 such as the Internet. The interface 25 can also provide a connection to an external wireless network such as, for example, a mobile radio network 27 . It will be obvious that the external network can also be special networks which are provided by the installation operator for, for example, remote maintenance of the elevator installation 1 . For example, an external maintenance center 28 can be connected with the interface 25 by way of the cable-supported external network 26 . In this case the maintenance center 28 (as well as the external network) forms a component of the control system 20 , which does not belong to the elevator installation 1 , thus is an external component.
[0078] The external wireless network 27 can be used for connection of the mobile control unit 23 . By way of example, if the mobile control unit 23 is, for example, a mobile telephone this can be connected with the interface 25 by way of the mobile radio network 27 . The mobile radio network 27 and the mobile telephone 23 in this case form external components of the control system 20 .
[0079] FIG. 2 shows a flow chart 50 for carrying out a first variant of the method according to the invention in the safety system 10 as well as in the control system 20 . At the start point 51 the safety system 10 is in an actual state. In a first step 52 the safety system 10 receives a reset request, which is transmitted to the safety system 10 by way of or from an internal or external control unit 21 , 22 , 23 , 28 of the control system 20 in a request step 53 . The reset request is in that case composed of a first data sub-set, by which the reset request from the safety system 10 is identifiable as such. A verification code can be included in a further data sub-set, which code is, for example, newly generated for each reset request in a generating step 58 by a system or a user. It will be obvious that the verification code, depending on the respective safety requirement, has to be suitable for enabling reliable verification of the reset request. For this purpose the verification code can, for example, be extracted from a predetermined list (cross-off list) or be generated by an independent device in a time-synchronous time window with a target verification code in the safety system 10 . The verification code can also include an authentication of the system or the user.
[0080] In a first verification step 54 the verification code is extracted by the safety system 10 from the reset request. In a second verification step 56 the extracted verification code is compared with a target verification code. The target verification code can in that case be generated in a generation step 55 a during performance of the first verification step 54 by the safety system 10 . Alternatively, the target verification step can already be generated during the step 52 on receipt of the reset request (step 55 b ). The generation of the target verification code can then be carried out analogously to generation of the verification code.
[0081] If it is established in the second verification step 56 that the extracted verification code agrees with the target verification code the verification is evaluated as valid. The safety system 10 consequently resets, insofar as the desired state is evaluated as safe, to the desired state (step 57 ). If verification code and target verification code do not agree, the reset request is verified as non-valid. The safety system 10 consequently remains in the actual state 51 . An alarm can optionally be triggered in the case of an invalid verification, which alarm indicates the non-verified reset request and thus potential faulty functioning or faulty processing with the reset request.
[0082] FIG. 3 shows a further flow chart 60 for carrying out a second variant of the method according to the invention in the safety system 10 as well as in the control system 20 . At the start point 61 the safety system 10 is in an actual state. In a first step 62 the safety system 10 receives a reset request, which is transmitted to the safety system 10 by way of or from an internal or external control unit 21 , 22 , 23 , 28 of the control system 20 in an interrogation step 63 . The reset request can in this case comprise only a single data set, which the reset request alone identifies as such. Obviously, additional data can also be transferred such as, for example, an identification of the control unit from which the reset request was transmitted.
[0083] In response to receipt 62 of the reset request from the control system 20 the safety system 10 generates the verification request, for example an enquiry code, in a generation step 64 . Simultaneously with the generation step, a further generation step 65 a can be performed, by which a target response code, which belongs to the enquiry code, is generated as target verification response and stored in the safety system. Enquiry code and target response code can in that case be uniquely associated with one another. After generation 64 of the enquiry code this is transmitted in a transmission step 66 from the safety system 10 to the control system 20 and received therein (step 67 ). The enquiry code can then be selectively transmitted to a specific control unit 21 , 22 , 23 , 28 of the control system 20 . This does not have to be identical with a control unit 21 , 22 , 23 , 28 from which the reset request was transmitted to the safety system 10 .
[0084] In response to receipt 67 of the enquiry code a response code as a verification response is generated in the control system 20 (step 68 ). This can be carried out automatically by a circuit or an appropriately programmed computer unit of the corresponding control unit 21 , 22 , 23 , 28 . Alternatively, for that purpose, for example, an independent release device (not illustrated) can be connected by a user to the corresponding control unit by way of, for example, the interface 21 . 3 . In a further variant the enquiry code is, for example, visually represented at the control unit 21 , 22 , 23 , 28 , insofar as this is appropriately constructed. The enquiry code can in this case be read out by a user in order to generate the response code (step 68 ). For that purpose the user can employ a rule for generation of the response code, which the user knows, or for example use an independent device which, on input of the enquiry code, is constructed for generation of the response code.
[0085] The response code is transmitted from the control system 20 to the safety system in a transmission step 69 . The control unit 21 , 22 , 23 , 28 used in that case does not need to be identical with the control unit 21 , 22 , 23 , 28 from which the reset request was transmitted and also not with the control unit 21 , 22 , 23 , 28 to which the enquiry code was transmitted.
[0086] The response code can be received in the safety system 10 in a receiving step 70 . As an alternative to the generation step 65 a the target response code can be generated only in a generation step 65 b on receipt 70 of the response code.
[0087] The received response code is compared in a comparison step 71 with the target response code. If it is established in the comparison step 71 that the response code agrees with the target response code the verification is evaluated as valid. The safety system 10 as a consequence resets, insofar as the desired state is evaluated as safe, to the desired state (step 72 ). Otherwise, the reset request is verified as non-valid. The safety system 10 consequently remains in the actual state 61 .
[0088] Further advantageous variants for performance of verification of the method according to the invention are readily evident to the expert.
[0089] In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.
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A method for resetting a safety system of an elevator installation from an actual state, in which a normal operation of the elevator installation is not released, to a desired state, in which a normal operation of the elevator installation is released by the safety system includes the steps of: receiving a reset request, which is transmitted from the elevator control system, for resetting from the actual state to the desired state, in the safety system; carrying out verification of the reset request by the safety system; evaluating the verification by the safety system; and resetting the safety system from the actual state to the desired state if the verification by the safety system is evaluated as valid.
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BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to an improved distributed capture system. Specifically, the invention relates to a system and method for distributing to a plurality of remote sites non-uniform rules related to the indexing or transfer of documents scanned at such remote sites.
[0003] 2. Description of Related Art
[0004] Many businesses are faced with the obstacle of how to transmit data and documents from remote locations to a centralized location. For example, larger banks typically gather many types of documents at their branch banks, such as checking account, mortgage, and car loan applications, and forward such documents to the bank's centralized location for processing and approval. Traditionally, such documents were mailed from the remote locations, such as bank branches, to the centralized location. There are a number of disadvantages to this traditional process; the most significant disadvantage is the delay associated with mailing.
[0005] Recently, businesses have begun using distributed capture systems to transmit documentation gathered at remote locations to the centralized location. An exemplary distributed capture system is depicted in FIG. 1 . Distributed capture system 110 includes central server(s) 115 that communicates with multiple remote locations 125 , 135 and 145 via a network 120 and/or the Internet. Each remote location includes a computer with a display device, such as CRT monitor or an LCD screen, a data entry device, such as a keyboard, and has access to network 120 and/or the Internet. Hard copies of documents are scanned into the computer to form a document image by way of document scanners 130 , 140 and 150 . Of course, each remote location may have multiple scanning stations and multiple document scanners. Scanned documents are transmitted from remote locations 125 , 135 and 145 to central server(s) 115 via the Internet 120 . Using such a distributed capture system, documents can be transmitted from remote locations to a central repository much more quickly-in a matter of seconds or minutes via upload to a server rather than as long as days through the mail.
SUMMARY OF THE INVENTION
[0006] The present invention relates to an improved distributed captures system capable of distributing to a plurality of remote sites non-uniform rules, such as rules governing the indexing or transfer of documents scanned at such remote sites. Documents are captured at remote locations by scanning and indexing such documents. Captured documents are transferred to a central location, where they are stored on a centralized image repository.
[0007] The invention allows for documents to be indexed differently at each remote location. Other aspects of the distributed capture system also may be managed differently at each remote site. For example, remote locations may be directed to periodically contact the central location for the purpose of transferring newly captured documents to the central location. Remote locations may be directed to perform this task at different times. Also, remote locations may be directed to retain captured documents at the remote location for a period of time following transfer of said captured documents to the central location. Remote locations may be directed to retain documents for different periods of time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
[0009] FIG. 1 is a block diagram of a distributed capture system constructed in accordance with an exemplary embodiment of the present invention.
[0010] FIG. 2 is a block diagram illustrating the primary components of an exemplary distributed capture system for the distributed capture system illustrated in FIG. 1 .
[0011] FIG. 3 is a logical flowchart diagram illustrating a method for capturing documents in accordance with an exemplary embodiment of the present invention.
[0012] FIG. 4 is an exemplary display screen for the web-based scan interface described in FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
[0013] The innovative distributed capture system will now be discussed with reference to FIGS. 2 through 4 .
[0014] FIG. 2 . A depiction of an embodiment of the distributed capture system of the present invention 200 is in FIG. 2 .
[0015] Remote location 205 is the site at which documents are collected for transmittal to central location 250 . For instance, remote location 205 might be a bank branch. Remote location 205 includes document scanner 215 , or some other means for creating a digital image out of documents collected at remote location 205 . Connected to document scanner 215 is computer workstation 210 , which includes a display device, such as CRT monitor or an LCD screen, a data entry device, such as a keyboard, and has access to the Internet.
[0016] Documents are scanned using document scanner 215 and indexed using web-based scan interface 220 running on computer workstation 210 . One of ordinary skill in the art will appreciate that the document scanner may be a multi-function device, as opposed to a dedicated document scanner. Web-based scan interface 220 is run by computer workstation 210 by accessing Internet information server 257 by way of the Internet.
[0017] “Batches” consist of one or more scanned documents. Batches that have been indexed are said to have been “captured.”
[0018] Batches are indexed according to “rules” set at central location 250 by web based administration interface 252 . Such rules, distributed by central location 250 to remote location 205 , essentially govern the manner in which the document capture process at remote location 205 proceeds. In the case of indexing, rules are established to govern how web-based scan interface 220 identifies or describes batches. Thus, for each document scanned by document scanner 215 , the user should be required to at least identify the batch content type, the transfer destination, and route distribution.
[0019] Batch content type essentially answers the question, “What type of document is it?” For each batch content type there may be any number of custom fields identifying such information as the loan number, social-security number, and the like. Of course, the custom fields will be tailored for each different batch content type. Therefore, each different batch content type may have different custom fields.
[0020] Transfer destination answers the question, “Where should the batch be sent?” In most instances, the proper transfer destination is “import,” that is the batch should be imported to central location 250 . Alternatively, a batch may not need to be transferred to central location 250 but maintained at remote location 205 or transferred to another central or regional location or some other location, in which case the user would so specify.
[0021] Route distribution refers to what to do with the batch when it arrives at central location 250 . The distributed capture system may be designed so that a batch is directed to the attention of a specific individual, group, unit, division or the like at central location 250 upon transfer of said document into central image repository 270 . For example, a closing file scanned at a remote bank branch may need to be routed to the bank headquarters file audit section at central location 250 . The distributed capture system obviously may also be designed so that a particular type of batch arriving at central location 250 may be viewed by anyone with authority or permission to see such documents.
[0022] During indexing, a prioritization for the document being captured may also be established. For example, central location 250 may desire to prioritize the transfer of batches from remote location 205 to make important documents available on central image repository 270 more quickly. This could be accomplished by having central location 250 automatically establish the priority of a batch based on the batch content type, such as automatically setting a priority of “1” or “highest” for all loan closing documents or a priority of “5” of “lowest” for all change of address forms. Central location 250 may also allow a user(s) at remote location 205 to override the automatically selected priority. Of course, central location 250 may prefer to have remote location 205 independently select a priority for a given batch based on the circumstances.
[0023] Documents scanned by document scanner 215 but for which indexing has not been completed may be stored in suspend folder 225 . Indexing of such batches may be completed later using web based scan interface 220 . Until indexing is completed, such documents are stored in suspend folder 225 .
[0024] Indexed batches are transferred to capture folder 230 , where they remain at least until the process of transferring said documents to central location 250 begins. Preferably, the batches also are retained at the remote location so that, for instance, the remote location can easily access documentation that was generated by it.
[0025] Discovery service 235 discovers whether there are any new batches in capture folder 230 whose transfer destination is central location 250 ; that is to say, batches that have not already been transferred to transfer working folder 240 but that must be. Discovery service 235 may identify new batches in capture folder 230 by querying capture folder 230 for the existence of trigger files. If discovery service 235 thereby discovers new batches in capture folder 230 , it moves such new batches to transfer working folder 240 and directs them to be processed by transfer service 245 . Discovery service 235 then creates a record in remote database 237 of which batches were transferred to transfer working folder 240 .
[0026] Transfer service 245 queries remote database 237 to determine whether any new batches have been transferred to transfer working folder 240 . If there are such new batches, then transfer service 245 directs said batches in transfer working folder 240 to be transferred to import working folder 260 located at central location 250 . Batches should be transferred to important working folder 260 in order of priority, from highest priority to lowest. A rule may be established by central location 250 or remote location 205 to direct transfer service 245 to perform this task at set times, such as every ten minutes or once per day at a specific time. Of course, the times at which this task is performed might also be established as a default setting when distributed capture system 200 is originally configured. Obviously, distributed capture system 200 can be designed so that transfer service 245 may also be activated sporadically as needed by authorized users at central location 250 and/or remote location 205 . Also, as noted above, the distributed capture system may be designed so that batches are retained in transfer working folder 240 for zero to n days after transfer service 245 moves said batches to import working folder 260 .
[0027] After batches are transferred to import working folder 260 , import service 265 directs said batches to be transferred to central image repository 270 , which also could be located at central location 250 . Import service 265 then creates a record in central database 263 of which batches were transferred from import working folder 260 . As noted earlier, distributed capture system 200 can be designed so that batches in central image repository 270 are made available on an unlimited or limited basis to central location 250 and/or remote location 205 .
[0028] Sync service 233 performs multiple functions. Firstly, sync service 233 performs the data synchronization between remote database 237 at remote location 205 and central database 263 at central location 250 . Such data synchronization may be useful for many reasons.
[0029] Sync service 233 also is the mechanism through which remote location 205 and central location 250 communicate to transmit and set new “rules” for central location 205 , if any. As stated above, rules are distributed by central location 250 to remote location 205 and essentially are the operating instructions for remote location 205 to follow in capturing documents.
[0030] Indexing rules were described in detail above. Sync service 233 enables central location 250 to communicate new indexing rules or changes in existing indexing rules to remote location 205 . For instance, remote location 205 may begin processing a new batch content type, in which case central location 250 will need to transmit and set the rules, including custom fields, for said new batch content type. Or, central location 250 may want to make changes to the rules governing an existing batch content type already being processed at remote location 205 , such as by adding or removing custom fields. Thus, central location 250 may adapt the rules governing the indexing of scanned documents to account for changing operating conditions at remote location 205 .
[0031] Of course, remote location 250 may set rules other than indexing rules. For instance, central location 250 may configure distributed capture system 200 such that remote location 205 contacts central location 250 periodically, such as every thirty minutes, to upload new batches whose transfer destination is central location 250 . Or, remote location 205 may be directed by central location 250 to retain batches in transfer working folder 240 for zero to n days following transfer of such batches to import working folder 260 at remote location 250 . One of ordinary skill in the art will appreciate that it may be beneficial for central location 250 to set numerous other rules to govern operation of remote location 205 .
[0032] Configuration of distributed capture system 200 , including but not limited to the rules settings, is managed by web based administration interface 252 at central location 250 . The existing configuration of distributed capture system 200 is stored on central database 263 . Whenever changes to the configuration are desired, web based administration interface 252 has internet information server 257 pull the existing configuration from central database 263 . Web based administration interface 252 then makes the desired changes to the configuration. Next, internet information server 257 transmits the new configuration back to central database 263 , where said new configuration is stored. The new configuration is communicated to remote location 205 through sync server at central location 250 to sync service 233 at remote location 205 .
[0033] FIG. 3 . A logical flowchart diagram is presented to illustrate the general tasks conducted by the distributed capture system of FIG. 2 . A method 300 begins at START step 305 and proceeds to step 310 , in which a web-based scan interface 220 is initiated on computer 210 at remote location 205 .
[0034] In step 315 , the user enters a username in the web-based scan interface 220 . Based on the determination that the user is an authorized user, the process of capturing documents begins. In step 320 , the user scans the batch that is going to be captured.
[0035] In step 325 , the user identifies the transfer destination of the batch, i.e. where is batch going.
[0036] In step 330 , the user identifies the batch content type of the batch. In other words, the user identifies what documents constitute the batch. In the banking context, the batch content type might be a car loan application, mortgage loan application, mortgage loan closing papers, etc. It should be appreciated that a virtually limitless number of custom fields, but preferably 20-30, may be associated with each batch. For example, the user may be required to identify for each batch, the loan number, the social security number, the date of execution, etc.
[0037] In step 335 , the user identifies the route distribution of the batch, i.e., what to do with the batch when it arrives at the central location 250 .
[0038] In step 337 , the user identifies the transfer priority of the batch.
[0039] In the event that the batch content type, transfer destination, route destination and transfer priority are not identified in steps 325 , 330 , 335 and 337 , the “NO” branch is followed to step 345 and the incomplete batch is stored in suspend folder 225 . If no additional documents are to be added to the batch, another “NO” branch is followed and the user completes the batch identification in steps 325 , 330 , 335 and 337 at a later time. If additional documents are to be added to the batch, the “YES” branch is followed to step 320 instead.
[0040] If the batch content type, transfer destination, route destination and transfer priority are identified in steps 325 , 330 , 335 and 337 , the “YES” branch is followed to step 350 and the batch is transferred to the capture folder 230 .
[0041] In step 355 , discovery service 235 detects whether there are any new batches in capture folder 230 whose transfer destination is central location 250 . If so, in step 360 , discovery service 235 transfers the new batches to transfer working folder 240 and proceeds to step 365 , in which an inquiry is conducted to determine whether the new batches can be transferred to central location 250 . If the response to this inquiry is negative, the “NO” branch is followed to step 370 and the new batches are stored in transfer working folder 240 at least until transfer of such new batches to the central location 250 can take place. Otherwise, the “YES” branch is followed from step 365 to 375 .
[0042] In step 375 , transfer service 245 transfers the new batches to import folder 260 at central location 250 . Of course, said batches are transferred in order of priority, from highest priority to lowest priority. Then, in step 380 , import service 265 transfers the new batches to central image repository 270 . The process 300 is terminated at the END step 385 .
[0043] FIG. 4 . Web-based scan interface 220 includes a file transfer monitor, visible on the display device of computer workstation 210 , similar to that depicted in FIG. 4 . File transfer monitor 400 is a depiction of the type of file transfer monitor that might be designed for use by a bank branch.
[0044] Batch ID 405 is a unique identifier associated with each separate batch. In one embodiment, a batch ID 405 is assigned. For example, it might consist of a site identifier, followed by the four-digit year, the two-digit month, the two-digit day of the month and a four-digit number representing sequentially what batch number for that day the batch represents. Thus, the fourth batch described in file transfer monitor 400 was the eleventh batch created on Sep. 27, 2004 at site “1”.
[0045] User name 410 represents the identity of the individual that used web-based scan interface 220 to capture that particular batch.
[0046] In the transfer status 415 column, the interface states whether transfer of a batch from transfer working folder 240 at remote location 205 to import working folder 260 at central location 250 has been completed. Transfer priority 420 references what transfer prioritization has been assigned to a batch. The transfer destination 430 column identifies where the batch is to be transferred. In the depicted column, all of the batches are to be imported to central location 250 .
[0047] Content type 435 is a general description of the batch content type for a batch. Loan number 425 is an example of a custom field for each of the depicted content types. “Route to” 440 is the route distribution as described in greater detail above. In the case of the batches portrayed in file transfer monitor 400 , wherein the remote location is a bank branch, the route distribution is the file audit section of the bank headquarters.
[0048] In the present embodiment, scan start time 445 and scan complete time 450 refer, respectively, to the time at which the process of scanning the documents comprising the batch begins and the time at which indexing of said documents is completed. A batch for which indexing has not been completed might not have an entry for scan complete time 450 .
[0049] FIGS. 5A and 5B . A depiction of an alternative distributed capture system 500 in which documents may be captured at remote and central locations is in FIG. 5A and FIG. 5B .
[0050] FIG. 5A . Remote location 501 is a site at which documents are collected for transmittal to central location 540 . As in the embodiment described with reference to FIG. 2 , remote location 501 might be a bank branch.
[0051] Remote location 501 includes remote site capture station 508 . Remote site capture station 508 has document scanner 503 , or some other means for creating digital images out of documents collected at remote location 501 . Batches are indexed at remote site capture station 508 using capture application 509 . Batches are indexed as in the embodiment described with reference to FIG. 2 . Batches captured at remote site capture station 508 are stored in site batch store 511 on site/store server 506 .
[0052] Capture application 509 may be implemented through user interface website 514 on site/store server 506 at remote location 501 or through user interface website 555 on web server 548 at central or regional location 540 or on a web server at another central or regional location. Regardless of whether capture application 509 is implemented at remote location 501 or central or regional location 540 , capture application 509 may take advantage of scan extender web service 584 and scan extenders 587 . Scan extender web service 584 and scan extenders 587 basically are part of an interface for validating batch data. During indexing of documents, batch data, such as the loan number associated with the scanned documents, is received by scan extender web service 584 . Scan extenders 587 then queries central database 592 to validate said batch data and/or to receive other data associated with said batch data. Distributed capture system 500 clearly can be designed so that scan extenders 587 query any external database or business logic. If said batch data is invalid, an error message may be displayed on capture application 509 . If said batch data is valid and there is other data associated with said batch data, such other data may then be transmitted by scan extender web service 584 to remote location 501 to be used in capture application 509 . For example, the user may enter the loan number associated with a document being indexed at remote site capture station 508 . Through scan extender web service 584 and scan extenders 587 , central database 592 may then be queried to determine whether said loan number exists on central database 592 and to provide any other information related to said loan number, including but not limited to the name, address, and telephone number associated with the loan number. That other information may then be transmitted to remote location 501 and automatically become populated, that is pre-filled, in capture application 509 . One advantage of this process is that it helps reduce the amount of time users take to index scanned documents.
[0053] Each batch transferred from remote site capture station 508 to site batch store 511 preferably comprises two related files. Firstly, there is an image file associated with the batch. The image file is simply the digital image of the scanned documents. The image file commonly is a TIFF or JPEG file. Secondly, there is a trigger file associated with each batch. The trigger file contains non-image related data associated with that particular batch. For instance, it would include the data that was associated with a batch during the indexing process. Preferably, the trigger file is an XML file.
[0054] Remote location 501 also may include an external device 505 , such as a fax machine. Documents that are received at remote location 501 by external device 505 are initially stored in external device folder 507 . Batch discovery service 517 discovers new batches in external device folder 507 and transfers said new batches to site batch store 511 .
[0055] Like batches created at remote site capture station 508 , batches in external device folder 507 preferably comprise an image file and trigger file. In the case of files in external device folder 507 , however, the trigger file may not be in a desirable or as useful format. If so, external device extenders 523 may be used to create a more desirable or useful trigger file. When a new trigger file is created, it replaces the old trigger file. Thus, only the new trigger file is transferred as part of the batch by batch discovery service 517 to site batch store 511 .
[0056] Batch discovery service 517 also is involved in the process of tracking new batches in site batch store 511 . Whenever batch discovery service 517 moves batches from external device folder 507 to site batch store 511 , it creates a record in site tracking database 526 of the existence of a new batch in site batch store 511 . Batch discovery service 517 also monitors site batch store 511 for trigger files received in site batch store 511 from capture application 509 and creates a record in site tracking database 526 of the existence of new batches received from remote site capture station 508 .
[0057] Transfer service 520 queries site tracking database 526 to determine whether there are any new batches in site batch store 511 . If there are such new batches, then transfer service 520 transfers said batches to central or regional location 540 . Such transfer is preferably made via HyperText Transfer Protocol or HyperText Transfer Protocol Secure, but it also may be made via File Transfer Protocol or other method. After transfer from remote location 501 to central or regional location 540 is completed, transfer service creates a record in site tracking database 526 of which batches were transferred.
[0058] FIG. 5B . Batches transferred to central or regional location 540 are first received by transfer web service 570 . Transfer web service 570 preferably places batches received from remote location 501 directly in central batch store 567 . If for some reason it is unable to do so, such batches are simply moved into transfer destination folder 564 on import/consolidation server 550 .
[0059] Batch discovery service 573 monitors transfer destination folder 564 for trigger files. Batch discovery service 573 receives trigger files first, which instruct batch discovery service 573 to move the trigger file's associated batch from transfer destination folder 564 . Whenever batch discovery service 573 thereby discovers newly transferred batches in transfer destination folder 564 , it transfers said newly transferred batches to central batch store 567 , which also resides on import/consolidation server 550 .
[0060] Central or regional location 540 also may include a capture station similar to remote site capture station 508 at remote location 501 . Central site capture station 546 has document scanner 542 , or some other means for creating digital images out of documents collected at remote location central or regional location 540 . Documents are indexed at central site capture station 546 using capture application 558 . Documents are indexed as in the embodiment described with reference to FIG. 2 . Documents captured at central site capture station 546 are stored in central batch store 567 on import/consolidation server 550 .
[0061] Capture application 558 should be implemented through user interface web site 555 on web server 548 at central or regional location 540 . Scan extender web service 584 and scan extenders 587 perform the same function for capture application 558 as they do for capture application 509 , which was described above.
[0062] Central or regional location 540 also may include an external device 544 , such as a fax machine. Documents that are received at remote location 540 by external device 544 are initially stored in external device folder 561 . Batch discovery service 573 discovers new batches in external device folder 561 and transfers said new batches to central batch store 567 . External device extenders 573 process batches in external device folder 561 like external device extenders 523 process batches in external device folder 507 . Batch discovery service
[0063] Like batch discovery service 517 at remote location 501 , batch discovery service 573 also is involved in the process of tracking new batches in central batch store 567 . Whenever batch discovery service 573 moves batches from external device folder 561 to central batch store 567 , it creates a record in central database 592 of the existence of a new batch in central batch store 567 . Batch discovery service 573 also monitors central batch store 567 for trigger files received in central batch store 567 from capture application 558 or directly from transfer web service 570 and creates a record in central database 592 of the existence of new batches received from central site capture station 546 or directly from transfer web service 570 .
[0064] New batches in central batch store 567 are transferred to image repository 595 by import service 578 . Import service 578 monitors central database 592 to determine whether there are any new batches in central batch store 567 . If there are such new batches, then import connectors directs import service 578 to transfer said batches to image repository 595 , which resides on enterprise servers 590 . Note that there may be more than one image repository and that import connectors will direct batches to the appropriate image repository.
[0065] Distributed capture system 500 also includes a feature for effectuating configuration changes. Sync web service 581 , which resides on sync server 552 , queries central database 592 for any changes to configuration of distributed capture system 500 that need to be communicated to remote location 501 . If there are such changes, sync web service 581 communicates said changes to sync service 529 on site/store server 506 at remote location 501 . Sync service 529 then transmits said changes to site tracking database 526 . Site tracking database 526 may effect changes to the configuration of remote location 501 , including changes that need to be made to user interface site 514 , as needed. Distributed capture system 500 configuration changes that should be made to user interface site 555 are communicated directly between central database 592 and user interface site 555 .
[0066] It should be appreciated that distributed capture systems may include multiple remote locations and multiple central or regional locations. Also, any given remote location may communicate with any number of central or regional locations. Moreover, distributed capture system may include the capability for authenticating users of the distributed capture system and documents captured by the distributed capture system. Of course, the description of the present invention has been presented for purposes of illustration and description, but is not to be assumed to be exhaustive, nor is the invention intended to be limited to the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
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The present invention relates to an improved distributed captures system capable of distributing to a plurality of remote sites non-uniform rules, such as rules governing the indexing or transfer of documents scanned at such remote sites. Documents are captured at remote locations by scanning and indexing such documents using a web-based scan interface. Captured documents are transferred to a central location, where they are stored on a centralized image repository. The invention allows for documents to be indexed differently at each remote location. Other aspects of the distributed capture system also may be managed differently at each remote site.
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BACKGROUND OF THE INVENTION
This invention relates to needle threaders and, in particular, to pneumatic needle threading assists.
Noting how tedious threading of a sewing needle may be, there are many needle threading assists available for aiding the operator in performing this function. Of these types, pneumatic needle threading assists use air pressure (or vacuum) to urge the thread end through the needle eye. With respect to the vacuum type, the thread, upon passing through the needle eye, travels up through the vacuum line. This allows lint to accumulate in the line and also in the vacuum source which may cause failure of the same.
SUMMARY OF THE INVENTION
The object of this invention is to provide a vacuum type needle threading assist which minimizes the accumulation of lint and bits of thread in the vacuum line and the vacuum source.
This object is achieved in a pneumatic needle threading assist having means for receiving a sewing needle into the needle threading assist, means for guiding the end of a thread supply to the needle eye, means for supplying an air vacuum to the needle threading assist for urging the end of the thread supply through the needle eye, and means for collecting a quantity of the thread supply therein having passed through the needle eye, in advance of the air vacuum supplying means, whereby the thread will not collect in the vacuum supplying means.
DESCRIPTION OF THE DRAWINGS
With the above and additional objects and advantages in mind as will hereinafter appear, the invention will be described with reference to the drawings of a preferred embodiment in which:
FIG. 1 is a perspective view of the invention being used to thread a sewing machine needle;
FIG. 2 is a rear elevational view of the invention;
FIG. 3 is a side elevational view of the invention; and
FIG. 4 is a cross-sectional view of the invention taken along the line 4--4 of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A sewing machine is partially illustrated in FIG. 1 and includes a bed 10 and a sewing head 12. A needle bar 14 is carried within the sewing head 12 and is arranged therein for reciprocatory motion. A sewing needle 16, having a thread receiving eye 18 formed therein, is clamped to an end of the needle bar 14 by a needle clamp 20. A first thread 22 is shown attached to the sewing head 12 with a screw 24 and a second thread guide 26 is shown attached to the needle bar 14 adjacent the needle clamp 20 with a screw 28. The thread guides 22 and 24 guide thread T from a thread supply (not shown) to the eye 18 of the needle 16.
A downwardly biased presser bar 30 is also carried in the sewing head 12 and has a presser foot 32 attached to an end thereof with a screw clamp 34. The presser bar 30 and the presser foot 32 urge a material M being sewn into engagement with a feed mechanism (not shown) carried within the sewing machine bed 10.
In FIG. 1, a pneumatic needle threading assist 40 is shown in threading engagement with the needle 16. As clearly shown in FIG. 2, 3 and 4 needle threading assist 40 includes an "L" shaped housing 42 having a first section 44 and a second section 46, joined at one end thereof, to one end of the first section 44 and having the axis thereof perpendicular to the axis of the first section 42. A conical thread guiding aperture 48 is axially formed in the first section 44 and tapers inwardly toward the second section 46 of the housing 42. A needle receiving slot 50 is formed in the first section 44 adjacent the second section 46 in a plane substantially normal to the axis of the first section 44. The needle slot 50 intersects the conical aperture, effectively terminating the conical aperture 48, and is formed with a lead in taper 52 to aid in the insertion of the sewing needle 16. At the intersection of the conical aperture 48 and the needle slot 50, the size of the conical aperture 48 is substantially the same as the size of the needle eye 18. A groove 54 is formed in the first section 44 of the housing 42 parallel to the axis thereof and intersects the conical aperture 48 along the entire length thereof, the purpose for which will be explained later.
The second section 46 is formed with a thread orifice 56 which intersects the needle slot 50. The orifice 56 is coaxial with the conical aperture 48 in the first section 44 and has a size substantially the same as the conical aperture 48 at the intersection thereof with the needle slot 50. The second section 46 is further formed with a cylindrical thread chamber 58 extending through the free end thereof having an axis substantially parallel to the axis of the second section 46. The orifice 56 extends inwardly to intersect the chamber 58 tangentially. A bleeder orifice 60, having a diameter substantially smaller than the thread orifice 56, is formed in the second section 46 and extends from the bottom of the thread chamber 58 through the housing second section 46 along an axis substantially parallel to the axis of the second section 46.
A rod 62 is provided for introducing an air vacuum to the needle threading assist 40. To this end, the rod 62 is formed with an axial aperture 64 therethrough. At one end 66 of the rod 62, the aperture 64 is conically formed with an opening substantially the same as the diameter of the thread chamber 58. The rod 62, which also has an overall diameter the same as the diameter of the thread chamber 58 is fitted within the end of the thread chamber 58 and is secured to the second section 46 of the housing 42 by any suitable means such as brazing. A vacuum hose 68 is attached to the exposed end of the rod 62 and terminates at a vacuum source (not shown).
In operation, the needle threading assist 40 is brought to the sewing needle 16 such that the needle receiving slot 50 embraces the needle 16 and the conical aperture 48 is manually aligned with the needle eye 18. The vacuum source is then activated causing air to be drawn through the needle eye. Thread T is then inserted into the conical aperture 48, as shown in FIG. 1, and is allowed to be drawn through the needle eye, through the thread orifice 56 and into the thread chamber 58. Due to the tangential intersection of the thread orifice 56 with the thread chamber 58, the thread T is caused to swirl within the thread chamber 58 (see FIG. 4). Air entering through the bleeder orifice 60 urges the entering thread T upwardly allowing a significant quantity of the thread T to enter and spirally collect in the thread chamber 58. At this point, the vacuum source is deactivated and the needle threading assist 40 is removed from the needle 16 and placed in an area remote to the sewing area, such as a retainer clip (not shown) mounted on the sewing head 12. The groove 54 in the first section 44 of the housing 42 allows the thread T to be removed from the conical aperture 48 without unthreading the needle eye 18.
Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to a preferred embodiment of the invention which is for purposes of illustrations only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.
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A pneumatic needle threading assist is disclosed which has a thread collecting chamber in which, due to the air flow therethrough, thread having passed through the eye of a sewing needle, is therein deposited in a series of spiral loops limiting the amount of thread in the vacuum line and preventing the vacuum source from being contaminated with the thread.
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The invention relates to detecting the phase of coherent light by interferometric procedures using a planar array of charge transfer devices (CTDs) constructed on a substrate for converting optical holograms to electrical signals and, more particularly, to performing preliminary processing of the detection measurements in the charge domain in a new way in electronic circuitry constructed on the same substrate as the planar array of CTDs.
BACKGROUND OF THE INVENTION
The inventors have been involved in the development of a detector for measuring the phase modulation of a hologram image. The hologram images are sensed by a solid state imager, which converts the hologram images to electronic data. The interferometer being developed promises to improve the sensitivity of the phase modulation measurement of optical wavefronts by 10 to 20 dB over prior art techniques. To realize this improvement, new light sensing and signal processing approaches have had to be followed that allow hologram images to be processed at high resolution and speed, i.e., 1000×1000 pixels at a 100 kHz frame-rate.
In an optical interferometer using a solid state imager to sense holograms, successive frames of pixels are correlated on a pixel-by-pixel basis to determine phase changes in the light illuminating that particular pixel, and the individual correlation results are then summed. In the summation process phase change information is correlated and thus sums in a scalar addition process, while noise is substantially uncorrelated and thus sums in a vector addition process. Consequently, in the summation result signal-to-noise ratio is improved by a factor nominally equal to the square root of the number of pixels being summed. The summation may be part of an averaging wherein the summation is subsequently divided by the number of samples that were summed.
U.S. Pat. No. 4,780,605 issued Oct. 25, 1988 to J. J. Tiemann, entitled "COHERENT LIGHT PHASE DETECTING FOCAL PLANE CHARGE-TRANSFER-DEVICE", assigned to General Electric Company and incorporated herein by reference describes detecting the phase of coherent light by interferometric procedures using a solid-state imager that has a planar array of charge-transfer devices (CTDs) constructed on a substrate of semiconductive material. The planar array senses the interference or "fringe" pattern between a coherent optical carrier and an optical signal generated through phase-modulation of a coherent optical carrier of similar frequency, but not necessarily the same phase. This pattern is a hologram. Each CTD in the focal-plane array has a first charge storage region associated therewith for storing charge generated by a reference-phase coherent optical carrier and has a second charge storage region for storing charge generated by an oppositely phased coherent optical carrier of the same wavelength. The stored charges stored in the first and second charge storage regions are differentially sensed to remove direct-current pedestal from the in-phase signals commutated from the solid-state imager. Each CTD has a third charge storage region associated therewith for storing charge generated by a quadrature-leading-phase coherent optical carrier and has a fourth charge storage region for storing charge generated by a quadrature-lagging-phase coherent optical carrier of the same wavelength. The stored charges stored in the third and fourth charge storage regions are differentially sensed to remove direct-current pedestal from the quadrature signals commutated from the solid-state imager. Utilizing scanning generators located on the imager substrate, the picture elements (or "pixels") are successively scanned to provide both a time-division-multiplexed in-phase output signal and a time-division-multiplexed quadrature output signal from the imager. Reading out in-phase and quadrature signals from the same pixels concurrently eliminates the need for long-time individual sample storage. The in-phase and quadrature signals for each pixel are processed in accordance with trigonometric algorithms to obtain hologram pixel phase variations. The hologram pixel phase variations are summed in a correlation procedure to increase the signal-to-noise ratio of the optical phase detection results. In a variant of the U.S. Pat. No. 4,780,605 apparatus charges are stored for only one phase of reference coherent optical carrier and for only one phase of quadrature coherent optical carrier and direct components are suppressed by resampling procedures. A practical difficulty encountered with implementing the U.S. Pat. No. 4,780,605 interferometer or variants thereof is the need for accurately matching the amplitudes of the various-phase pulses of coherent light used for charging respective ones of the pair of charge storage regions associated with each CTD.
J. Chovan, W. E. Engeler, W. Penn and J. J. Tiemann in allowed U.S. patent application Ser. No. 338,881 filed Apr. 17, 1989, entitled "ELECTRONIC HOLOGRAPHIC APPARATUS", assigned to General Electric Company and incorporated herein by reference describe interferometers in which a single pulse of coherent light is used for generating both in-phase and quadrature signals for each pixel. To do this the spatial frequency of the pixels as defined by the spacing of the CTDs in parallel rows normal to the fringe pattern is arranged to be four times the spatial frequency of the fringe pattern. Utilizing scanning generators located on the imager substrate, the in-phase and quadrature-phase responses of successively scanned pixels are extracted on a time-division-multiplexed basis to be separated by comb filtering procedures taking place mostly outside the solid state imager.
To meet the requirements of the new optical interferometer small phase-shifts in a hologram image must be detected and processed at extremely high rates. Currently, solid-state imagers are viewed providing the best electronic cameras for real-time hologram image detection. However, system throughput would be limited by the relatively slow rate at which data can be read-out from existing solid-state imagers in which pixel locations are successively scanned.
A solid-state imager of the most usual type reads out individual picture-element (or "pixel") information on a time-division-multiplexed basis through a single output port. The maximum read-out rate on an output port is typically 20M pixels/sec, which limits the imager frame rate (the rate at which all the imager pixels can be read-out) to 20 Hz for a 1000×1000 pixel imager with a single output port.
The inventors knew at the time of their respective inventive contributions of a newer type of optical interferometer using a plane array of CTDs constructed on a substrate of semiconductive material, developed by J. Chovan, a coworker of theirs. With the Chovan type of optical interferometer, the spatial frequency of the pixels as defined by the spacing of the CTDs in parallel rows normal to the fringe pattern is arranged to be only two times the spatial frequency of the fringe pattern, and accommodations for variations in laser pulse amplitudes can be made. Considering the successive fields of pixels generated by the array of CTDs to be consecutively numbered modulo two, the odd-numbered fields of pixels are generated by the fringe pattern between the optical signal and an in-phase coherent optical carrier, and the even-numbered fields of pixels are generated by the fringe pattern between the optical signal and a quadrature coherent optical carrier. The computation of phase variations can be done on the basis of successive overlapping frames identified by respective ones of consecutive ordinal numbers, each odd-numbered frame consisting of an odd-field image succeeded by an even-field image, each even-numbered frame consisting of an even-field image succeeded by an odd-field image, and each frame overlapping its preceding and succeeding frames each by one field. The direct-current pedestal is removed from each field of pixels by performing a subtraction between each pair of pixels that abut each other in the direction normal to the fringe pattern, resampling the fields without DC terms and with the same degrees of attendant phase shift. The resultant in-phase and quadrature-phase field images without direct-current pedestals are correlated in an initial correlation procedure, by multiplying together correspondingly located pixels in each pair of successive fields in a frame, to generate a new succession of image frames, each consisting of but a single field. In this new succession of image frames, pixel values vary in response both to the phase-modulation of the optical signal and the amplitude of the coherent optical signal and the coherent optical carriers used to form the hologram in the focal plane. The variation of pixel values with the product-of-amplitudes term is removed in an amplitude-normalization procedure, using information concerning the amplitudes of the direct-current pedestals removed from the original in-phase and quadrature-phase field images. Amplitude normalization is done either before or after a final correlation procedure in which the pixel values of each of the image frames in the new succession are summed together, which final correlation procedure is done to increase the signal-to-noise ratio of the optical phase detection results.
Before Chovan's newer type of optical interferometer was invented, frame-rates above 10 kHz had only been achieved in optical interferometers using solid-state imagers by:
(a) limiting the pixel resolution, (e.g., using 128×1 pixel line arrays) and/or
(b) providing multiple parallel read-out ports from the imager. For the optical interferometers the inventors and their co-workers including Chovan have been called upon to develop, even multi-port imagers are unfeasible. To read out a 1000×1000 pixel imager at a 100 kHz frame-rate, 5000 ports running at 2×10 4 pixels/sec would be required. Wiring these ports from the imager and providing the digital hardware to support 5000 high-speed processing channels is too costly in terms of size, power, and packaging complexity.
Chovan in developing his new type of optical interferometer had discerned that if pixel-by-pixel correlation procedures can be done parallelly within the solid state imager, rather than sequentially outside the imager, and if the subsequent summation procedure can then be done within the imager as well, then the number of samples of output signal from the imager can be reduced by a factor equal to the number of photosensors in the imager. That is, by a factor of a million for a 1000×1000-pixel imager. Furthermore, the parallel processing of photosensor data avoids the need for pixel-scanning generators, which generators and connections from them to individual photosensors take up considerable area on the substrates of prior-art solid state imagers.
Some practical difficulties have been encountered in developing Chovan's new type of optical interferometer. It has been difficult to find a good design for analog multipliers that permits them to be constructed on the imager substrate and integrated with respective photosensors. The amplitude normalization procedure to remove dependency of phase response to the amplitudes of the illuminating and reference beams is cumbersome.
The invention concerns an optical interferometer that does parallel processing of pixel data within the solid state imager. Processing of the in-phase and quadrature-phase images with direct-current pedestals removed is done differently than in the Chovan imager, so as to avoid actually having to multiply correspondingly located pixels in each pair of successive fields together. This better facilitates the pixel processing being done in the charge domain in circuitry constructed on the same substrate as the planar array of CTDs.
SUMMARY OF THE INVENTION
Respective processors for pairs of photodetecting elements are included in an imager, embodying an aspect of the invention, which is particularly suited for sensing hologram fringe patterns in an optical interferometer. These processors remove the direct-current pedestal from in-phase and quadrature-phase field images, then perform partial correlations of the resulting field images on a pixel-by-pixel basis, and then sum the partial correlations to complete the image correlation process and to provide imager output signal or the basis therefor. This localized processing greatly reduces the number of samples that have to be brought out of the imager each frame when the imager is used in an optical interferometer to detect phase modulation in an optical signal, allowing for increased frame rates in accordance with a further aspect of the invention. Image correlation is done according to a novel algorithm that avoids actually having to multiply together correspondingly located pixels in each pair of successive fields forming a successive non-overlapping frame. The multiplier-free processors are compact enough to be located within the solid state imager close to the pairs of photosensors they respectively serve in the imager.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of an apparatus for measuring phase changes in the hologram of an object field.
FIG. 2 is a diagram relating picture element ("pixel") indexing to the hologram fringe patterns during odd and even fields.
FIG. 3 is a diagram illustrating how phase-rate vectors are determined in optical interferometers constructed in accordance with the invention.
FIG. 4 is a schematic diagram of one of the respective on-substrate interpixel processors as serves each successive non-overlapping pair of photosensors in the row of a solid state imager that is an embodiment of the invention in one of its aspects.
FIG. 5 is a schematic diagram showing off-imager-substrate phase calculation circuitry for use with a solid state imager using interpixel processors as shown in FIG. 4.
FIG. 6 is an assembly drawing showing how FIGS. 6A, 6B, 6C and 6D of the drawing are assembled to provide a representative timing diagram for the FIG. 1 apparatus for measuring phase changes in the hologram of an object field, when the FIG. 1 apparatus includes a solid state imager having on-substrate processors as shown in FIG. 4 and uses off-substrate phase calculation circuitry as shown in FIG. 5. This timing diagram in its entirety is referred to as the FIG. 6 timing diagram in the remainder of this specification.
FIG. 7 comprises FIGS. 7A, 7B and 7C which diagram the flows of charge into and out of a magnitude capacitor to the top plate of which connects the interpixel bus in the FIG. 2 interpixel processor.
FIG. 8 comprises FIGS. 8A, 8B and 8C which are charge flow diagrams of how, during processing in the FIG. 4 interpixel processor, charge is transferred away from charge storage locations to which the interpixel bus connects, transferring therefrom to other charge storage locations.
FIG. 9 comprises FIGS. 9A, 9B and 9C which are charge flow diagrams of how, during processing in the FIG. 4 interpixel processor, charge is transferred to charge storage locations to which the interpixel bus connects, transferring thereto from other charge storage locations.
FIG. 10 is a wiring diagram for the FIG. 4 interpixel processor, giving an idea of the layout of the processor on the imager substrate.
FIG. 11 shows the way in which pixel subsampling by FIG. 4 interpixel processors, as fitted between non-overlapping pairs of photosensors in a solid state imager constructed per an aspect of the invention, is preferably staggered in spatial phasing from row to row of the photosensing sites.
FIG. 12 shows a conceptual diagram of the layout of modified FIG. 4 interpixel processors on the substrate of another solid state imager constructed per an aspect of the invention, which modified interpixel processors fit between each overlapping pair of photosensors in rows of photosensing sites that need not have staggered spatial phasing.
FIG. 13 is an assembly drawing showing how FIGS. 13A, 13B, 13C, 13D, 13E, 13F, 13G and 13H of the drawing are assembled to provide a representative timing diagram for the FIG. 1 apparatus for measuring phase changes in the hologram of an object field when that apparatus includes a solid state imager having on-substrate processors as shown in FIG. 12 and uses off-substrate phase calculation circuitry as shown in FIG. 5. This timing diagram in its entirety is referred to as the FIG. 13 timing diagram in the remainder of this specification. The waveforms in the FIG. 6 and FIG. 13 timing diagrams assume the designer's choice is to use N-channel devices throughout the on-substrate processors, rather than using all or some P-channel devices.
DETAILED DESCRIPTION
FIG. 1 is a perspective view of an apparatus for measuring phase changes in the hologram of an object field. This apparatus, which can be considered to be a type of optical interferometer, uses optical processing similar to that shown in U.S. patent application Ser. No. 338,881 filed Apr. 17, 1989 and entitled "ELECTRONIC HOLOGRAPHIC APPARATUS", except for being modified to include a Bragg cell 28 placed for modulating the phase of a coherent light wavefront used as a reference beam in the optical mixing process. The Bragg cell 28 is a device responding to an electrical control signal to selectively retard the wavefront of the light passing therethrough by an extra quarter wavelength for alternate image fields.
(An alternative modification would be to place the Bragg cell 28 for modulating the phase of a coherent light wavefront used as an illuminating beam in the optical mixing process, instead of for modulating the phase of a coherent light wavefront used as a reference beam in the optical mixing process. FIG. 1 shows a suitable location for the Bragg cell in this alternative modification of the U.S. patent application Ser. No. 338,881 apparatus.)
The FIG. 1 apparatus comprises means for producing mutually coherent optical illuminating and reference beams, and a Charge Transfer Device (CTD) camera 15 having an aperture directed toward the object field to receive reflections of the illuminating beam therefrom, arranged to receive the reference beam as well, and suitably aligned with respect to the beams and object field to record holographic data. The camera 15, which operates without a conventional focusing lens, samples the illumination impinging on photosensors disposed on the sensor plane, the illumination passing through an optical aperture of sufficient size to resolve individual elements of the object field to be used in sensing displacements of the object field. The illumination impinging on the sensor plane is a hologram that may be characterized as a Fresnel/Fourier transform of the light reflected from the illuminated object. This transform is often referred to as an "optical fringe pattern", or simply "fringe pattern", since it is a grating pattern of alternating brightness and darkness.
The CTD camera 15, like the U.S. patent application Ser. No. 338,881 camera includes a solid state imager of a type having a bulk substrate of a semiconductor material of a first conductivity type; an epitaxial layer of a second conductivity type disposed on a first surface of the bulk substrate, said second conductivity type being opposite to said first conductivity type; a layer of electrically insulating material having a first surface disposed against the epitaxial layer and having a second surface; electrodes of electrically conductive material disposed within the layer of electrically insulating material, the electrodes being essentially planar and parallel to the first surface of the bulk substrate; means for making electrical connections to the electrodes via paths of electrically conductive material disposed within the layer of electrically insulating material; a layer of optically opaque mask material disposed against the first surface of the layer of electrically insulating material and provided with windows therethrough arranged at regular intervals in parallel rows evenly spaced apart, the layer of electrically insulating material being thin enough in the vicinity of the windows for light to pass therethrough; and a plurality of photosensors disposed in a sensor plane along the first surface of the bulk substrate, in spatial registration with the windows in the opaque mask, for generating respective electrical responses to impinging light. The epitaxial layer is connected to electrical ground, and the bulk substrate is biased to reverse bias the semiconductor junction between it and the epitaxial layer disposed on its first surface. The camera 15 differs from the U.S. patent application Ser. No. 338,881 camera in that the windows in the opaque mask adjacent to each other in a row have a pixel index, or spacing between their centers, that corresponds to one-half, rather one-quarter, the wavelength of the hologram fringe pattern.
The camera 15 also differs from the U.S. patent application Ser. No. 338,881 camera in that the charge packets accumulated by the photosensors are not remotely sensed serially by column and by row, but rather are locally sensed, in parallel. Accordingly, the solid state imager used in camera 15 does not include scanners for serially sensing the charge packets accumulated by the photosensors. The sensing results are locally processed within the solid state imager to generate processor results that are parallelly summed to generate imager output signal. The camera electronics 30 used with the camera 15 and described in detail further on also differs from the camera electronics of prior-art holographic cameras.
As shown in FIG. 1, the illuminating and reference beams originate from a single laser 10, the beam from the laser impinging on a beam splitter 11 which diverts a portion of the laser energy into a separate path for the reference beam. The portion of the laser beam which is not diverted is supplied to the illuminating beam optics 12 where the laser beam is expanded to illuminate the object field 13. Thus, coherent light reflected from the object field enters the aperture 14 of the CTD camera 15, and creates a speckle pattern over the sensor plane 16 of the camera. The portion of the laser energy which is diverted at the beam splitter 11, traverses a Bragg cell 28, the time delay optics 17, a mirror 18, reference beam shaping optics 19 and a mirror 20. The mirror 20 projects the reference beam back via the aperture 14 to the sensor plane 16 of the camera. The function of the illuminating beam shaping optics is to illuminate that portion of the object field viewed by the camera. The function of the reference beam shaping optics 19 is to illuminate the sensor plane which provides a means for obtaining the phase information for the hologram. The Bragg cell 28 responds to an electrical control signal that alternates in value from field to field to change by a quarter wavelength the phase relationship of the illuminating and reference beams from field to field, resulting in a 90 degree shift in the spatial frequency of the fringe pattern generated on the sensor plane of the solid state imager in the camera 15. Successive fields are considered to be consecutively ordinally numbered modulo two, the first fields being termed odd fields and the zeroeth fields being termed even fields. An odd field and its following even field will be considered to constitute a respective odd-numbered frame in a succession of overlapping frames identified by respective ones of consecutive ordinal numbers assigned in order of the occurence of the frames. An even field and its following odd field will be considered to constitute a respective even-numbered frame in that succession of overlapping frames. As will be explained, the optics 19 is designed to place the virtual source of the reference beam at the same distance (Z coordinate) from the sensor plane as the center of the object field.
In the FIG. 1 illustration, the optical paths of both the illuminating and reference beams originate at the laser 10 and both terminate on the sensor plane of the camera. If the path lengths of the two beams are sufficiently equalized, both beams will reach the sensor plane at the same time on the average during odd fields and with a quarter wavelength displacement on average during even fields. Any laser instability will exhibit itself in equal degrees in both the illuminating and reference beams, thus preserving fractional optical wavelength accuracy in the holographic information read out at the sensor plane. The time delay optics 17 provides the means to equalize the path lengths of the two beams during odd fields. Differences in the path lengths of the two beams from the laser 10 to the sensor plane 16 will always exist if the object field is of extended depth (in the Z axis direction). Greater differences between the two path lengths may be tolerated, however, as the coherence length of the laser is increased. Therefore, the more stable the laser, the greater the tolerable differences in path lengths, and the greater the depth of field, before instability in the measurements becomes significant.
The reference beam provides the means for obtaining the phase information for the hologram. As the reference beam impinges on the speckle pattern already present on the sensor plane of the camera, due to the illuminating beam, a spatially periodic interference pattern, which may be termed a "grated speckle pattern" is created. The interference pattern with its successive light and dark regions allows appropriately placed sensors which sense only the intensity of the light to determine both in-phase components of its amplitude and quadrature components of its amplitude, from which the phase of the illuminating beam relative to the reference beam may be calculated. The phase is, of course, measured with respect to the phase of the reference beam.
The recording of holographic information gains greatly in accuracy of amplitude and phase measurement and in overall sensitivity if the spatial relationships illustrated in FIG. 1 are maintained. The illumination, the source of the reference beam, and the location of the object field establish a three-axis coordinate system, with which the angular aperture and sensor plane of the camera 15 must be brought into alignment for optimum phase and amplitude fidelity and for maximum sensitivity. Proper positioning of the reference source, object field and camera establishes the position, orientation and spatial frequency of the fringes, and in the preferred disposition, makes the spatial frequency of the fringes substantially constant over the camera aperture. Proper orientation of the sensor plane of the camera in relation to the fringes, and proper magnification of fringes in relation to the interval between sensors on the sensor plane further facilitates accuracy in detecting the holographic information. These matters will now be discussed in detail.
Referring again to FIG. 1, the camera is ideally positioned to place the center 21 of the object in a line perpendicular to the sensor plane erected from the center 22 of its aperture. Thus the origin of a three-axis coordinate system is the center of the sensor plane, the Z axis being the line perpendicular to the sensor plane passing through the center 21 of the object. The X and Y axes lie in the sensor plane, but their orientation remains undetermined until the position of the reference beam is fixed.
The reference beam shaping optics 19 are adjusted to place the position of the virtual source of the reference beam at the point 23. The virtual source 23 of the reference beam is small in relation to the object field, and may be treated as a point source. The interference fringes produced by the reference illumination and the illuminated object field are perpendicular on the average to the plane defined by the points 21, 22 and 23. On the other hand only light originating along the line of intersection of the plane 21, 22, 23 with the object field will produce fringes exactly perpendicular to that plane. Exactness is not required to achieve accurate results over a reasonable field of view. Thus, to sample the spatial frequency of the fringes generated from all points of the object field, the photosensors should be arranged in rows parallel to the plane (21, 22, 23). The intersection of this plane (21, 22, 23) with the sensor plane thus defines the X axis, and by inference the position of the Y axis, which is defined to be perpendicular to both the X axis and the Z axis. The columns of sensors are parallel to the Y axis. The rows of sensors, which are used for determining the spatial phase of the fringes are thus parallel to the X axis.
Further, the virtual reference source is preferably disposed at the same Z coordinate distance from the origin as the center of the object field. This has the advantage of reducing parallax from different view points within the receive aperture as to the same object point and tends to make the fringe spacing more uniform. With uniformity in the fringe spacing, constancy of the spatial sampling rate becomes more efficient. As noted previously, the pixel index in the solid state imager used in camera 15 is to be one-half the wavelength of the fringe pattern.
Continuing, the spatial angular spectrum depends upon the angle between the point of origin 23 of the reference beam and the resolution points in the object field. The number of fringes per speckle is controlled by the angle, and the average size of speckles is selected so there is at least a full wave of brightness variation in the spectrum, in order to permit detection of the spatial phase of the speckle. When the object field is in the far field of the receive aperture, the angle between a given point in the object field and the normal to the plane of the receive aperture (i.e., the Z axis) has the same value θ for all viewpoints within the receive aperture. Under these conditions, a collimated reference beam appearing to come from the far field is desirable. However, when the object field is in the near field of the receive aperture, a fixed point 27 in the object field appears at different angles as seen from different points within the aperture. Under these conditions, the superposition of a collimated reference beam at a fixed angle results in an interference pattern whose fringe spacing varies considerably with position in the aperture. A large variation in the fringe spacing results in inefficient sampling of the pattern. The condition can be mitigated by placing the point 23 of the reference beam at nominally the same Z coordinate distance as the center of the object field. Under these conditions there is no parallax between points in the object field and the reference point. This results in the angle between the reference point and any fixed point in the object field being nominally the same value θ for all viewpoints within the receive aperture and leads to uniformity in the fringes spacing and efficiency in sampling those fringes at a constant spatial sampling rate. When the angle between the reference point and any fixed point in the object field is nominally the same value θ for all viewpoints within the receive aperture, then θ can be arranged so that the fringe pattern wavelength is twice the pixel index, as required in the FIG. 1 apparatus.
Camera electronics 30 includes a timing generator 31 that transmits a number of control signals via a multiple-wire cable 32 to the camera 15 to be broadcast to each of the processors associated with a respective photosensor in the solid state imager, as will be described in detail further on. The timing generator 31 also generates pulses indicative of the beginning of each imager field.
The pulses indicative of the beginning of each imager field supplied by the timing generator 31 are counted modulo two by a field counter 33 to determine whether each successive field is odd or even. Field counter 33 may simply comprise a triggered or "T" flip-flop, for example, and feeds back the field count to timing generator 31. Odd fields are determined by a one count from field counter 33; and even fields, by a zero count. The zero count from field counter 33 conditions Bragg cell 28 to retard the phase of the reference beam an additional 90 degrees.
Camera electronics 30 also includes phase calculation circuitry 35 that responds to analog output currents to generate digital output signals descriptive of the phase differences in the illuminating and reference beams of light impinging on the sensor plane of the solid state imager in the camera 15. The nature of the phase calculation circuitry 35 will be more specifically described further on, when FIG. 5 is considered.
Certain optical processing systems require the high speed tracking of a hologram fringe pattern which moves in the X direction in the sensor plane of the solid-state camera 15. Since it is the target motion which creates the fringe pattern motion, the fringe tracking signal obtained from the system corresponds to the motion of the target. It is desired to detect and track motion of this fringe pattern even when the return light from the target is weak. Under this condition, the fringe pattern modulation amplitude is small and rides of top of a large direct current pedestal. The motion of this fringe pattern may also be corrupted by noise sources which become uncorrelated when observed a speckle distance apart in the focal plane. To increase the system signal-to-noise ratio, measurements of fringe motion are made over a large area are averaged, so an imager having a large number of pixels is required. The target may also be moving at high rates, so imager fields rates in excess of 100 Khz may be required.
To track the fringe pattern motion using correlation processing, an image is generated with the reference beam phase at 0 degrees. To remove the DC pedestal from the fringe pattern, pixel subtraction is performed between adjacent pixels along the direction of the fringe pattern. This information is stored, and a second image is generated with the reference beam phase changed by a quarter wavelength, to 90 degrees. The pixel subtraction is again performed, the two resultant images are now multiplied pixel by pixel, and the results summed. If no object motion occurred during the imager exposures, the fringe patterns will be exactly 90 degrees apart, and the resultant sum will be approximately zero. However, any fringe motion which occurred between fields will product a net sum which corresponds to the fringe motion.
FIG. 2 may help the reader to visualize the odd-field hologram fringe pattern R and even-field hologram fringe pattern S as measured in a direction parallel to the X axis of the sensor plane of the camera 15 in FIG. 1, which fringe patterns obtain when no object motion occurred between fields R and S. Distances in the direction parallel to the X axis may be expressed in terms of a pixel index value p that is chosen to be at 180-degree intervals in the hologram fringe patterns. Note the 90 degree spatial phase retardation of the even-field hologram fringe pattern S compared to the odd-field hologram fringe pattern R, which arises from the reference beam being retarded an additional quarter wavelength during even fields.
The fringe patterns in two fields R and S which together comprise a frame can be represented simply as a sine wave signal oriented along an imager now if the DC pedestal is removed, as may be done by subtractively combining successive pixels in a resampling procedure.
Image R=sin (ωX) (Eq. 1)
Image S=sin (ωX+φ+90)=cos (ωX+φ) (Eq. 2) ##EQU1## where: ω=fringe frequence
φ=degree of fringe motion between frames
X=position along the imager row
The first term in Eq. 3 will sum to a small high frequency error which can be filtered out. The second term becomes the fringe tracking signal, which is a measure of the phase shift in the reflected illuminating beam as measured against the reference beam.
The algorithm described above requires pixel subtraction, image storage, image multiplication, and data summation. Implementation of these functions in the charge domain has been demonstrated using CID imagers except the four quadrant multiply. This function is inherently difficult to implement in the charge domain because the charge collected in an imager is one polarity, either electrons or holes.
To implement the correlation processing scheme in the charge domain on the same substrate as the imager, the correlation processing algorithm is rewritten as shown in the following equation.
∫R×S=1/4∫(R+S).sup.2 -1/4∫(R-S).sup.2 (Eq. 4)
By evaluating the right side of (Eq. 4), the equivalent frame multiplication can be implemented with additions, subtractions and a square law function. Since we know of no precise square law function in the charge domain, the magnitude function (absolute value) is used as an approximation. To remove the DC pedestal adjacent pixels along an imager row can be differentially combined as an initial part of the processing, much as in the prior-art electronic holographic cameras.
The expression to the right of the equal sign in (Eq. 4) is a distributive function inasfar as individual pixels are concerned. If a charge domain processor is provided for each pixel in an imager, the ith pixel on a row calculates the following two expressions.
|(R.sub.p -R.sub.q)+(S.sub.p -S.sub.q)| (Exp. 1)
|(R.sub.p -R.sub.q)-(S.sub.p -S.sub.q)| (Exp. 2)
where:
R=imager signal from a row, 0 degrees laser phase;
S=imager signal from a row, 90 degrees laser phase;
p=pixel index along a row; and
q=p+1.
The results of an expression calculation from each processor in the imager are summed on a common node which provides the only output from the imager. The summation of the Exp. 1 terms for the pairs of adjacent pixels minus the summation of the Exp 2 terms for those pairs of adjacent pixels completes the distributed calculation of Eq. 4 as shown below. ##EQU2## The subtraction of the summation terms could be performed digitally off-chip at relatively slow data rates.
The measure of phase change obtained by the foregoing procedure needs to be normalized for the variations of the illuminating beam (and of the reference beam where such variations can exist). This normalization can be made based from DC pedestal measurements, for example, but is unwieldy to implement. Where only the variation in phase of the hologram is sought, a more powerful interpretation of the terms ##EQU3## to be computed (in large part) on the imager, the inventors find, is to consider them to be the in-phase and quadrature components (real and imaginary) of the phase-rate vector of the hologram. Consider why this may be done.
Referring to Eq. 5 suppose the fringe patterns are sinusoidal with the fields R and S respectively defined as in Eq. 6 and in Eq. 7 following:
Image R=M sin (ωX) (Eq. 6)
Image S=M sin (ωX+φ+Δ) (Eq. 7)
where
M is the light intensity of the fringes and
Δ is the reference beam shift between frames.
Substituting Eq. 6 and Eq. 7 into Eq. 5, the following equation results. ##EQU4## Expanding Eq. 8 using the trigonometric identities
sin A+sin B=2 cos [(A-B)/2] sin [(A+B)/2]
and
sin A-sin B=2 sin [(A-B)/2] cos [(A+B)/2],
and factoring out M, the following equation is obtained ##EQU5## If |φ|<Δ/2, then cos [(φ/2)+(Δ/2)] is always positive and sin [-(φ/2)-Δ/2)] is always negative. The cos [(φ/2)+(Δ/2)] and sin [-(φ/2)-(Δ/2)] terms accordingly can be factored out of the bracketed terms and the summations to generate the following equation ##EQU6##
Note that the summation expressions are just the sum of a rectified sine wave and the sum of a rectified cosine wave, respectively. If the number of fringe cycles over the imager is larger the results of the summation will be approximately the same, a constant Γ called the "carrier" estimate. This is because any error owing to the imager not summing over an integral number of cycles of fringe pattern will be negligibly small compared to the entire summation result. Eq. 10 can be rewritten substituting Γ for each of the summation results to obtain the following equation.
∫R×S=Γ{cos [(φ/2)+(Δ/2)]-sin [(φ/2)+(Δ/2)]} (Eq. 11)
Note that Exp. 3 has been shown to yield a cos [(φ/2)+(Δ/2)] term scaled by a factor Γ and Exp. 4 has been shown to yield a sin [(φ/2)+(Δ/2)] term scaled by the same factor Γ. One can view the Exp. 3 and Exp. 4, then, as the in-phase and quadrature components of the phase rate of the hologram.
FIG. 3 diagrams this relationship. If the reference beam is shifted 90 degrees between fields as disclosed above, the difference between the angle of this vector and one-half the reference beam phase shift (45 degrees) is the phase-shift of the hologram fringe pattern between imager exposures. To compute the phase-shift, the better expression is therefore the one following. ##EQU7## The expression above is the preferred one to calculate, since it compensates for changes in the magnitude of the phase-rate vector simply. As will be described in detail further on, the computation of the above expression is done in the phase calculation circuitry 34 of camera electronics 30, rather than in the solid state imager within camera 15.
FIG. 4 shows a respective multiplier-free processor 40 associated with a pair of photosensors 36 and 37 sequentially located in one row of the multiple-row solid state imager of the electronic camera 15 of FIG. 1. Processor 40 includes first through fourth charge injection devices (CIDs) 41-44; an interpixel bus 45; a reset transistor 46 for periodically DC-restoring the interpixel bus 45; a magnitude capacitor having one of its plates in the reverse-biased bulk substrate, and having electrode 47 as another plate; a barrier electrode 48 for contolling the flow of charge from the magnitude capacitor; and a portion 49 of a summation drain to which there is the controlled flow of charge from the magnitude capacitor with electrode 47 as top plate. Respective busses for VG, C1, C2, C3, C4, IVD, IVG, SCROD, SCREV, XOD, XEV and DCSET voltages connect from the timing generator 31 in camera electronics 30 to respective substrate interface connections to be distributed by on-substrate busing to each multiplier-free processor, including processor 40, on the solid state imager substrate. The summation drain disposed in the epitaxial layer on the imager substrate collects charge drained from the respective magnitude capacitors of each multiplier-free processor, including processor 40, on the imager substrate. The summed charge provides the imager output signal or, alternatively, the basis for the imager output signal. The imager output signal may be an analog voltage measuring the integral of the summed charge drawn from the sum drain as generated by a Miller integrator in one such alternative, for example, or may be a digital output signal measuring the integral of the summed charge drawn from the sum drain as generated by an analog-to-digital converter.
Photosensors 36, 37 etc. are in locations (as indicated by the areas enclosed by dashed line) on a planar surface of the substrate of semiconductive material which are beneath windows transparent to light in an opaque mask layer overlying the rest of that substrate, including the portions of that substrate into which the processors 40 etc. are integrated. The photosensors 36, 37 etc. may simply be MOS capacitors, or may be photodiodes, or may be composite structures each combining at one situs an MOS capacitor with a photodiode. Photosensors 36 and 37 can be considered as being MOS capacitors that have the substrate as respective first plates and that have as respective second plates electrodes 38 and 39 each connected to a bus that supplies a bias voltage VG.
The first CID 41 in processor 40 has a charge-sensing electrode 51 connecting to the electrode 47 of the magnitude capacitor via interpixel bus 45, a transfer gate electrode 55 that maintains a barrier potential to prevent charge transfer between wells under electrodes 38 and 51 except at the beginning of odd fields, a control electrode 61 for controlling the direction of charge flow to or from under the charge-sensing electrode 51 during odd-field computation, and a screen electrode 65 for preventing the transients of the C1 clock signal applied to the control electrode 61 coupling to the electrode 51 and thence to the interpixel bus 45. The second CID 42 in processor 40 has a charge-sensing electrode 52 connecting to the electrode 47 of the magnitude capacitor via interpixel bus 45, a transfer gate electrode 56 that maintains a barrier potential to prevent charge transfer between wells under electrodes 38 and 52 except at the beginning of even fields, a control electrode 62 for controlling the direction of charge flow to or from under the charge-sensing electrode 52 during even-field computation, and a screen electrode 66 for preventing the transients of the C2 clock signal applied to the control electrode 62 coupling to the electrode 52 and thence to the interpixel bus 45. The third CID 43 in processor 40 has a charge-sensing electrode 53 connecting to the electrode 47 of the magnitude capacitor via interpixel bus 45, a transfer gate electrode 57 that maintains a barrier potential to prevent charge transfer between wells under electrodes 39 and 53 except at the beginning of odd fields, a control electrode 63 for controlling the direction of charge flow to or from under the charge-sensing electrode 53 during odd-field computation, and a screen electrode 67 for preventing the transients of the C3 clock signal applied to the control electrode 63 coupling to the electrode 53 and thence to the interpixel bus 45. The fourth CID 44 in processor 40 has a charge-sensing electrode 54 connecting to the electrode 47 of the magnitude capacitor via interpixel bus 45, a transfer gate electrode 58 that maintains a barrier potential to prevent charge transfer between wells under electrodes 39 and 52 except at the beginning of even fields, a control electrode 64 for controlling the direction of charge flow to or from under the charge-sensing electrode 54 during even-field computation, and a screen electrode 68 for preventing the transients of the C4 clock signal applied to the control electrode 64 coupling to the electrode 54 and thence to the interpixel bus 45.
FIG. 5 shows a solid state imager 70 of a type employing multiplier-free processors (e.g., like 40) to generate the half-wave-rectified SUMDRAIN output currents supplied to the phase calculation circuitry 35 assumed to be located externally to imager 70. A Miller integrator 71 in circuitry 35 receives half-wave-rectified SUMDRAIN output currents from imager 70. The Miller integrator 71 includes an operational amplifier 72 having an inverting input connection from the input connection of the Miller integrator 71 and having an output connection to the output connection of the Miller integrator 71. The Miller integrator 71 includes a Miller-feedback capacitor 73 connecting from the output connection of the operational amplifier 72 to its inverting input connection. The non-inverting input connection of operational amplifier 72 receives a FILL & SPILL voltage from the timing generator 31. The FILL & SPILL voltage is normally at the enable potential, but has periodic negative pulses to implement the fill portion of a fill and spill process involving the magnitude capacitors in the processors 40 etc. During intersample periods when these these negative pulses occur, the Miller-feedback capacitor 73 is selectively shunted by an MOSFET 74 conducting in response to an INTEGRATE RESET pulse applied to its gate electrode. This shunting of the capacitor 73 arranges for resetting of the Miller integrator 71 as well as selectively connecting the operational amplifier 72 as a voltage follower, causing its interconnected output connection and inverting-input connection to follow the FILL & SPILL voltage applied to its non-inverting input connection during the intersample periods to implement the fill portion of a fill and spill process involving the magnitude capacitors in the processors 40 etc.
An analog-to-digital converter 75 digitizes the analog output voltage from the Miller integrator 71 just prior to each resetting of integrator 71 and supplies the digitized imager output signal to a multiplexer 76. The multiplexer 76 routes the half-wave-rectified components of (Exp. 3) to an in-phase (I) accumulator 77 for accumulation and routes the half-wave-rectifier components of (Exp. 4) to a quadrature-phase (Q) accumulator 78 for accumulation. The accumulated (Exp. 3) and (Exp. 4) terms appear in parallel after both accumulations have been completed and address a read-only memory (ROM) 79 that stores (Exp. 5) terms. ROM 79 supplies the arc tangent of (Exp. 3) divided by (Exp. 4), as offset by 45 degrees at times that a digital latch 80 is clocked to store temporarily the sought after PHASE MEASUREMENT.
The Miller integrator 71 and analog-to-digital converter 75 have been assumed to be a part of the camera electronics 30 external to the solid state imager in camera 15. Alternatively, the Miller integrator 71 and analog-to-digital converter 75 may instead be located within the solid state imager in camera 15 transmitting the bits of the digital conversion result from the imager by respective wires, or time-division multiplexing those bits onto a single wire from the imager. Taking digital rather than analog output signal from the imager makes it easier to transmit imager output over some distance without as much problem with noise pickup degrading the signal; on the other hand, taking analog signal from the imager avoids some of the problems associated with the presence of high-speed switching signals on the imager.
FIGS. 4, 5 and 6A are to be referred to during the following more detailed description of the operation of the FIG. 1 optical interferometer using an imager 70 using processors like 40 and camera electronics per FIG. 5. The waveforms in the FIG. 6 timing diagram assume a bulk substrate of N type semiconductive material overlaid with an epitaxial layer of P type semiconductive material and N channel charge injection devices disposed within the epitaxial layer. That is enable voltages are positive, and disable voltages are negative.
Initially, at time t 0 , all four charge injection devices 41, 42, 43 and 44 in each processor 40 contain charge from the two previous readout sequences. To begin the next readout sequence, charge in the odd-readout CIDs 41 and 43 is injected into the substrate (cleared). This is done by clamping the interpixel electrode 45 (and thus the electrodes 53 and 51) to disable potential with reset transistor 46 and disabling C1, C3 and SCROD. During the injection procedure, the drain potential IVD of reset transistor 46 is at disable potential, and the gate potential IVG of reset transistor 46 is at enable potential to drive reset transistor 46 channel into conduction to clamp to its drain potential IVD its source electrode and electrodes 51-54 connected thereto by the interpixel bus 45. Control voltages C2 and C4 remain enabled to allow the respective quantities of charge in the even-readout CIDs 42 and 44 to be kept in temporary storage under electrodes 62 and 64 during injection of the odd-readout CIDs 41 and 43.
After injection, at time t 1 , in preparation for charge transfer from the photosensors 36 and 37 into CIDs 41 and 43 respectively, control voltage C3 is made high to enable electrode 63, the odd-field screen voltage SCROD is made high to enable electrodes 65 and 67, and the electrodes 51-54 (particularly 53) are enabled responsive to the interpixel electrode 45 being brought to full enable voltage. Interpixel electrode 45 is brought to full enable voltage by the reset transistor 46 being maintained in clamp by its gate voltage IVG continuing to be enabling and by its drain voltage IVD being changed to full enable voltage. The XOD voltage applied to transfer gates 55 and 57 goes high to enable them. The enablement of gates 55 and 57 transfers charge (integrated from 0 degree laser phase) from the photosensor 36 into CID 41 to repose under electrode 51 and from the photosensor 37 into CID 43 to repose electrode 63 receptive of the high control voltage C3. After the charge packet is transferred from the photosensor 36 into CID 41, it reposes under electrode 51 connecting to the interpixel bus 45 because electrode 61 is disabled by the C1 control voltage applied thereto remaining low.
At time t 2 , the screen electrodes 65-68 are disabled by the SCROD and SCREV screen voltages going low voltage. This is done in preparation for charge transfer within CIDs 41 and 43. A fill and spill operation is then used to fill the magnitude capacitor with charge, which operation is diagrammed in FIG. 7A. At time t 2 the interpixel electrode 45 is clamped to one half the enable potential, by continuing an enabling IVG to keep reset transistor 46 in clamp and by setting transistor 46 drain potential IVD to one half the enable potential. The summation drain 49 is dropped in potential to fill the the magnitude capacitor under electrode 47 with charge. The dropping of summation drain 49 potential is in response to the timing generator 31 applying a relatively low FILL voltage to the non-inverting input connection of the operational amplifier 72, while the integrator reset transistor 74 is held in clamp to condition the operational amplifier 72 for operation as a voltage follower.
Thereafter during a spill period including time t 3 the potential on the sumdrain 49 is restored to a more positive potential. This restoration is in response to the timing generator 31 applying a relatively high SPILL voltage to the non-inverting input connection of the operational amplifier 72. During spill the gate electrode of reset transistor 46 is enabled, clamping the interpixel bus 45 to half-enable potential. Charge is held on the magnitude capacitor by maintaining a bias DCSET on the barrier electrode 47 that is negative with respect to the top plate electrode 47 of the magnitude capacitor, and thus with respect to the interpixel bus 45.
Just before the time t 4 the IVG signal is disabled to allow the top plate electrode 47 of the magnitude capacitor, the interpixel bus 45 and the electrodes 51-54 connected to bus 45 all to float together in potential. A charge transfer operation is then performed in the four CIDS 41-44 to allow the algebraic combination of the charge packets necessary for the calculation of Exp 1.
At time t 4 the screen voltage SCROD applied to electrodes 65 and 67 and the screen voltage SCREV applied to electrodes 66 and 68 both are enabled to permit charge transfer between the electrodes 61-64 receptive of the control voltages C1-C4 and respective ones of the electrodes 51-54 connecting to interpixel bus 45. At time t 4 electrodes 61, 62, 63, 64 are clocked +C1, -C3, +C2, -C4. Clocking with positive control voltages +C1 and +C2 transfers charge away from the electrodes 51 and 52 connecting to interpixel bus 45 as diagrammed in FIGS. 8A, 8B and 8C; and clocking with negative control voltages -C3 and -C4 transfers charge towards the electrodes 53 and 54 connecting to the interpixel bus 45 as diagrammed in FIGS. 9A, 9B and 9C. At time t 4 charge summation result calculating Exp. 1 for the particular processor 40 appears as a voltage change on its interpixel bus 45 due to the net charge difference under the electrodes 51-54 connecting thereto. After time t 4 , the screen electrodes 65-68 are disabled. Note that the clock coupling between the screen electrodes and the interpixel bus 45 is canceled by the equal and opposite clocking of the screen electrodes 65-68 during the transfers of charge responsive the electrodes 61, 62, 63, 64 being clocked +C1, -C3, +C2, -C4.
FIG. 7B diagrams operation of the magnitude capacitor during an integration period including time t 5 when the change in the interpixel bus 45 voltage has been positive. The magnitude capacitor potential well under the electrode 47 is increased. Accordingly, no charge can flow over the potential barrier maintained by the barrier electrode.
FIG. 7C diagrams operation of the magnitude capacitor during the integration period including time t 5 when the change in the interpixel bus 45 voltage has been negative. The magnitude capacitor potential well under the electrode 47 is decreased. Accordingly, charge spills over the barrier potential and is sensed on the drain electrode.
The current flow on the drain of each processor in the imager is summed on the common SUMDRAIN connection which is made available at the imager interface for application to the inverting input connection of the operational amplifier 72. At time t 5 the integrator reset transistor 74 has been removed from clamp, to restore the capacitor 73 as a Miller feedback connection for the operational amplifier 72, conditioning the operational amplifier 72 for operation as a Miller integrator.
The total SUMDRAIN current near the end of the integration period including time t 5 represents the sum of the individual processor results for those processors which had negative voltage changes on their interpixel buses 45 at time t 4 . The Miller integrator 71 response to the SUMDRAIN current near the end of the integration period including time t 5 is digitized by the analog-to-digital converter 75, in response to a SAMPLE pulse. The digitized SUMDRAIN current is selected by the multiplexer 76 to the in-phase accumulator 77 as a portion of the measured magnitude of Exp. 3, responsive to I/Q SELECT control signal applied to the multiplexer 76 being low.
To complete the operation of determining the magnitude of Exp. 3, it is necessary to determine the sum of the individual processor results for those processors which had positive voltage changes on their interpixel buses 45 at time t 4 . To achieve this goal, it is necessary to move charge packets from under the electrodes 61 and 62 to under the electrodes 51 and 52 and to move charge packets from under the electrodes 53 and 54 to under the electrodes 63 and 64, then read out again. Preparatory to doing this, the fill and spill operation is repeated, with fill taking place at time t 6 and with spill taking time during a period including time t 7 . During spill the gate electrode of reset transistor 46 is enabled, clamping the interpixel bus 45 to half-enable potential and the sumdrain electrode 49 is pulsed low. Then, at time t 8 , the gate electrode of reset transistor is disabled, so interpixel bus 45 and electrodes 51-54 and 47 can float in potential; the screen voltage SCROD applied to electrodes 65 and 67 and the screen voltage SCREV applied to electrodes 66 and 68 both are enabled to permit charge transfer between the electrodes 61-64 receptive of the control voltages C1-C4 and respective ones of the electrodes 51-54 connecting to interpixel bus 45; and the four electrodes 61-64 are clocked in the opposite direction (-C1, +C3, -C2, +C4) as at time t 4 . This results in the same voltage change on the interpixel bus 45 at time t 8 as at time t 4 , but with the opposite sign.
The current on the SUMDRAIN near the end of an integration period including time t 9 represents the sum of the individual processor results for those processors which had positive voltage changes on their respective interpixel buses 45 at time t 4 and have subsequently had negative voltage changes on their respective interpixel buses 45 at time t 8 . The Miller integrator 71 response to the SUMDRAIN current at the end of the integration period including time t 9 is digitized by the analog-to-digital converter 75 responsive to a SAMPLE pulse applied thereto as a command signal. The digitized SUMDRAIN current at this time is selected by the multiplexer 76 to the in-phase accumulator 77 as the remaining portion of the measured magnitude of Exp. 3. The two SUMDRAIN intermediate results being accumulated in the in-phase accumulator 77 completes the calculation of Exp. 3.
To prepare for the calculation of Exp. 4, charge in the even-readout CID 42 has to be moved from under electrode 52 to under electrode 62, and charge in the even-readout CID 44 has to be moved from under electrode 64 to under electrode 54. At time t 9 the odd-field screen voltage SCROD has been made low to disable electrodes 65 and 67 so the charge packets under electrodes 61 and 53 will remain in place. At time t 10 , the even-field screen voltage SCREV is high to enable electrodes 66 and 68; the gate electrode of reset transistor 46 is enabled to clamp interpixel bus 45 and electrodes 51-54 and 47 to the half-enable potential IVD drain voltage of reset transistor 46; the sumdrain electrode 49 is pulsed to fill the magnitude capacitor; and electrodes 62 and 64 are clocked (+C2, -C4). I/Q SELECT control signal is made high by time t 11 to condition the multiplexer 76 for the upcoming calculation of Exp. 4.
At time t 11 SRCEV is low to disable electrodes 66 and 68. The gate electrode of reset transistor 46 remains enabled to clamp interpixel bus 45 and electrodes 51-54 and 47 to the half-enable potential IVD drain voltage of reset transistor 46; and the sumdrain voltage on electrode 49 goes high as SPILL voltage is applied to the non-inverting input connection of the operational amplifier 72 conditioned to operate as a voltage follower.
Then, at time t 12 , the gate electrode of reset transistor is disabled, so interpixel bus 45 and electrodes 51-54 and 47 can float in potential; the screen voltage SCROD applied to electrodes 65 and 67 and the screen voltage SCREV applied to electrodes 66 and 68 both are enabled to permit charge transfer between the electrodes 61-64 receptive of the control voltages C1-C4 and respective ones of the electrodes 51-54 connecting to interpixel bus 45; and the four electrodes 61-64 are clocked (+C1, -C3, -C2, +C4).
The total SUMDRAIN current at time t 13 represents the sum of the individual processor results for those processors which had a negative voltage change on their interpixel buses 45. The Miller integrator 71 response to the SUMDRAIN current near the end of the integration period including time t 13 is digitized by the analog-to-digital converter 75, responsive to a SAMPLE pulse. The digitized SUMDRAIN current is selected by the multiplexer 76 to the quadrature-phase accumulator 78 as a portion of the measured magnitude of Exp. 4.
To complete the operation of determining the magnitude of Exp. 4, it is necessary to determine the sum of the individual processor results for those processors which had a negative voltage change on their interpixel buses 45 at time t 12 . To achieve this goal, it is necessary to move charge packets from under the electrodes 61 and 64 to under the electrodes 51 and 54 and to move charge packets from under the electrodes 52 and 53 to under the electrodes 62 and 63, then read out again. Preparatory to doing this, the fill and spill operation is repeated, with fill taking place at time t 14 and with spill taking time during a period including time t 15 . During spill the gate electrode of reset transistor 46 is enabled, clamping the interpixel bus 45 to half-enable potential and the sumdrain electrode 49 is pulsed low. Then, at time t 16 , the gate electrode of reset transistor is disabled, so interpixel bus 45 and electrodes 51-54 and 47 can float in potential; the screen voltage SCROD applied to electrodes 65 and 67 and the screen voltage SCREV applied to electrodes 66 and 68 both are enabled to permit charge transfer between the electrodes 61-64 receptive of the control voltages C1-C4 and respective ones of the electrodes 51-54 connecting to interpixel bus 45; and the four electrodes 61-64 are clocked (-C1, +C3, +C2, -C4) to obtain the charge summation required for completing the calculation of Exp. 4.
The current on the SUMDRAIN near the end of an integration period including time t 17 represents the sum of the individual processor results for those processors which had a positive voltage change on their respective interpixel buses 45 at time t 16 . The Miller integrator 71 response to the SUMDRAIN current at time t 17 is digitized by the analog-to-digital converter 75, responsive to a SAMPLE pulse applied as a command signal. The digitized SUMDRAIN current is selected by the multiplexer 76 to the quadrature-phase accumulator 78 as the remaining portion of the measured magnitude of Exp. 4. The two SUMDRAIN intermediate results being accumulated in the quadrature-phase accumulator 78 completes the calculation of Exp. 4, and the I/Q SELECT control signal is made low to condition the multiplexer 76 for the upcoming calculation of Exp. 3.
The above sequence, consisting of charge injection on the odd-readout CIDs 41 and 43, charge transfer from the photosensors 36 and 37 and four readouts from the imager is followed by a corresponding sequence for the even-readout CIDs 42 and 44. (Times t 18 through time t 33 are not used in describing the FIG. 6 timing diagram, but are saved with times t 51 through t 66 for use in describing the FIG. 13 timing diagram.) The charge injection on the even-readout CIDs 42 and 44 takes place after time t 17 , at time t 34 , followed by charge transfer from the photosensors 36 and 37 to the even-readout CIDs 42 and 44 as an enabling XEV transfer pulse is applied to the transfer electrodes 56 and 58 during a time interval including time t 35 . The fill and spill/charge transfer operation then proceeds at times t 34 to t 51 essentially the same way as at times t 2 to t 17 , respectively, as previously described. The alternating of charge transfer from the photosensors to the odd-readout CIDs and to the even-readout CIDs allows two successive-in-time images to be compared, as implements the proper calculation of Exp. 3 and Exp. 4. The corresponding laser phase is changed after each XEV or XOD gate enable (0°, 90°, 0°, 90° . . . ) so that the image corresponding to the correct laser phase is generated prior to charge transfer from the photosensors.
A variant of the operation specified by the FIG. 6 timing diagram is possible in which Exp. 4 is calculated before, rather than after Exp. 3, which variant can be readily worked out by one skilled in the art and acquainted with the foregoing description of operation. Further variants of the two operational variants thusfar described are possible wherein the order of calculating the positive and negative components of Exp. 3 and/or Exp. 4 is permuted. In still further variants of the invention as thusfar described, the injection of charge packets into the substrate at times t 0 and t 34 may be dispensed with, instead gating the charge packets away at these times into drain structures specifically provided for this purpose. All these variants are within the scope of the invention as considered in certain of its aspects and are to be considered equivalents of each other inasfar as interpreting the scope of claims which follow this specification.
FIG. 11 shows the top left corner of the sensor plane of the solid stage imager 70. The left hand portions of eight rows of photosensors, ROW1, ROW2, ROW3, ROW4, ROW5, ROW6, ROW7 and ROW8 are shown. The individual photosensors are shown as smaller rectangles having widths of less extent than their heights. Non-overlapping pairs of photosensors as contained in larger rectangles having widths of greater extent than their heights share the same charge-domain processor. The processors in the odd rows ROW1, ROW3, ROW5, ROW7, differently combine adjacent pixels in non-overlapping pairs of a first spatial phasing to derive 2:1 subsampled pixel information having an average location that is staggered from the 2:1 subsampled pixel information that the processors in the even rows ROW2, ROW4, ROW6, ROW8, . . . derive by differentially combining adjacent pixels in non-overlapping pairs of a second spatial phasing, staggered respective to the first spatial phasing. The row-to-row staggering of samples introduces a row-by-row alternation in spatial phasing that mitigates loss in spatial resolution in the row direction caused by the 2:1 subsampling.
FIG. 12 illustrates how the 2:1 subsampling along row direction is avoided by differentially combining adjacent pixels in overlapping pairs, so adjacent pixels are differentially combined in both first and second spatial phasings, staggered respective to each other, to generate partial spatial correlation results. That is, two charge domain processors are provided each pixel, one processor shared with the pixel to the left and the other processor shared with the pixel to the right. A portion of a row of photosensors includes photosensors 81, 82, 83 and 84. A processor included in a first spatial phasing and shared by photosensors 81 and 82 has a magnitude capacitor 91 and a reset transistor 101; a processor included in a second spatial phasing and shared by photosensors 82 and 83 has a magnitude capacitor 92 and a reset transistor 102; and a processor included in the first spatial phasing and shared by photosensors 83 and 84 has a magnitude capacitor 93 and a reset transistor 103. The respective odd-field transfer electrode overlapping one of the photosensors 81, 82, 83 and 84 also overlaps a split electrode the halves of which respectively connect to the interpixel bus of the processor to the left of the photosensor and to the interpixel bus of the processor to the right of the photosensor. Similarly, the respective even-field transfer electrode overlapping one of the photosensors 81, 82, 83 and 84 also overlaps a split electrode the halves of which respectively connect to the interpixel bus of the processor to the left of the photosensor and to the interpixel bus of the processor to the right of the photosensor.
Consider by way of example an odd-field transfer electrode 85 overlapping the top electrode of the photosensor 82. The odd-field transfer electrode 85 also overlaps a split electrode having halves 86 and 87 connecting respectively to the top electrode of magnitude capacitor 91 and to the top electrode of magnitude capacitor 92. The split electrode having halves 86 and 87 is overlapped by an odd-field-screen electrode, which also overlaps the electrode to which C3 control voltage is applied.
Alternatively, one may view the split electrode halves 86 and 87 connecting respectively to the top electrode of magnitude capacitor 91 and to the top electrode of magnitude capacitor 92 as electrodes in two charge injection devices that have corresponding ones of their other electrodes merged together. This is the view taken in formulating certain of the claims following this specification.
FIG. 13 timing diagram is representative of how an imager constructed in accordance with FIG. 12 is operated. Operation of the processors in the second spatial phasing during successive times including t 0 through differs from that in the FIG. 6 timing diagram in that the IVGE voltage applied to the gate electrodes of their respective reset transistors maintains them in clamp, to clamp the interpixel buses to which their source electrodes respectively connect to the low IVDE potential that disables the halves of the split electrodes to which these interpixel electrodes connect. All transfers of charge packets from the photosensors 81-84 etc. are thus forced to take place into the processors in the first spatial phasing during successive times including t 0 through t 17 . Operation of the processors in the first spatial phasing during successive times including t 0 through t 17 is the same as that in the FIG. 6 timing diagram.
Operation of the processors in the second spatial phasing during successive times including t 18 through t 33 differs from that during successive times including t 2 through t 15 in the FIG. 6 timing diagram in that the IVGO voltage applied to the gate electrodes of their respective reset transistors maintains them in clamp, to clamp the interpixel buses to which their source electrodes respectively connect to the low IVDO potential that disables the halves of the split electrodes to which these interpixel electrodes connect. All transfers of charge packets from the photosensors 81-84 etc. are thus forced to take place into the processors in the second spatial phasing during successive times including t 18 through t 33 . Operation of the processors in the second spatial phasing during successive times including t 18 through t 33 is the same as that during successive times including t 2 through t 17 in the FIG. 6 timing diagram.
Operation of the processors in the second spatial phasing during successive times including t 34 through t 51 differs from that in the FIG. 6 timing diagram in that the IVGE voltage applied to the gate electrodes of their respective reset transistors maintains them in clamp, to clamp the interpixel buses to which their source electrodes respectively connect to the low IVDE potential that disables the halves of the split electrodes to which these interpixel electrodes connect. All transfers of charge packets from the photosensors 81-84 etc. are thus forced to take place into the processors in the first spatial phasing during successive times including t 34 through t 51 . Operation of the processors in the first spatial phasing during successive times including t 34 through t 51 is the same as that in the FIG. 6 timing diagram.
Operation of the processors in the second spatial phasing during successive times including t 52 through t 67 differs from that during successive times including t 36 through t 51 in the FIG. 6 timing diagram in that the IVGO voltage applied to the gate electrodes of their respective reset transistors maintains them in clamp, to clamp the interpixel buses to which their source electrodes respectively connect to the low IVDO potential that disables the halves of the split electrodes to which these interpixel electrodes connect. All transfers of charge packets from the photosensors 81-84 etc. are thus forced to take place into the processors in the second spatial phasing during successive times including t 52 through t 67 . Operation of the processors in the second spatial phasing during successive times including t 52 through t 67 is the same as that during successive times including t 36 through t 51 in the FIG. 6 timing diagram.
Just as numerous variants of operation from that shown in the FIG. 6 timing diagram are possible in various embodiments of the invention, so too are numerous variants of operation from that shown in the FIG. 13 timing diagram possible in various other embodiments of the invention. Indeed, the number of possible variants of the FIG. 13 operation is larger yet, since the order of making calculations in the first and second spatial phasings can be altered to increase the number of permutations in operation that are possible, and since the calculations in the first and second spatial phasings can be performed on interleaved as well as sequential bases. All these variants are within the scope of the invention as considered in certain of its aspects and are to be considered equivalents of each other inasfar as interpreting the scope of claims which follow this specification.
One skilled in the art of digital design will be aware that variations in regard to the calculation of arc tangents are possible. Calculation of Exp. 5 from a look-up table without the minus one-eighth-circle, -π/2 radian or -45 degree offset, then subsequently adding the offset in a digital adder, is feasible. Indeed, this procedure allows one to reduce the size of the arc tangent look-up table in ROM by taking advantage of mirror symmetry in the function. The amplitudes of the Exp. 3 and Exp. 4 terms are compared, the order these terms is permuted where necessary to always place the larger and the smaller of these terms in the same positions in the input address to the look-up table ROM; and the ROM output is selectively two's complemented depending on whether or not the Exp. 3 and Exp. 4 terms had to be permuted. Algorithms for calculating arc tangent rather than looking up from tables in ROM are possible, also, providing speed requirements on optical interferometer measurements are not too high.
One skilled in the art of solid state imager design and acquainted with the foregoing specification will be able to design a number of variants of the apparatus described and this should be borne in mind when construing the scope of the claims which follow. For example, the charge transfer devices may be either of surface-channel or buried-channel type.
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Respective processors for pairs of photodetecting elements are included in an imager used for sensing hologram fringe patterns in an optical interferometer. These processors remove the direct-current pedestal from in-phase and quadrature-phase field images, then perform partial correlations of the resulting field images on a pixel-by-pixel basis, and then sum the partial correlations to complete the image correlation process and to provide imager output signal or the basis therefor. This localized processing greatly reduces the number of samples that have to be brought out of the imager each frame when the imager is used in an optical interferometer to detect phase modulation in an optical signal, allowing for increased frame rates in accordance with a further aspect of the invention. Image correlation is done according to a novel algorithm that avoids actually having to multiply together correspondingly located pixels in each pair of successive fields forming a successive non-overlapping frame. The multiplier-free processors are compact enough to be located within the solid state imager close to the pairs of photosensors they respectively serve in the imager.
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STATEMENT REGARDING GOVERNMENT SUPPORT
[0001] This invention was made with government support under Contract No. N-00019-12-D-0002 awarded by the United States Navy. The government has certain rights in this invention.
BACKGROUND
[0002] Ceramic material, glass material and other high temperature-resistance materials can provide desirable properties for use in relatively severe operating environments, such as in gas turbine engines. Often, such materials are used in ceramic matrix composites, such as fiber-reinforced silicon carbide composites. Such composites are typically fabricated using techniques such as polymer impregnation and pyrolysis (PIP), chemical vapor deposition (CVD), and chemical vapor infiltration (CVI). Ceramic matrix composites also include fiber reinforced glass and glass-ceramic composites. Such composites are typically formed by hot pressing.
[0003] Another known technique for forming composites is transfer molding. In a typical transfer molding process, a fiber preform is provided into a die, and a softened glass or glass/ceramic material is impregnated into the preform using a hydraulically driven ram.
SUMMARY
[0004] One exemplary embodiment of this disclosure relates to a transfer molding assembly. The assembly includes a die having a molding cavity interconnected with a reservoir. The assembly further includes a heater operable to heat the die, and a load plate configured to move under its own weight to transfer material from the reservoir into the molding cavity.
[0005] In a further embodiment of any of the above, the material softens as the material is heated by the heater, and wherein the softened material is transferred into molding cavity under the weight of the load plate.
[0006] In a further embodiment of any of the above, the material is rigid before the heater heats the material, the rigid material resisting movement of the load plate under its own weight.
[0007] In a further embodiment of any of the above, the assembly includes a control rod, and an injection ram configured to translate along the reservoir under the weight of the load plate. The control rod supports the load plate above the injection ram before the heater softens the control rod.
[0008] In a further embodiment of any of the above, the material received in the reservoir is a first material, and wherein the control rod is made of a second material different than the first material.
[0009] In a further embodiment of any of the above, the heater is configured to heat the first material to a transfer molding point before the second material reaches the transfer molding point.
[0010] In a further embodiment of any of the above, the heater is configured to heat the first material to a transfer molding point before the second material reaches a working point.
[0011] In a further embodiment of any of the above, the heater is configured to heat the first material to a transfer molding point before the second material reaches a softening point.
[0012] In a further embodiment of any of the above, the first material and the second material are glass-based materials.
[0013] In a further embodiment of any of the above, the first material has a lower viscosity than the second material at a first temperature.
[0014] In a further embodiment of any of the above, the reservoir is located above, relative to a direction of gravity, the cavity.
[0015] In a further embodiment of any of the above, the assembly includes a controller, the heater including a chamber having a plurality of heating elements, the heating elements in communication with the controller and configured to generate heat in the heater.
[0016] In a further embodiment of any of the above, the load plate is configured to move solely under its own weight to transfer material from the reservoir into the molding cavity.
[0017] Another exemplary embodiment of this disclosure relates to a method of transfer molding. The method includes heating a first material such that the material softens and is injected into a preform under the weight of a load plate.
[0018] In a further embodiment of any of the above, the method includes supporting the load plate with a control rod, and releasing at least a portion of the weight of the load plate in response to the first material reaching a predefined temperature.
[0019] In a further embodiment of any of the above, the control rod is made of a second material configured to soften at a higher temperature than the first material.
[0020] In a further embodiment of any of the above, the first material and the second material are glass-based materials.
[0021] In a further embodiment of any of the above, the first material has a viscosity at or below 10 2.6 poises at a temperature of about 1500° C., and wherein the second material has a viscosity above 10 2.6 poises at a temperature of about 1500° C.
[0022] In a further embodiment of any of the above, the second material has a viscosity of about 10 7.6 poises at a temperature of about 1500° C.
[0023] The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The drawings can be briefly described as follows:
[0025] FIG. 1 illustrates an example transfer molding assembly.
[0026] FIG. 2 graphically illustrates the relationship between viscosity and temperature for two example materials.
[0027] FIG. 3 illustrates another example transfer molding assembly.
DETAILED DESCRIPTION
[0028] FIG. 1 schematically illustrates an example assembly 20 that can be used in conjunction with a method for processing a process-environment-sensitive material (hereafter “material”), which is a material that is formed into a desired article geometry at high temperatures in a controlled environment, such as under vacuum and/or inert cover gas (e.g., argon). Such materials require high temperatures to enable formation and consolidation into the desired geometry and a controlled environment to manage reactions that can undesirably alter the chemistry of the material.
[0029] In non-limiting examples, the material can be a ceramic-based material, a glass-based material or a combination of a ceramic/glass-based material. One example includes silicon carbide fiber reinforced ceramic-glass matrix materials. The ceramic-glass matrix can be lithium-aluminosilicate with boron or barium magnesium aluminosilicate, for example. The fibers can include one or more interface layers, such as carbon or boron nitride layers. These and other process-environment-sensitive materials can be rapidly processed into an article using the assembly 20 .
[0030] In the illustrated example, the article being formed is an annular engine component. Example annular components include turbine rings, rub strips, seals, acoustic tiles, combustor liners, shrouds, heat shields, etc. It should be understood that this disclosure is not limited to annular articles, and extends to articles having other shapes.
[0031] In this example, the assembly 20 provides a transfer molding assembly. The assembly 20 includes a chamber 24 and a plurality of heaters 26 , 28 provided therein. It should be noted that although two heaters 26 , 28 are illustrated, there may be any number of heaters, including only one heater. The heaters 26 , 28 are configured to provide heat H, which raises the temperature within the chamber 24 . While only one chamber 24 is illustrated, the assembly 20 could include additional chambers.
[0032] The chamber 24 is connected, through a port 30 , to a gas environment control device 32 , which is in turn in communication with a vacuum pump 34 and/or a pressurized gas source 36 . The gas environment control device 32 is controlled by command of a controller 38 , which is configured to control evacuation of, and process gas flow into, the chamber 24 . Thus, for a given process having a predefined controlled gas environment, the controller 38 can purge the interior of the chamber 24 of air, evacuate the interior to a desired pressure and/or provide an inert process cover gas to a desired pressure.
[0033] The assembly 20 further includes a support plate 40 located within the chamber 24 , which may be supported by a plurality of legs 42 . A die 44 is provided on the support plate 40 . In this example, the die 44 includes a molding cavity 46 and a reservoir 50 above, relative to the direction of gravity G, the molding cavity 46 . The molding cavity 46 is in fluid communication with the reservoir 50 , as will be appreciated from the below.
[0034] In FIG. 1 , a fiber preform 48 is provided in the molding cavity 46 , and a material 52 is placed in the reservoir 50 . An injection ram 54 is provided above the material 52 . The injection ram 54 is shaped to correspond to the shape of the reservoir 50 , and to travel within the reservoir in the direction of gravity G. The injection ram 54 in one example is sealed against the side walls of the reservoir 50 to prevent the material 52 from escaping during injection. Optionally, there may be an exit port at the bottom of the reservoir 50 , or at the bottom of the molding cavity 46 , for directing excess material 52 away from the preform 48 .
[0035] A load plate 56 is provided above the injection ram 54 , and is in direct contact with the injection ram 54 in this example. The load plate 56 may be rigidly attached to the injection ram 54 in some examples. In other examples, however, the load plate 56 is moveable relative to the injection ram 54 . The weight and/or size of the load plate 56 can be adjusted depending on the properties associated with the particular material being worked upon.
[0036] Before heat is applied to the die 44 , the material 52 may be a plurality of rigid glass cutlets. These rigid cutlets resist the weight W of the load plate 56 . In order to inject the material 52 into the preform 48 , the controller 38 activates the heaters 26 , 28 to increase the temperature within the chamber 24 . In response, the temperature of the material 52 rises, which decreases the viscosity of the material 52 , and the material 52 softens.
[0037] The softened material 52 is injected into the fiber preform 48 under at least a component of the gravitational weight W of the load plate 56 , via movement of the injection ram 54 in the downward direction. The load plate 56 is unforced by a mechanical actuator (such as that commonly associated with a hot press assembly). In other words, the softened material 52 is injected solely under the weight of the load plate 56 . After injection, the preform 48 and the material 52 provide are allowed to cool, and may undergo further processing, as needed, to prepare the article for use.
[0038] The chamber 24 provides a controlled gas environment for the application of heat, which could otherwise cause undesired reactions in the material (e.g., the preform 48 , or the material 52 ) or degrade the die 44 or other structures of the chamber 24 , particularly if the die 44 is made of graphite.
[0039] While the assembly illustrated in FIG. 1 may be effective, the material 52 may be prematurely injected into the preform 48 depending on a number of factors, including the composition and properties of the material 52 . In particular, in some instances, the weight W of the load plate 56 may urge the glass 52 into the preform 48 before the material 52 has been heated to viscosity to avoid or limit damaging the preform 48 . Thus, the force of the flow into the preform 48 could alter the fiber orientations of the preform 48 , or even physically damage the fibers.
[0040] The relationship between viscosity and temperature for an example material M 1 is illustrated in FIG. 2 . In one example, the material M 1 is used as the material 52 in FIG. 1 , and as the material 152 in FIG. 3 . The material M 1 in one example is a glass-based material, which is initially in the form of glass cutlets. The material M 1 experiences softening at a temperature of about 750° C. (about 1382° F.), wherein the material M 1 has a viscosity V 1 of about 10 7.6 poises (about 580 reyn). This point is illustrated in FIG. 2 as the “Softening Point,” which is associated with a viscosity at which uniform fibers (e.g., 0.55-0.75 mm [about 0.02-0.03 inches] in diameter and 23.5 mm [about 0.93 in] long) in a material (e.g., such as silicate fibers) elongate under their own weight at a rate of 1 mm (about 0.04 inches) per minute.
[0041] As the temperature of the material M 1 continues to rise, the material M 1 achieves a working point viscosity V 2 of about 10 4 poises (about 0.15 reyn), at temperature T 2 of about 1100° C. (about 2010° F.). The “Working Point” illustrated in FIG. 2 corresponds to a viscosity level where a material is soft enough for hot working.
[0042] Finally, the material M 1 reaches a viscosity of 10 2.6 poises (about 0.006 reyn) at V 3 , at which point the material M 1 is in a substantially fluid state such that it is acceptable for glass transfer molding. The viscosity V 3 is reached at about 1500° C. in this example, and is referenced as a “Transfer Molding Point.” Any viscosity at or below V 3 is acceptable for transfer molding. It should be understood that the illustrated material M 1 is only one example material, and materials having other characteristics come within the scope of this disclosure.
[0043] FIG. 3 illustrates another example assembly 120 according to this disclosure. To the extent not otherwise described or shown, the reference numerals in FIG. 3 correspond to the reference numerals of FIG. 1 , with like parts having reference numerals preappended with a “1.”
[0044] In the assembly 120 of FIG. 3 , a plurality of control rods 158 , 160 are configured to delay a force transfer from the load plate 156 to the material 152 . In particular, the control rods 158 , 160 support the load plate 156 above the injection ram 154 before the material 152 is heated. That is, before heating, there is an initial clearance C between an upper surface 154 U of the injection ram 154 and a lower surface 156 L of the load plate 156 .
[0045] In one example, the control rods 158 , 160 are made of a material M 2 , illustrated in FIG. 2 , and the material 152 is made of the material M 1 . With reference to FIG. 2 , the material M 2 of the travel control rods 158 , 160 is initially rigid, and does not reach the softening point viscosity V 1 until temperature T 3 , which is the temperature for preparing the material M 1 of the material 152 for transfer molding at the viscosity V 3 .
[0046] At a minimum, the material M 2 is selected such that it has a viscosity greater than V 3 at temperature T 3 . In another example, the material M 2 has a viscosity of about V 2 at temperature T 3 . In still another example, the material M 2 is rigid and has a viscosity above the softening point viscosity V 1 at temperature T 3 .
[0047] At any rate, in the example of FIG. 3 , the weight W of the load plate 156 does not transfer to the injection ram 154 until a point at which the material 152 has reached an acceptable transfer molding viscosity V 3 .
[0048] In one example, the first material M 1 is a Corning Glass Works (CGW) 7070 glass, and the second material M 2 is CGW 7913 glass. This disclosure is not limited to these two particular glass types, however, and it should be understood that other materials come within the scope of this disclosure.
[0049] In either of the example assemblies 20 , 120 , the expenses typically associated with transfer molding, such as purchasing a relatively expensive hot press (including the corresponding hydraulics, etc.), are eliminated. The transfer molding assembly and method discussed herein allow for passive injection by the weight of the load plate 56 , rather than active injection by way of a hydraulic actuator. Accordingly, this disclosure can be relatively easily incorporated into a chamber (e.g., a furnace) which is relatively more available, and less expensive than a hot press, which in turn reduces manufacturing costs, etc.
[0050] Although the different examples have the specific components shown in the illustrations, embodiments of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from one of the examples in combination with features or components from another one of the examples. Further, it should be understood that terms such as “above,” “downward,” etc., are used herein for purposes of explanation, and should not otherwise be considered limiting. Also, as used herein, the term “about” is not a boundaryless limitation on the corresponding quantities, but instead imparts a range consistent with the way the term “about” is used by those skilled in this art.
[0051] One of ordinary skill in this art would understand that the above-described embodiments are exemplary and non-limiting. That is, modifications of this disclosure would come within the scope of the claims. Accordingly, the following claims should be studied to determine their true scope and content.
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One exemplary embodiment of this disclosure relates to a transfer molding assembly. The assembly includes a die having a molding cavity interconnected with a reservoir. The assembly further includes a heater operable to heat the die, and a load plate configured to move under its own weight to transfer material from the reservoir into the molding cavity.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is related to the field of perpendicular magnetic recording (PMR) on magnetic recording hard disk drive systems and, in particular, to fabricating a stitched wrap around shield for a PMR write head.
2. Statement of the Problem
Magnetic hard disk drive systems typically include a magnetic disk, a recording head having write and read elements, a suspension arm, and an actuator arm. As the magnetic disk is rotated, air adjacent to the disk surface moves with the disk. This allows the recording head (also referred to as a slider) to fly on an extremely thin cushion of air, generally referred to as an air bearing. When the recording head flies on the air bearing, the actuator arm swings the suspension arm to place the recording head over selected circular tracks on the rotating magnetic disk where signal fields are written to and read by the write and read elements, respectively. The write and read elements are connected to processing circuitry that operates according to a computer program to implement write and read functions.
In a disk drive utilizing perpendicular recording, data is recorded on a magnetic recording disk by magnetizing the recording medium in a direction perpendicular to the surface of the disk. In this type of recording, the magnetic easy axes of the magnetic grains which store the recorded data are arranged perpendicular to the disk surface, instead of parallel to the disk surface as is the case in longitudinal recording. Perpendicularly recorded data is more stable than longitudinal data, and the data can be recorded at a higher density than longitudinal data. The coercivity of the medium is higher, since the magnetic recording layer is in effect “inside the gap” between the head and a soft underlayer (SUL) that is located under the magnetic layer. In addition, for the same read head design, perpendicular data provides greater read back amplitude. The disk has a higher magnetic moment-thickness product (MrT). For the same physical width of the read head, the magnetic read width is narrower.
High track density heads use narrow write pole widths. A sufficiently short flare length (i.e., the distance between the ABS and the point where the write pole flares out) is used to maintain the write field strength of a narrow track width perpendicular write head. As a result, the widened portion of a write pole behind the flare point is close to the recording medium and can produce undesired fields to the extent that the data in adjacent tracks may be erased. A balance between writeability and adjacent track interference (ATI) is needed for high track density perpendicular write heads.
Wrap around shield designs are utilized for high track density recording to shield adjacent tracks from unintended recording. FIG. 1 illustrates an ABS view of a typical write head 100 with a wrap around shield 120 . As shown in FIG. 1 , wrap around shield 120 has a trailing shield 122 placed in the proximity of the trailing surface 112 of the write pole 110 , separated from write pole 110 by a gap 135 . The function of trailing shield 122 is to improve the write field gradient and transition curvature of write pole 110 . Wrap around shield 120 also has side shields 124 and 126 disposed on sides of write pole 110 . Side shields 124 and 126 are separated from write pole 110 by a gap 130 . Utilizing wrap around shield 120 , the fringe fields are mostly confined between write pole 110 and side shields 124 and 126 and therefore the fringe fields create much less interference with adjacent tracks. Gap 135 is smaller than gap 130 , and the thickness for both is important for proper write performance, and thus, there is a need for accurately controlling the thickness of trailing gap 135 and side gap 130 during manufacturing.
In prior art processes, trailing shield 122 and side shields 124 and 126 are fabricated at the same time. As a result, the manufacturing process focuses more on the alignment of trailing shield 122 with write pole 110 than the alignment of side shields 124 and 126 with write pole 110 . This is because the tolerance of aligning trailing shield 122 with write pole 110 is less than the tolerance of aligning side shields 124 and 126 with write pole 110 . Further, prior art processes lack flexibility and require very aggressive design points, such as flare point and shield throat height, which are challenging for processing control during manufacture. Further, fabrication is more difficult because of the topography caused by present fabrication methods.
SUMMARY OF THE SOLUTION
Embodiments of the invention solve the above and other related problems with improved methods for fabricating write heads. More specifically, a wrap around shield of a write head is fabricated in multiple processes, with side shields fabricated in one process, and a trailing shield formed in another process. These multiple processes form a stitched wrap around shield, with the side shields and trailing shield magnetically coupled. Advantageously, the gap between the side shields and the write pole may be accurately defined in one process, and the gap between the trailing shield and the write pole may be accurately defined in a separate process. As a result, the wrap around shield is more accurately aligned with the write pole.
Further, the shapes and sizes of the trailing shield and side shields can be independently made and controlled to balance writeability, saturation, and adjacent track interference (ATI) of the write head. The trailing shield and the corresponding gap may be accurately defined on a more relatively flat surface. The placement of the side shields is easier and more accurately controlled compared to prior art wrap around shield fabrication processes, which focus more on the placement of the trailing shield.
Further, a notch may be formed in the trailing shield gap and the trailing shield. A perpendicular head with a notched wrap around shield structure has less transition curvature and better writeability. The reduced transition curvature is due to the modification of the main pole field contour by the notched top write gap. The better writeability of the recording head is a result of less flux shunting to the shield.
An embodiment of the invention is a method for forming a stitched wrap around shield of a write head. The method comprises forming a write pole of the write head. The method further comprises forming side shield gap structures on side regions of the write pole. The side shield gap structures may be formed by depositing a first layer of non-magnetic material. The method further comprises forming side shields on side regions of the write pole above the side shield gap structures. The side shield gap structures define a first gap separating the write pole and the side shields. The method further comprises removing portions of the first layer of non-magnetic material above the write pole. The method further comprises forming a trailing shield gap structure above the write pole, and forming a trailing shield of the write head. The trailing shield gap structure defines a second gap separating the write pole and the trailing shield, and the second gap is less than the first gap. Advantageously, the method allows the side shields and trailing shield to be formed separately, resulting in more accurate alignment of the shields with respect to the write pole, and independent sizes and shapes of the side shields and trailing shield.
The invention may include other exemplary embodiments described below.
DESCRIPTION OF THE DRAWINGS
The same reference number represents the same element or same type of element on all drawings.
FIG. 1 illustrates an ABS view of a write head with a wrap around shield.
FIG. 2 illustrates a flow chart of a prior art method for fabricating the write head of FIG. 1 .
FIGS. 3-11 illustrate cross sectional views of a prior art write head of FIG. 1 during fabrication according to the method of FIG. 2 .
FIG. 12 illustrates a method for fabricating a write head with a stitched wrap around shield in an exemplary embodiment of the invention.
FIGS. 13-18 illustrate cross sectional views of a write head fabricated according to the method of FIG. 12 in an exemplary embodiment of the invention.
FIG. 19 illustrates a method for fabricating a write head with a stitched wrap around shield in another exemplary embodiment of the invention.
FIGS. 20-29 illustrate cross sectional views of a write head fabricated according to the method of FIG. 19 in an exemplary embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 2 illustrates a flow chart of a prior art method 200 for fabricating the write head 100 of FIG. 1 . FIGS. 3-11 illustrate cross sectional views of a prior art write head 100 during fabrication according to method 200 of FIG. 2 . The steps of method 200 will be described in reference to write head 100 illustrated in FIGS. 3-11 .
In step 202 , laminated layers 304 of a write pole (e.g., write pole 110 of FIG. 1 ) are deposited on an insulator layer 302 (see FIG. 3 ). A hard masking layer 306 (such as Alumina) is deposited above laminated layers 304 . In step 204 , a photoresist mask structure 308 is formed (see FIG. 4 ) using a photolithographic process. In step 206 , a reactive ion etching (RIE), ion milling, or reactive ion milling process is then performed to remove exposed portions of masking layer 306 not protected by photo resistive layer 308 to form hard mask structure 306 (see FIG. 5 ). In step 208 , an ion milling process is performed to define write pole 110 (see FIG. 6 ). In step 210 , a stripping process removes photoresist layer 308 (see FIG. 7 ).
In step 212 , a gap thickness of a wrap around shield 120 (see FIG. 1 ) is defined around write pole 110 . First, a layer of non-magnetic material 802 (such as atomic layer deposition (ALD) Alumina) is deposited (see FIG. 8 ). Ion milling removes non-magnetic material 802 above hard mask 306 (see FIG. 9 ). Gaps are defined around write pole 110 , with the side shield gap 130 (see FIG. 1 ) being the thickness of the layers of ALD Alumina 802 , and the trailing shield gap 135 (see FIG. 1 ) being the thickness of the layer of Alumina mask 306 . In step 214 , an electroplating process is performed to fabricate wrap around shield 120 (see FIG. 10 ). CMP is performed to planarize a top surface of write head 100 .
FIG. 11 illustrates a top view of write head 100 after completion of step 212 . Trailing shield 122 is disposed on a trailing edge of write pole 110 . Below trailing shield 122 are side shields 124 and 126 on each side of write pole 110 . Side shields 124 and 126 drape from trailing shield 122 , and the dimensions of side shields 124 and 126 are determined by the dimensions of trailing shield 122 . Thus, write head 100 fabricated according to method 200 does not provide flexible control of independent sizes and shapes of trailing shield 122 and side shields 124 and 126 . As previously discussed, method 200 may not be adequately flexible to form gaps and shields of write head 100 to achieve desired writing performances. The processing control is also challenging during manufacture. The subsequently described methods of fabricating a stitched wrap around shield solves the previously described problems and other problems encountered in fabrication of write head 100 .
FIGS. 12-29 and the following description depict specific exemplary embodiments of the invention to teach those skilled in the art how to make and use the invention. For the purpose of teaching inventive principles, some conventional aspects of the invention have been simplified or omitted. Those skilled in the art will appreciate variations from these embodiments that fall within the scope of the invention. Those skilled in the art will appreciate that the features described below can be combined in various ways to form multiple variations of the invention. As a result, the invention is not limited to the specific embodiments described below, but only by the claims and their equivalents.
FIG. 12 illustrates a method 1200 for fabricating a write head with a stitched wrap around shield in an exemplary embodiment of the invention. FIGS. 13-18 illustrate cross sectional views of a write head 1300 fabricated according to method 1200 of FIG. 12 in an exemplary embodiment of the invention. The steps of method 1200 will be described in reference to write head 1300 illustrated in FIGS. 13-18 . The steps of method 1200 may not be all-inclusive, and may include other steps not shown for the sake of brevity.
Step 1202 comprises forming a write pole 1304 (see FIG. 13 ) above insulator layer 1302 using hard mask 1306 (e.g., Alumina material) of write head 1300 . Step 1204 comprises forming side shield gap structure 1402 (see FIG. 14 ) of write head 1300 . Side shield gap structure 1402 may be formed by depositing one or more layers of non-magnetic material (such as ALD Alumina). The deposition thickness of the layers of non-magnetic material may correspond to the desired side shield gap thickness of write head 1300 . The resulting structure of write head 1300 is illustrated in FIG. 14 .
Step 1206 comprises ion milling to remove a top portion of the non-magnetic material (e.g. side shield gap structure 1402 ) to form a trailing shield gap 1306 , and to remove a bottom portion of the non-magnetic material to allow subsequently formed side shields to cover write pole 1304 (see FIG. 15 ).
Step 1208 comprises forming side shields 1602 (see FIG. 16 ) of write head 1300 . Side shields 1602 may be formed through an electroplating process, and a CMP process may be used to planarize side shields 1602 to mask structure 1306 . The resulting structure of write head 1300 is illustrated in FIG. 16 .
Step 1210 comprises forming a trailing shield 1702 (see FIG. 17 ). Trailing shield 1702 may be formed through an electroplating process. A CMP process may be used to planarize trailing shield 1702 to a desired height. The resulting structure of write head 1300 is illustrated in FIG. 17 .
FIG. 18 illustrates a top view of write head 1300 after completion of step 1210 . Trailing shield 1702 is disposed on a trailing edge of write pole 1304 . Below trailing shield 1702 is a side shield 1602 on each side of write pole 1304 . Side shields 1602 don't drape from trailing shield 1702 like the side shields of write head 100 in FIG. 11 . Advantageously, write head 1300 of FIGS. 17-18 has a side shield gap defined by side shield gap structure 1402 and a trailing shield gap defined by mask structure 1306 . These gaps are of different widths and more accurately aligned with write pole 1304 . Also, the dimensions of side shields 1602 are determined independently of the dimensions of trailing shield 1702 and are more flexibly controlled, as are the dimensions of trailing shield 1702 .
FIG. 19 illustrates a method 1900 for fabricating a write head with a stitched wrap around shield in another exemplary embodiment of the invention. FIGS. 20-29 illustrate cross sectional views of a write head 2000 fabricated according to method 1900 of FIG. 19 in an exemplary embodiment of the invention. The steps of method 1900 will be described in reference to write head 2000 illustrated in FIGS. 20-29 . The steps of method 1900 may not be all-inclusive, and may include other steps not shown for the sake of brevity.
Step 1902 comprises forming a write pole 2004 (see FIG. 20 ) of write head 2000 . Write pole 2004 may be formed over an insulator layer 2002 in a similar manner as described in steps 202 to 208 of method 200 of FIG. 2 . The laminated layers may be AFC CoFe/Cr/CoFe/CrNi. The stripping process may be performed in multiple steps, such as a Tetra-methyl ammonium hydroxide (TMAH) etching process, an N-methyl pyrrolidinone (NMP) stripping process, and an O 2 RIE process to remove the photoresist mask. As such, a hard mask Alumina structure 2006 may be present above write pole 2004 after the write pole definition process is completed. The resulting structure of write head 2000 is illustrated FIG. 20 .
Step 1904 comprises depositing one or more layers of non-magnetic material to define a side gap of write pole 2004 . First, a layer of non-magnetic material 2102 (see FIG. 21 ) may be deposited, such as ALD Alumina.
In step 1906 , an Ar ion milling process is performed to remove non-magnetic material 2102 above hard mask layer 2006 on top of write pole 2004 . The ion milling process may be performed at an angle between 45-60 degrees using SIMS end point detection, such as an angle of 55 degrees. The ion milling process end point may be controlled by detecting Ta, Ti, and Si if hard mask structure 2006 comprises a TaO 2 layer, a TiO 2 layer, or a SiO 2 layer above a hard mask Alumina layer. The ion mill process also removes the bottom regions of non-magnetic material 2102 on each side of write pole 2004 to allow subsequently formed side shields to cover write pole 2004 . The resulting structure of write head 2000 is illustrated in FIG. 22 .
In step 1908 , a layer of non-magnetic material 2302 (see FIG. 23 ) may be deposited, such as an Rh layer, which acts as a seed layer for electroplating the side shields as well as a stop layer during a subsequent CMP process. Multiple layers may form non-magnetic material 2102 , such as 5 nm of Ta, 15 nm of Rh and 5 nm of CoFe. The Ta acts as an adhesion layer, the Rh acts as an electroplating seed and a CMP stop layer, and the CoFe acts as a photo adhesion promotion layer for an electroplating process. The resulting structure of write head 2000 is illustrated in FIG. 23 .
Step 1910 comprises depositing side shield material 2402 (see FIG. 24 ). Side shield material 2402 may be deposited using an electroplating process with non-magnetic layer 2302 (e.g., an electroplating seed layer). CMP is performed on side shield material 2402 down to non-magnetic layer 2302 (e.g., the CMP stop layer) to planarize side shield material 2402 and form side shields 2402 . Non-magnetic material 2302 may act as both an electroplating seed layer and a CMP stop layer for the CMP process. For electroplating seed layer purposes, non-magnetic material 2302 may be Rh, Ru, or Au. For CMP stop layer purposes, Rh provides better properties than Ru, and Ru provides better properties than Au. Side shields 2402 are separated from write pole 2004 by a side gap defined by non-magnetic material 2102 and non-magnetic material 2302 . The side gap may be between about 20 nm and about 200 nm. The resulting structure of write head 2000 is illustrated in FIG. 24 .
Step 1912 comprises ion milling to remove non-magnetic material 2302 above hard mask layer 2006 on write pole 2004 . An Ar ion milling process controlled by SIMS end-point detection of mask structure 2006 may be used to remove non-magnetic material 2302 above hard mask layer 2006 . For example, the ion milling process may detect Ta, Ti, and Si if hard mask structure 2006 comprises a TaO 2 layer, a TiO 2 layer, or a SiO 2 layer on a hard mask Alumina layer. An RIE process may be performed, if necessary, to remove the TaO 2 layer, the TiO 2 layer, or the SiO 2 layer on a hard mask Alumina layer 2006 . The ion milling process may also form a notch in write head 2000 after removing non-magnetic material 2302 above hard mask Alumina layer 2006 . The resulting structure of write head 2000 is illustrated in FIG. 25 .
Step 1914 comprises depositing a layer of non-magnetic material 2602 (see FIG. 26 ), which acts as an electroplating seed layer. Step 1916 comprises milling to remove portions of non-magnetic material 2602 from each side region of write pole 2004 using a patterned photo mask to fabricate contacts in non-magnetic material 2602 on each side of write pole 2004 . The contacts allow contact between side shields 2402 and a trailing shield. The resulting structure of write head 2000 is illustrated in FIG. 27 .
Step 1918 comprises forming a trailing shield 2802 (see FIG. 28 ) above non-magnetic material 2602 (i.e., above a trailing surface of write pole 2004 ). Trailing shield 2802 may be formed by depositing trailing shield material using an electroplating process, and performing CMP to planarize the trailing shield material to a desired height to form trailing shield 2802 . Trailing shield 2802 is separated from write pole 2004 by a second gap defined by a thickness non-magnetic material 2602 and a thickness of hard mask Alumina layer 2006 . The trailing gap may be between about 10 nm and about 50 nm. The resulting structure of write head 2000 is illustrated in FIG. 28 . The notch which may be formed in trailing shield gap structure 2602 (see above write pole 2004 in FIG. 28 ) achieves better transition curvature and less flux shunting to the stitched wrap around shield for better writeability of write head 2000 .
FIG. 29 illustrates a top view of write head 2000 after completion of step 1914 . Trailing shield 2802 is disposed on a trailing edge of write pole 2004 . Below trailing shield 2802 is a side shield 2402 on each side of write pole 2004 . Side shields 2402 don't drape from trailing shield 2802 like the side shields of write head 100 in FIG. 11 . Thus, the dimensions of side shields 2402 advantageously are determined independently of the dimensions of trailing shield 2802 and are more flexibly controlled, as are the dimensions of trailing shield 2802 .
Although specific embodiments were described herein, the scope of the invention is not limited to those specific embodiments. The scope of the invention is defined by the following claims and any equivalents thereof.
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A wrap around shield of a write head is fabricated in multiple processes, with side shields fabricated in one process, and a trailing shield formed in another process. These multiple processes form a stitched wrap around shield, resulting in more flexible and accurate placement of the trailing shield and side shields with respect to the write pole. These processes also independently form the dimensions (shapes and sizes) of the side shields and the trailing shield which allows better control of writeability, saturation, and adjacent track interference of the perpendicular recording write head.
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FIELD OF THE INVENTION
[0001] The present invention relates to a new methodology for production of lutein formulations, basically esters of lutein with various fatty acids, starting from any natural or synthetic source, which impart a high added value to these molecules, since they make it possible to obtain stabilized preparations thereof for direct application in the foodstuffs, pharmaceutical and cosmetics fields.
STATE OF THE ART
[0002] Traditionally, the carotenoids have been regarded as plant pigments. In fact they occur in all green tissues in the form of photosynthetic pigment-protein complexes within the chloroplasts. Despite the fact that the typical yellow to red colour of the carotenoids is masked by the green colour of the chlorophylls, the typical colouration imparted by the carotenoids can be observed in the leaves of many trees in the autumn, when the chlorophyll decomposes, and the xanthophylls are esterified by mixtures of fatty acids. With few exceptions, the carotenoids present in the majority of the leaves of all species are P,P-carotene, lutein, violaxanthin and neoxanthin. Of course, small quantities of other carotenoids may also be encountered, such as β,ε-carotene, β-cryptoxanthin, zeaxanthin, antheraxanthin, lutein 5,6-epoxide and lactucaxanthin. Many flowers or fruits (tomato, orange, peppers, marigold, etc.), displaying a colour range from yellow to red, owe their colouration to the carotenoids located in their chromoplasts, and are often present in the form esterified by fatty acids (G. Britton, S. Liaaen-Jensen, H. Pfander, Carotenoids, Volume 1A: Isolation and Analysis, 201, Publ. Birkhäuser, 1995).
[0003] The carotenoids can be divided into two classes: pure hydrocarbons, called carotenes, which include compounds such as β-carotene, α-carotene, γ-carotene or lycopene and xanthophylls, molecules that contain oxygenated functions, examples of this type being asthaxanthin, capsanthin, cantaxanthin or lutein. The two groups of compounds behave differently as regards their physicochemical properties and solubility in organic solvents.
[0004] All these compounds play an important role in the human diet, and their properties as antioxidants for the prevention of cancer and other human diseases and as precursors of vitamin A have been investigated extensively. Furthermore, owing to their yellow to red colouration, the carotenoids are used as a food supplement and colourant in margarine, butter, oils, soups), sauces, etc. (Ninet et al., Microbial Technology, 2nd Edn, Vol. 1, 529-544 (1979), Academic Press NY, Eds. Peppler H. J. and Perlman D.).
[0005] Lutein, (3R, 3′R, 6′R)-β,ε-carotene-3,3′-diol, is a carotenoid belonging to the group of the xanthophylls or carotenoids with oxygenated functions. It is a polyunsaturated asymmetric molecule that consists of a carbon skeleton similar to that of α-carotene ((6′R)-β,ε-carotene), but having a β hydroxyl at C-3 and an α hydroxyl at C-3′. Its empirical formula is C 40 H 56 O 2 with a molecular weight of 568.85 and the following molecular formula:
[0006] In 1907, on the basis of combustion analysis, together with classical determinations of molecular weight, the molecular formula C 40 H 56 O 2 was proposed for a compound isolated from green leaves, which was called “xanthophyll” (R. Willstatter and W. Mieg, Liebig's Ann. Chem., 335, 1 (1907)). Nevertheless, the formula C 40 H 56 O 2 for the lutein isolated from egg yolk was postulated some years later (R. Willstatter and H. H. Escher, Z. Physiol. Chem., 76, 214 (1912)), and it was not known at that time that lutein and the compound isolated previously from leaves and called “xanthophyll” were the same.
[0007] Up to that moment, all attempts to elucidate the molecular structures of the carotenoids by classical experiments of chemical degradation until identifiable fragments were found, had not met with success. The highly unsaturated nature of the carotenoids was confirmed some years later (1928) by experiments of catalytic hydrogenation, and it was then that the term polyene was applied for the first time (L. Zechmeister, L. Von Cholnoky and V. Vrabely, Ver. Deut. Chem. Ges., 61, 566 (1928)). Starting from this moment, a clear and direct relation was established between colour and the number of conjugated double bonds present in these molecules (R. Kuhn and A. Winterstein, Helv. Chim. Acta, 11, 87; 116; 123; 144 (1928), and R. Kuhn and A. Winterstein, Helv. Chim. Acta, 12, 493; 899 (1929)).
[0008] The correct formula of lutein (or “xanthophyll”) was established by Karrer in studies based on reactions of oxidative degradation (P. Karrer, A. Zubrys and R. Morf, Helv. Chim. Acta, 16, 977 (1933)).
[0009] The instability of the carotenoids in crystalline form is well known, and one method of stabilizing them is to prepare oily dispersions. Moreover, it is thought that when the carotenoids are dispersed in oil they are absorbed more easily by the body.
[0010] An alternative method for the stabilization of unstable compounds is their microencapsulation in starch matrices.
[0011] Thus, patents U.S. Pat. No. 2,876,160, U.S. Pat. No. 2,827,452, U.S. Pat. No. 4,276,312 and U.S. Pat. No. 5,976,575 describe a considerable increase in the stability of various compounds, including the carotenoids, by encapsulating them in a starch matrix.
[0012] One of the main difficulties in using the carotenoids in the field of colourants is their zero solubility in water, since many of their applications take place in aqueous media. This problem of solubility is mentioned in document U.S. Pat. No. 3,998,753, and was solved by preparing solutions of carotenoids in volatile organic solvents, such as halogenated hydrocarbons, and emulsifying them with an aqueous solution of sodium lauryl sulphate.
[0013] Document U.S. Pat. No. 5,364,563 describes a method of producing a preparation of carotenoids in powder form, which involves forming a suspension of a carotenoid in a high-boiling-point oil. The suspension is superheated with steam for a maximum period of 30 seconds to form a solution of carotenoid in oil. Next, this solution is emulsified with an aqueous solution of a colloid and then the emulsion is spray-dried.
[0014] In general, in the state of the art we have not found formulations of lutein that are resistant to oxidation for prolonged periods of storage and, at the same time, are soluble in lipophilic or hydrophilic media, permitting their use as colourants for foodstuffs, pharmaceuticals and in cosmetics, for example, or as diet supplements. Most of the commercial samples of lutein consist of extracts or oleoresins from plants, which have inadequate stability owing to their limited content of antioxidants. Moreover, these oleoresins are difficult to use in hydrophilic environments, owing to their zero solubility in water, so that their use is limited to applications in lipophilic environments. In contrast, our formulations exhibit high stability owing to their controlled content of antioxidants, and are perfectly applicable in both hydrophilic and lipophilic environments.
BRIEF DESCRIPTION OF THE INVENTION
[0015] The invention describes a method of formulation, finishing or final presentation of lutein, related compounds (basically esters of lutein with various fatty acids) or mixtures of both, obtained from any natural or synthetic source, depending on their final application, which consists of premixing with antioxidants in the presence of oils and/or organic solvents, in suitable proportions.
[0016] It is possible to obtain, according to this method:
A microcrystalline suspension of lutein and/or related compounds, in vegetable oil; suitable for applications in lipophilic environments. CWD lutein (cold-water-dispersible lutein); suitable for applications in hydrophilic environments.
[0019] Each variant of the method of preparation of formulations comprises the following stages:
Microcrystalline suspension of lutein and/or related compounds in vegetable oil: Mixing of the vegetable oil with the active molecule and an antioxidant. Milling of the mixture. CWD lutein (cold-water-dispersible lutein): Molecular dissolution of lutein and/or related compounds in an organic solvent, preferably in the presence of antioxidants or vegetable oils or both Emulsifying of the organic solution of the active molecule with an aqueous solution of modified starches Evaporation of the organic solvent and of the water until the dry residue is obtained and the appropriate level of residual solvents Drying and finishing of the product.
[0027] The method described endows this molecule with stability that is sufficiently high (longer than 6 months in suitable conditions of packaging) to prevent its oxidation during storage.
DETAILED DESCRIPTION OF THE INVENTION
[0028] A principal object of this invention is a method of preparation of various formulations as a function of the characteristics of the application for which it is intended to use lutein and/or its related compounds. The said method consists of premixing of microcrystalline lutein with antioxidants in the presence of oils and/or organic solvents, in suitable proportions.
[0029] A first formulation, called microcrystalline suspension of lutein in vegetable oil, consists of premixing the lutein molecule to be formulated, with a variable quantity of vegetable oil. A great variety of vegetable oils can be used, and the commonest, but not the only ones, are sunflower oil, olive oil, corn oil, soya oil, cottonseed oil, etc. The dose of lutein and/or related compound will depend on the final strength it is desired to achieve, the commonest values being suspensions with a content of active principle between 5 and 60%, preferably between 10 and 30%. To increase the stability of the mixture, the usual liposoluble antioxidants are used, such as natural tocopherols, and preferably D,L-alpha-tocopherol. The proportion of this compound varies between 0.2 and 15% relative to the weight of the active molecule, preferably between 0.5 and 5%. So that the formulations containing lutein and/or related compounds have satisfactory physiological activity it is necessary to reduce the size of the crystals. This is achieved with the usual milling systems applicable to liquid mixtures. A special object of this invention is ball mills that permit reduction of crystal size below 10 microns, preferably below 5 microns and even more preferably below 2 microns, using microspheres between 0.5 and 0.75 mm in diameter. However, crystal size can vary in relation to the particular application of the suspension, in each case employing suitable spheres and milling conditions. The crystal size will also determine the rheological properties of the mixture, especially its viscosity, which can also be adjusted depending on requirements.
[0030] These microcrystalline suspensions of lutein and/or related compounds in oil are suitable for applications in lipophilic environments.
[0031] A second formulation, called cold-water-dispersible (CWD) lutein formulation, is based on the dissolution of lutein and/or related compounds in an organic solvent and their subsequent microencapsulation in modified starches. This invention will refer in particular to the use of food-grade solvents that are regarded as natural, such as acyl esters, preferably. ethyl, propyl, isopropyl, butyl or isobutyl acetates, which combine the reasonably high solubility for the carotenoid components with compatibility as solvents included in the Group of Class III of the ICH. These solvents are permitted both at national and at community level, in both the pharmaceutical and the foodstuffs fields (RDL12/04/90 and RDL16/10/96). According to the ICH, the content of residual solvents must be below 5000 ppm, preferably below 1000 ppm and more preferably below 100 ppm, always based on the dry matter of the liquid mixture. The concentration of lutein and/or related compounds in the organic solvent can vary between 1 and 50 g/l, preferably between 10 and 30 g/l. The temperature of dissolution can vary between room temperature and the boiling point of the solvent, preferably between 20 and 130° C. The fact that the percentage of cis lutein is a function of the temperature/time relation in the operation of dissolution of the molecule in the organic solvent means that if we wish to obtain a product with a low content of this isomer, either a low dissolution temperature will be used, or otherwise a very short dissolution time. Thus, in order to achieve low levels of cis, and owing to the relatively low solubility of these compounds in solvents of this type (acyl esters) at temperatures of the order of 20-40° C., dissolution will preferably be effected between 70 and 130° C. for a few seconds. It should be noted that the trans isomer is the natural isomer, and that there are differences in shade of colouration between the two isomers. On the other hand, if the levels of cis isomer are not important, dissolution can be carried out without restriction on its conditions rather than achievement of complete solubility at the molecular level. Alternatively, it is possible to use a solvent with greater solubility for these molecules at relatively low temperatures (20-35° C.), such as chloroform, methylene chloride, THF, etc. In this case dissolution can be effected at low temperature (around 30° C.) for some minutes, without any risk of forming cis isomers in excessively high proportions. To increase the stability of the final formulation, an antioxidant, or mixtures of several antioxidants, preferably such as tocopherol, ascorbyl palmitate, etc., each of them in a proportion between 1 and 30%, preferably between 10 and 20%, relative to the weight of the active molecule, are dissolved together with the lutein and/or related compounds in the organic solvent. It is also possible to incorporate vegetable oil in the mixture, i.e. sunflower oil, olive oil, corn oil, soya oil, cottonseed oil, etc., with the aim of promoting the dissolution of the lutein and/or related compounds, and giving the preparation additional stability. The lutein/oil ratio can vary between 10/1 and 1/10.
[0032] The solution of the active molecule thus obtained is mixed and emulsified with an aqueous solution containing an emulsifying agent, for example modified starch, more concretely esters derived from starch, preferably octenyl succinates derived from starch of various molecular weights, particularly, but not exclusively, Purity Gum 2000® from National Starch or Cleargum CO 01® from Roquette, and a microencapsulating agent, formed for example from modified starch, more concretely esters derived from starch, preferably octenyl succinates derived from starch of various molecular weights, particularly, but not exclusively, Hi Cap 100® or Capsul® from National Starch. The mixing ratio of the emulsifying agent and the microencapsulating agent can vary between 5/95 and 95/5, preferably between 25/75 and 75/25, and more preferably between 40/60 and 60/40. The water content of each of the components of the mixture of emulsifying agent and microencapsulating agent is variable, and can be between 1 and 30%, preferably between 5 and 20%, and more preferably 10%. The mixture of aqueous and organic phases is emulsified and the emulsion obtained is homogenized using pressure-difference homogenization systems of the Manton Gaulin or Microfluidizer type, which are commonly used, and preferably by homogenization by tangential friction, for example with an emulsifier of the Ultraturrax type, for a time that varies according to the energy supplied by the equipment and the volume of mixture to be emulsified, with the aim of obtaining an average micelle size below 10 microns, preferably below 2 microns and more preferably between 0.1 and 1 micron.
[0033] Once the emulsion has formed, evaporation of the organic solvent is effected, preferably by vacuum distillation at a temperature below 50° C. As evaporation of the solvent takes place, microcrystallization of the active molecule occurs in the starch matrix. Once the solvent has evaporated, evaporation is continued, with successive additions of water until a content of residual solvents is obtained that meets the specifications for maximum concentration stipulated in the legislation, and a dry residue that is suitable for the type of drying that is to be applied to this liquid mixture. Suitable values of dry matter of the suspension of microencapsulated lutein and/or related compounds are between 1 and 30%, preferably between 10 and 25%.
[0034] It is found, in accordance with the present invention, that both the method of drying by high-temperature spraying (atomization) and the method of fluidized-bed spraying (granulation) are suitable for drying the aqueous suspension of active molecule obtained. Another alternative would be freeze-drying.
[0035] According to the method of drying by atomization, suitable inlet temperatures of the drying air would be between 100 and 200° C. whereas the outlet temperatures would be between 60 and 120° C. The atomized product has a particle size between 10 and 100 microns. In order to increase the particle size and thus reduce the available surface area, and hence increase the oxidation stability of the product, the atomized product can be submitted to a finishing process, consisting of agglomeration by spraying a solution of one of the modified starches used in the formulation, or of the actual suspension of microencapsulated active molecule within a fluidized bed of the said atomized product, making it possible to reach particle sizes in the range 50-500 microns, and preferably in the range 200-300 microns.
[0036] The granulation method involves the use of a fluidized-bed granulator in which seed material is placed, which can be a typical inert material, such as particles of sugar, or fine powder of the actual material to be dried, obtained in previous granulation operations or in a spray-drying operation. The particles are kept in motion by means of air, and the temperature of the bed is maintained between 30 and 90° C., preferably between 50 and 80° C. The suspension of lutein and/or related molecules is sprayed by means of air preheated to, a temperature between 20 and 140° C. within the fluidized bed, at a velocity that ensures that the particles to be coated are not wetted excessively and do not form lumps. The granulated product has a particle size between 100 and 2000 microns, preferably between 100 and 800 microns, and more preferably between 100 and 300 microns.
[0037] On completion of the spray-drying stage by one or other method, as well as optional agglomeration, the particles obtained can be submitted to a finishing process by coating. This coating can be effected with approximately 0.5-10% by dry weight, of aqueous solutions of sugars or even starches.
EXAMPLE 1
[0038] A laboratory ball mill of the Minizeta 003 type from Netzsch is loaded with—in this order—microspheres 0.5-0.75 mm in diameter, 30 g of sunflower oil (Koipe), 0.08 g of D,L-alpha-tocopherol (Merck) and 20 g of lutein eter Xantopina Plus (Bioquimex), which has an equivalent lutein content of 40%. The mixture was milled at 3000 rpm for 5 minutes, obtaining 45 g of an orange-coloured, viscous liquid. Spectrophotometric analysis of the oily suspension revealed a lutein content of 15%. The crystal size was less than 10 microns.
EXAMPLE 2
[0039] 20 g of lutein ester Xantopina Plus (Bioquimex), which has an equivalent lutein content of 40%, was resuspended in 410 ml of isobutyl acetate, and 0.8 g of D,L-alpha-tocopherol (Merck) was added. The mixture was heated to boiling (114° C.) for 2 minutes, achieving complete dissolution of the solid. As a parallel operation, 26.65 g of Hi Cap 100® (National Starch) and 26.65 g of Purity Gum 2000® (National Starch) were dissolved in 325 ml of demineralized water. The hot organic phase was emulsified for 10 minutes in one stage over the aqueous phase using an Ultraturrax emulsifier from IKA, obtaining an average micelle size of 0.4 micron, measured with a Coulter LS230 analyser. The emulsion was transferred to a vacuum distillation system, adding 600 ml of water, so that the 410 ml of isobutyl acetate was evaporated with approximately 700 ml of water. 225 g of liquid formulation (25.9% of dry matter) was obtained with an equivalent lutein content of 2.6% (10.1% based on the dry mass). This liquid formulation was dried in an Aeromatic AG laboratory granulator, employing an inlet gas temperature of 90° C. and achieving a product temperature of 70° C., obtaining an orange-coloured powder with an equivalent lutein content of 9.7% and a water content of 2.6%.
EXAMPLE 3
[0040] 20 g of lutein ester Xantopina Plus (Bioquimex), which has an equivalent lutein content of 40%, was resuspended in 410 ml of isobutyl acetate, and 0.8 g of D,L-alpha-tocopherol (Merck), 1.6 g of ascorbyl palmitate (Merck) and 8 g of sunflower oil (Koipe) were added. The mixture was heated to boiling (114° C.) for 2 minutes, achieving complete dissolution of the solid. As a parallel operation, 21.5 g of Hi Cap 100® (National Starch) and 21.5 g of Purity Gum 2000® (National Starch) were dissolved in 325 ml of demineralized water. The hot organic phase was emulsified for 10 minutes in one stage over the aqueous phase using an Ultraturrax emulsifier from IKA, obtaining an average micelle size of 0.5 micron, measured with a Coulter LS230 analyser. The emulsion was transferred to a vacuum distillation system, adding 600 ml of water, so that the 410 ml of isobutyl acetate was evaporated with approximately 700 ml of water. 205 g of liquid formulation (25.0% of dry matter) was obtained with an equivalent lutein content of 2.5% (10.0% based on the dry mass). This liquid formulation was dried in an Aeromatic AG laboratory granulator, employing an inlet gas temperature of 90° C. and achieving a product temperature of 70° C., obtaining an orange-coloured powder with an equivalent lutein content of 9.5% and a water content of 3.0%.
EXAMPLE 4
[0041] 20 g of lutein ester Xantopina Plus (Bioquimex), which has an equivalent lutein content of 40%, was resuspended in 500 ml of dichloromethane, and 0.8 g of D,L-alpha-tocopherol (Merck) was added. The mixture was heated at 35° C. for 5 minutes, achieving complete dissolution of the solid. As a parallel operation, 26.65 g of Hi Cap 100® (National Starch) and 26.65 g of Purity Gum 2000® (National Starch) were dissolved in 400 ml of demineralized water. The hot organic phase was emulsified for 10 minutes in one stage over the aqueous phase using an Ultraturrax emulsifier from IKA, obtaining an average micelle size of 0.5 micron, measured with a Coulter LS230 analyser. The emulsion was transferred to a vacuum distillation system, adding 600 ml of water, so that the 500 ml of dichloromethane was evaporated with approximately 800 ml of water. 200 g of liquid formulation (26% of dry matter) was obtained with an equivalent lutein content of 2.6% (10.0% based on the dry mass). This liquid formulation was dried in an Aeromatic AG laboratory granulator, employing an inlet gas temperature of 90° C. and achieving a product temperature of 70° C., obtaining an orange-coloured powder with an equivalent lutein content of 9.8% and a water content of 2.0%.
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The present invention describes a method of preparation of formulations of microcrystalline lutein, particularly in the form of esters, which are resistant to oxidation and are soluble in hydrophilic and/or lipophilic media. For these formulations, the esters of lutein are mixed with antioxidants, vegetable oils and/or organic solvents, and this initial mixture is submitted to various stages depending on the type of final formulation required. These formulations are suitable for direct application as colourants in the pharmaceutical, food and cosmetics fields. They can also be used as diet supplements.
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The present application is a division of U.S. patent application Ser. No. 14/356,519, filed May 6, 2014, which is a national stage filing under 35 U.S.C. § 371 of International Patent Application No. PCT/AT2012/000259, filed Oct. 11, 2012, which claims priority to Austrian Patent Application No. A 1658/2011 filed Nov. 9, 2011, the entire disclosure of each of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
Field of the Invention
This invention is directed towards rapidly dispersible absorbent nonwoven fabrics and methods for making and using such products. This invention is especially directed towards rapidly dispersible wet wipes that are flushable through a standard toilet system and disintegrate into easily dispersible fragments that biodegrade after disposal.
Not-woven textiles are defined with the terminology “nonwoven”. The definition of nonwoven is described in the norm ISO 9092:1988. Absorbent nonwoven fabrics include materials such as dry wipes, wet wipes and cosmetic wipes and masks. They are also materials used in hygiene products like panty liners, sanitary napkins and incontinence products. The nonwoven fabrics used in these applications should fulfil the requirements of European Pharmacopoeia.
Disposable absorbent wipes such as toilet wet wipes offer high levels of convenience, comfort and efficacy that are greatly appreciated by consumers. However, the popularity of these products has created a need regarding their disposal. General disposal methods used for waste materials such bin disposal for subsequent incineration or landfill are not convenient for the consumers, especially for using of toilet wet wipes. One of the alternative disposal methods is flushing the wet wipes directly into a conventional toilet. Flushing the product in the toilet, dispersing it by mechanical forces and finally biodegrading the material in the sewage system is more convenient and discrete for the consumers. For this disposal method, the suitable material should maintain its structural integrity and strength for use, but also disintegrate readily when flushing into the toilet without causing any blockage in the pumping and drain systems.
Such products like toilet wipes are pre-moistened wipes. Therefore the nonwoven fabrics used for these applications should maintain their mechanical strength and integrity in the wet state during storage and also be biodegradable in the sewage system.
Flushable wet wipes are known for example from U.S. Pat. No. 5,629,081 and EP 1 285 985 A1.
SUMMARY OF THE INVENTION
The object of the invention is to provide a dispersible nonwoven fabric with good tensile strength but which disintegrate readily when flushed.
By the present invention there is provided a dispersible nonwoven fabric comprising pulp and solvent spun cellulosic fibers characterized in that the solvent spun cellulosic fibers are fibrillated.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an unfibrillated Tencel by light microscope,
FIG. 2 : shows an exemplary fibrillated Tencel by light microscope, and
FIG. 3 : shows an exemplary fibrillated Tencel by scanning electron microscope.
DETAILED DESCRIPTION OF THE INVENTION
Especially suited as starting material for the fibrillated fibers are solvent spun short cut cellulosic fibers with a length of 2 to 20 mm, preferably 3 to 12 mm, most preferably 4 to 10 mm. The titer of the solvent spun short cut fibers is 0.9 to 6.7 dtex, preferably 1.3 to 1.7 dtex.
Preferably the solvent spun short cut fibers are present in the dispersible nonwoven fabric in an amount of 1 to 90 wt.-%, preferably 5 to 40 wt.-%, most preferably 10 to 30 wt.-% based on the fabric.
A preferred solvent spun short cut fiber is a lyocell fiber, produced according to the Aminoxide-process, which is known e.g. from U.S. Pat. No. 4,246,221 (McCorsley). A suited solvent spun fiber is sold under the trade name “Tencel”.
The dispersible nonwoven fabric has a weight of 30 to 100 g/m2, preferred of 40 to 60 g/m2 and a thickness of 0.1 to 0.7 mm.
The dispersible nonwoven fabric may comprise a dispersing aid in an amount of 0.1 to 1% wt.-%, preferably 0.5 to 1 wt.-% based on the fabric.
To increase the strength, optionally a binder is present in an amount of 0.01 to 5 wt.-%, preferably 0.1 to 0.5 wt.-% based on the fabric, preferably in form of an acrylic resin or epichlorohydrin based resin, such as polyamide-polyamine-epichlorohydrin resins or polyamide-epichlorohydrin resins. Other examples for suited binders are polyethylenimine resins and aminoplast resins.
Any type of pulps are suited, especially softwood pulps, hardwood pulps or a pulp made from plants like abaca or bamboo.
The dispersible nonwoven fabric according to the invention has a wet tensile strength in machine direction of 2 to 20 N/5 cm, preferably 3 to 13 N/5 cm and most preferably 3 to 7 N/5 cm based on a basis weight of 60 g/m2 and in cross direction 1 to 10 N/5 cm, preferably 1 to 7 N/5 cm and most preferably 1 to 3 N/5 cm. The wet tensile strength has been measured according to the EDANA Method WSP 110.4 (09) “Standard Test Method for Breaking Force and Elongation of Nonwoven Materials (Strip Method)”.
One standardized test method for testing the properties of disposable wipes is known from “EDANA Guidance Document for Assessing the Flushability of Nonwoven Consumer Products”. This test is used to assess the dispersibility or physical breakup of a flushable product during its transport through household and municipal conveyance systems (e.g., sewer pipe, pumps and lift stations). This test assesses the rate and extent of disintegration of a test material by turbulent water in a rotating tube. Results from this test are used to evaluate the compatibility of test materials with household and municipal wastewater conveyance systems. The principle of the test method is that the rotation of the tube is used to simulate the physical forces acting to disintegrate a product during passage through household sewage pumps and municipal conveyance systems. In this test the product is placed in a clear plastic tube containing 700 ml of tap water or raw wastewater, which is rotated end-over-end. After a specified number of cycles or rotations, the contents in the tube are passed through a series of screens. The various size fractions retained on the screens are weighed, and the rate and extent of disintegration determined.
The test material is disintegrating when at least 95% of the size fractions pass a 12 mm screen and the residue is less than 5%.
The invention also concerns a process for the production of a dispersible nonwoven fabric.
According to this wet lay process, pulp is dispersed in water and a solvent spun fiber is dispersed in water, either separately or together as a mixture. A dispersing aid such as CMC (Carboxymethyl cellulose) may be added to improve dispersion quality. The dispersions are passed through a refiner either separately or are co-refined. The refining energy is from 20 to 400 kWh/t, prefer 40 to 150 kWh/t. A binder solution may be added to the slurry. In the case of separate refining, the slurries are mixed to form an intimate blend to form one slurry. The slurry is then wet-laid, e.g. on a papermaking machine, to form a sheet. The sheet then passes through a hydroentanglement process either on-line or as a separate off-line process to form a fabric.
FIG. 1 shows an unfibrillated Tencel (light microscope). Fibrillation or refining is a wet abrasion process that exposes and releases fibrils emerging from the surface region of the filaments. As refining progresses, more fibrils are released from the filaments and the diameter of the residual filaments decreases ( FIG. 2 : light microscope, FIG. 3 : scanning electron microscope).
In further steps the fabric is sliced into the appropriate format, folded and packed.
A treatment, preferably an impregnation, with a liquid or lotion can be carried out before packaging.
The invention is shown by the following examples:
Example 1 and Example 2 (Both Comparative)
Wetlaid fabrics made of blends of woodpulp (Camfor pulp, a long fiber woodpulp derived from spruce and pine, grown in British Columbia, Canada) with 15% Tencel short cut 1.7 dtex at 6 mm cut length (example 1) or 25% Tencel short cut 1.7 dtex at 6 mm cut length (example 2) without any refining process and without additional of any additives showed a very good dispersibility according to the Tier 1 Test-FG 511.2-Dispersability Tipping Tube Test of the “EDANA Guidance Document for Assessing the Flushability of Nonwoven Consumer Products”. According to example 1, 100% of the disintegrated size fractions pass the 12 mm, the 6 mm and even the 3 mm screen, 21% retain and 79% passes the 1.5 mm screen. But the fabrics did not show a high mechanical strength, both in machine direction (MD) and cross direction (CD) as shown in Table 1.
TABLE 1
Dispersibility of samples
Tensile
Mass of each fraction
Thick-
Strength
Elon-
in % in relation
Fabric
ness
wet
gation
to dry mass
Fiber
weight
dry
[N/5 cm]
wet [%]
>12
>6
>3
>1.5
<1.5
Ex
blends
[g/m 2 ]
[mm]
MD
CD
MD
CD
mm
mm
mm
mm
mm
1
15%
60
0.65
2.0
0.9
2.2
8
0
0
0
21
79
Tencel
85%
camfor
pulp
2
25%
57
0.60
1.9
1.2
2.4
5
0
0
0
28
72
Tencel
75%
camfor
pulp
Example 3, 4 and 5
Blends of woodpulp (Camfor pulp) with 25% Tencel short cut 1.7 dtex at 6 mm cut length including an addition of 0.5% CMC dispersing aid to the slurry. In these trials the pulp/Tencel blend was refined through 1× disc refiner and 4× conical refiners in series to levels of 40 kWh/t and 60 kWh/t. Acrylic dry strength resin was added to the slurry at 1% (based on dry fiber weight). The fabrics were dispersible and the tensile strength of fabrics was improved (Table 2).
Example 6
A blend of 80% woodpulp (Camfor pulp) with 20% Tencel short cut 1.7 dtex at 6 mm cut length was used to make wetlaid fabrics. Fibers were refined to 100 kWh/t, 1% CMC (based on dry fiber weight) as dispersing aid was added and also 0.5% epichlorhydrin based wet strength resin (based on dry fiber weight) was added to increase the wet strength (Table 2). The fabric was dispersible.
TABLE 2
Tensile
Dispersibility of samples
Thick-
Strength
Mass of each fraction in %
Refining
Fabric
ness
wet
Elongation
in relation to dry mass
Fiber
Energy
weight
dry
[N/5 cm]
wet [%]
>12
>6
>3
>1.5
<1.5
Ex
blends
(kWh/t)
[g/m 2 ]
[mm]
MD
CD
MD
CD
mm
mm
mm
mm
mm
3
25%
40
59
0.28
3.6
1.3
4.2
39
0
0
0
55
45
Tencel
75%
camfor
pulp,
4
25%
60
56
0.25
3.3
1.5
5.0
33
0
0
0
53
47
Tencel
75%
camfor
pulp
5
25%
60
60
0.32
3.4
1.5
1.3
6.6
0
0
0
78
22
Tencel
75%
camfor
pulp +
acrylic
resin at
1%
6
20%
100
57
0.23
5.4
2.1
2.8
17
0
11
34
29
26
Tencel
80%
camfor
pulp +
0.5%
epichlor-
ohydrin
Example 7, 8, 9 and 10
A blend of 75% woodpulp (Camfor) with 25% Tencel short cut 1.7 dtex at 6 mm cut length was used to make wetlaid fabrics. Fibers were refined to 80 kWh/t, 1% CMC as dispersing aid was added and also an epichlorhydrin based wet strength resin was added to increase the wet strength at concentrations of 0.05%, 0.10%, 0.15% and 0.20%. The results, demonstrated in Table 3, show that all samples were dispersible.
The fabric according to the invention can be used in dry wipes and wet wipes like toilette wipes, facial wipes, cosmetic wipes, baby wipes and sanitary wipes for cleaning and densification as well as in absorbent hygiene products such as panty liners, sanitary napkins and incontinence pads.
TABLE 3
Tensile
Dispersibility of samples Mass of
Thick-
Strength
each fraction in % in relation to
Refining
Fabric
ness
wet
Elongation
dry mass
Fiber
Energy
weight
dry
[N/5 cm]
wet [%]
>12
>6
>3
>1.5
<1.5
Ex
blends
(kWh/t)
[g/m 2 ]
[mm]
MD
CD
MD
CD
mm
mm
mm
mm
mm
7
25%
80
58
0.59
3.7
1.6
11
50
0
0
1
64
35
Tencel
75%
camfor
pulp +
0.05%
epichlor-
ohydrin
resin
8
As
80
60
0.53
4.1
1.9
11
50
0
0
4
63
33
Ex. 7
except
with
0.10%
epichlor-
ohydrin
resin
9
As Ex.
80
59
0.29
6.5
2.6
2.9
10
0
27
31
16
26
7
except
with
0.15%
epichlor-
ohydrin
resin
10
As Ex.
80
59
0.42
5.5
2.2
8.8
28
0
2
30
36
32
7
except
with
0.20%
epichlor-
ohydrin
resin
|
The present invention relates to a dispersible nonwoven fabric comprising pulp and solvent spun cellulosic fibers, characterized in that the solvent spun cellulosic fibers are fibrillated. Furthermore the invention concerns the use of the fabric in dry wipes and wet wipes.
| 3
|
FIELD OF THE INVENTION
The present disclosure relates to the petrochemical engineering field, and more specifically, to a radiant coil structure of an ethylene cracking furnace used in petrochemical engineering.
BACKGROUND OF THE INVENTION
The ethylene cracking techniques used in petrochemical ethylene equipments mainly include those developed by LUMMUS Co. (USA), Stone & Webster Co. (USA), Kellog & Braun Root Co. (USA), Linde Co. (Germany), Technip KTI Co. (Netherlands), and the CBL cracking furnace developed by China Petrochemical Corporation.
FIG. 1A shows a typical ethylene cracking furnace 10 , which comprises a radiant section 11 , a convective section 13 , and a flue section 12 located between the radiant section 11 and the convective section 13 . Within the radiant section 11 , a radiant coil 14 is provided in the central plane P of the radiant section 11 along the longitudinal direction thereof. In addition, the radiant section 11 is further provided with bottom burners 15 and/or side burners 16 for heating. Moreover, the ethylene cracking furnace 10 further comprises a transfer line exchanger 17 , a high-pressure steam drum 18 , and an induced draft fan 19 , etc.
To significantly reduce the feedstock consumption, maintain a suitable run length, and have a good feedstock flexibility, nowadays a two-pass high-selectivity radiant coil with or without branches of variable diameters is used. The first-pass tube of the radiant coil is of a small diameter. Therefore, a quick temperature rise can be achieved since the specific surface area of a small-diameter tube is relatively large. The second-pass tube is of a large diameter, in order to reduce the influences on coking sensitivity. The two-pass radiant coil can be configured as 1-1 type (U type), 2-1 type, 4-1 type, 6-1 type coil, etc.
A two-pass 1-1 type coil structure, which can be matched to transfer line exchanger(s), is of a large specific surface area and good mechanical performance. The run length thereof, however, is slightly short.
For an N−1 (N>1) type coil structure, the number of tubes in the first pass is N times as more as the number of the tubes in the second pass. Therefore, the N tubes in the first pass need to be combined into one tube before being connected to a corresponding second-pass tube. EP 1146105 discloses a cracking furnace having a two-pass 2-1 type coil structure. As indicated in FIG. 1B , a two-pass radiant coil comprises first-pass tubes 51 (16 tubes) and second-pass tubes 52 (8 tubes) perpendicularly arranged in an inner chamber of a radiant section. All these tubes are located in one common plane, with all the first-pass tubes 51 arranged together, and all the second-pass tubes 52 arranged together, wherein every two first-pass tubes 51 are combined into one tube by a Y-shaped manifold 53 at a lower portion of the first-pass tubes 51 before being connected to a second-pass tube 52 via two S-shaped elbows 54 and a U-shaped elbow 55 .
CN 1067669 discloses a cracking furnace having a two-pass 6-1 type coil structure, which includes 6 first-pass tubes, and one second-pass tube. Similarly, these 6 first-pass tubes are first combined into one tube via a rigid manifold arranged in a lower portion thereof, and then are connected to the second-pass tube.
In the above structures, since the number of the first-pass tubes is a plurality of times higher than the number of the second-pass tubes, when the coil is heated to expand, the second-pass tubes first expand downward, and then the first-pass tubes are dragged by the second-pass tubes to move downward also, wherein the first-pass tubes are easily bent because they are deformed under different forces. The rigidity of the manifold connected in the lower portion of the first-pass tubes prevents expansion differences thereof from being absorbed by an S-shaped tube (if any), rendering the coil easily being bent. Hence, the mechanical performance of the coil is reduced, thereby shortening the service life of the coil and the run length of the cracking furnace.
SUMMARY OF THE INVENTION
To overcome the technical defects existing in the prior art, the present disclosure discloses a new ethylene cracking furnace having a two-pass or multi-pass radiant coil, wherein a special arrangement structure of the radiant coil can reduce bending of the coil, thereby improving the mechanical performance of the coil, extending service life thereof, and prolonging the run length of the cracking furnace.
According to the present disclosure, it provides an ethylene cracking furnace, comprising at least one radiant section, which is provided with a bottom burner and/or a side burner, and at least one set of radiant coil arranged along a longitudinal direction of the radiant section, wherein the radiant coil is an at least two-pass coil having an N−1 structure, N preferably being a natural number from 2 to 8; and wherein a manifold is arranged at an inlet end of a downstream tube of said at least two-pass coil, and an outlet end of each upstream tube of said at least two-pass coil is connected to the manifold through a curved connector.
In the text of the present disclosure, the term “coil having an N−1 structure” means that in two adjacent passes of tubes, for each downstream tube there are N corresponding upstream tubes. It is easily understood, in a two-pass coil having an N−1 structure, a manifold therein can have N input ends and one output end. According to one preferred embodiment, the manifold is in the form of an invertedly Y-shaped pipe having N input ends and one output end, N equaling 2 or 4. When N equals 4, every two upstream tubes are first combined together via one Y-shaped pipe element before being connected to a curved connector. According to another embodiment, the manifold is in the form of a palm-like pipe having a plurality of input ends and one output end. In a coil having more than two passes, N−1 indicates N input ends and one output end, with all connection manners of a two-pass coil having an N−1 structure capable of being applied therein.
In one preferred embodiment, the radiant coil is a two-pass coil, wherein the upstream tube is a first-pass tube, while the downstream tube is a second-pass tube. In another embodiment, the radiant coil is a multi-pass coil having more than two passes, wherein the upstream tubes are odd-number ones such as a first-pass tube, a third-pass tube, etc., while the downstream tubes are even-numbered ones such as a second-pass tube, a fourth-pass tube, etc.
According to one embodiment, the upstream tubes are divided into two groups each with the same number of tubes respectively arranged at two sides of the downstream tube, and all of the upstream tubes and the downstream tube are arranged in a common plane.
According to one embodiment, the curved connector comprises a U-shaped elbow and an S-shaped elbow, of which one connects to a lower portion of a corresponding upstream tube, and the other connects to an inlet end of the manifold. It should be noted that the curved connector of the present disclosure can “connect” to the tube or manifold either directly or indirectly via a transition pipe, which can be selected as specifically required. In some preferred embodiments, the tube diameter of the curved connector equals the tube diameter of the upstream tube, which, for example, is especially suitable when N equals 2, or when N is larger than 2 and the manifold is in the form of a palm-like pipe.
According to one embodiment, viewed from a top view of the radiant coil, with respect to the downstream tube, corresponding S-shaped elbows are in parallel with each other, and/or corresponding U-shaped elbows are arranged in one and the same line. Preferably, all the S-shaped elbows are parallel with one another. Alternately, all the S-shaped elbows are divided into a plurality of groups, with all S-shaped elbows in each group in parallel with one another.
According to one embodiment, the upstream tubes are divided into two groups each with the same number of tubes respectively arranged at two sides of the downstream tube. In this embodiment, however, the plane in which the upstream tubes arranged at one side of the downstream tube are located and the plane in which the upstream tubes arranged at the other side of the downstream tube are no longer arranged in a common plane with the downstream tube. Instead, with respect to the plane in which the downstream tube is located, the plane in which the upstream tubes arranged at one side of the downstream tube are located is in mirror relationship with the plane in which the upstream tubes arranged at the other side of the downstream tube are located. In one alternative embodiment, the upstream tubes arranged at one side of the downstream tube, the upstream tubes arranged at the other side of the downstream tube, and the downstream tube are respectively in three planes parallel with one another.
According to the present disclosure, the upstream tubes can be all arranged at one and the same side of the downstream tube with all the upstream tubes and the downstream tube positioned in a common plane. According to one embodiment, the curved connectors of two adjacent upstream tubes are respectively located at two sides of the plane in which the tubes are located. In one embodiment, the upstream tubes do not have a common plane with the downstream tube, but are respectively arranged in two parallel planes, which is in parallel with the plane in which the downstream tube is arranged. In another embodiment, the upstream tubes are respectively arranged in two planes in mirror relationship with each other with respect to the plane in which the downstream tube is located.
Comparing with the prior art, the present disclosure brings about the following advantageous technical effects:
(1) Since the first-pass tube is combined with the second-pass tube at the lower portion thereof, and S-shaped elbows and U-shaped elbows are used, the stress caused by expansion differences among the first-pass tubes that exist in 2-1 type, 4-1 type, and other types of coils can be effectively reduced. Consequently, bending of the radiant coil can be avoided, thereby extending the service life of the radiant coil.
(2) The S-shaped elbows and U-shaped elbows of the upstream tubes have smaller tube diameters when the upstream tubes are combined at the lower portion the downstream tube than when the upstream tubes are combined at the lower portion of the upstream tubes. Therefore, the upstream tubes have better flexibility, which facilitates absorption of heat expansion differences in two adjacent passes of tubes, thus avoiding bending of the tubes and finally extending service life of the radiant coil.
(3) A small tube diameter of the first-pass tube results in a high specific surface area thereof. Therefore, when the first-pass coil is extended, the specific surface area of the whole coil would be increased, which facilitates extension of the run length of the cracking furnace at the same cracking depth, and improves olefin yield at the same run length.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows a typical ethylene cracking furnace according to the prior art;
FIG. 1B shows a typical two-pass 2-1 type coil structure according to the prior art;
FIGS. 2A , 2 B, and 2 C respectively show a front view, a top view, and a side view of one embodiment of a two-pass 2-1 type coil structure according to the present disclosure, wherein first-pass tubes are divided into two groups with the same number of tubes in each group respectively arranged at two sides of a second-pass tube;
FIGS. 3A , 3 B, and 3 C respectively show a front view, a top view, and a side view of another embodiment of the two-pass 2-1 type coil structure according to the present disclosure, wherein all the first-pass tubes are arranged at one and the same side of the second-pass tube;
FIGS. 4A , 4 B, and 4 C respectively show a front view, a top view, and a side view of one embodiment of a two-pass 4-1 type coil structure according to the present disclosure;
FIGS. 5A to 7C show front views, top views, and side views of three variations of the two-pass 2-1 type coil structure according to the present disclosure, wherein the first-pass tubes are divided into two groups with the same number of tubes in each group respectively arranged at the two sides of the second-pass tube, or all the first-pass tubes are arranged at one and the same side of the second-pass tube;
FIGS. 8A to 10C show front views, top views, and side views of three variations of the two-pass 2-1 type coil structure according to the present disclosure, wherein all the first-pass tubes are arranged at one and the same side of the second-pass tube; and
FIGS. 11A to 11C respectively show a front view, a top view, and a side view of one variation of the two-pass 4-1 type coil structure according to the present disclosure.
In the accompanying drawings, the same component or structure is indicated by the same reference sign.
DETAILED DESCRIPTION OF THE EMBODIMENTS
In the following the present disclosure will be discussed in details with reference to the accompanying drawings. It should be noted that the present disclosure aims to provide improvements on radiant coil in the radiant section of the ethylene cracking furnace. Other structures in the ethylene cracking furnace, such as the convective section, the transfer line exchanger and the like, are already known in the prior art. For example, the transfer line exchanger suitable for the present disclosure can be a double-coil transfer line exchanger (such as a linear transfer line exchanger, U-type transfer line exchanger, and the first level of a two-level transfer line exchanger, etc.), conventional boiler, etc. Moreover, the two-pass radiant coil of the present disclosure can be mainly suitable for cracking liquid material, but also suitable for cracking gas material. In contrast, the multiple-pass radiant coil of the present disclosure can be mainly suitable for cracking gas material, but also suitable for cracking liquid material. In addition, both of the two-pass radiant coil and the multiple-pass radiant coil of the present disclosure can be used in building new cracking furnaces or reconstructing existing cracking furnaces. These are known to one ordinarily skilled in the art, and thus their details thereof are omitted here.
FIGS. 2A , 2 B, and 2 C illustrate a first embodiment according to the present disclosure, which involves a two-pass 2-1 type coil structure. As shown in the Figures, the two-pass 2-1 type coil according to the embodiment comprises two first-pass tubes 1 and one second-pass tube 2 . The front view, i.e., FIG. 2A indicates that said two first-pass tubes 1 are respectively arranged at two sides of the second-pass tube 2 . Moreover, the three tubes have three center lines positioned in a common plane P (see FIG. 2B ).
According to the present disclosure, a lower end (i.e., an input end) of the second-pass tube 2 is provided with a manifold 3 , which is used for combining the two first-pass tubes 1 and connecting the same to the second-pass tube 2 . In the specific embodiment, the manifold 3 is in the form of an invertedly U-shaped pipe, i.e., having two input ends and one output end, wherein the output end is connected to the lower end of the second-pass tube 2 . The two first-pass tubes 1 are respectively connected to the two input ends of the manifold 3 via two respective curved connectors (each consisting of an S-shaped elbow 5 and a U-shaped elbow 4 ) arranged at lower ends of the two first-pass tubes 1 (i.e., output ends thereof). It can be easily understood, for an N−1 type coil structure (N>2), the manifold can be designed to have N input ends and one output end, i.e., in the form of a palm. In addition, the curved connector can be connected to the two input ends of the manifold 3 via a transition pipe to satisfy the requirements of process and mechanical design. In one specific embodiment, the transition pipe, which can be a straight pipe or an elbow, has the same tube diameter as the curved connector.
With the arrangement of the manifold 3 as a rigid connecting structure at the lower end of the second-pass tube 2 instead of at the lower end of the first-pass tubes 1 , stress caused by the expansion differences between the first-pass tubes 1 and the second-pass tube 2 under heating, and stress unbalances caused by expansion differences between the first-pass tubes 1 can be absorbed by the S-shaped elbow 5 and the U-shaped elbow 4 arranged at the lower end of the first-pass tubes 1 . Hence, deformation is reduced, thus extending the service life of the coil.
Furthermore, according to the present disclosure, the S-shaped elbow 5 and the U-shaped elbow 4 are connected to the lower end of the first-pass tubes 1 and have the same tube diameter as the first-pass tubes 1 , thereby essentially extending the length of the first-pass tubes 1 . Such being the case, the specific surface area of the tubes is increased, which is advantageous for extending the run length of the cracking furnace under the same cracking depth, and for improving product yield under the same run length of the cracking furnace. Besides, because the curved connector has the same tube diameter as the first-pass tubes, the flexibility thereof is improved, which facilitates elimination of thermal stress, thereby reducing deformation of the tubes and extending service life thereof.
Advantageously, the S-shaped elbow 5 and U-shaped elbow 4 connected to the lower end of the first-pass tube 1 which is arranged at a left side of the second-pass tube 2 (see FIG. 2A ), and the S-shaped elbow 5 and U-shaped elbow 4 connected to the lower end of the other first-pass tube 1 which is arranged at a right side of the second-pass tube 2 (see FIG. 2A ) are respectively located at two sides of the plane P (see FIGS. 2B and 2C ). This arrangement facilitates more homogeneous absorption of deformation caused by the thermal stress, thus further reducing the temperature on the surface of the tubes and extending the service life thereof.
In one preferred embodiment, as indicated in FIG. 2B , the top view, the respective S-shaped elbows 5 of the two first-pass tubes 1 are in parallel with each other, while the respective U-shaped elbows 4 of the two first-pass tubes 1 are in one and the same line. More preferably, with respect to the center line of the second-pass tube 2 , the S-shaped elbow 5 and U-shaped elbow 4 of the first-pass tube 1 located at one side of the plane P are in 180° rotation symmetry with the S-shaped elbow 5 and U-shaped elbow 4 of the first-pass tube 1 located at the other side of the plane P.
Moreover, as required in the process or mechanical design, a straight pipe of certain length and of the same tube diameter as the first-pass tubes can be provided between the manifold 3 and the curved connector.
According to one variation of the first embodiment, the first-pass tubes 1 and the second-pass tube 2 can be arranged at different planes, wherein the curved connector can merely comprises the U-shaped elbow 4 , while the S-shaped elbow 5 can be omitted.
Other embodiments according to the present disclosure will be explained in the following. For the sake of simplicity, only features or components that are different from those in the embodiment as explained above and the functions thereof will be discussed, while the same features or components or the functions thereof will not be repeated.
FIGS. 3A , 3 B, and 3 C show a second embodiment according to the present disclosure. The second embodiment distinguishes from the first embodiment in that both of the two first-pass tubes 1 are arranged at one and the same side of the second-pass tube 2 (see the front view FIG. 3A ). This arrangement can also realize the advantages as stated in the first embodiment, and is applicable in some cracking furnaces of specific structures. In the second embodiment, the S-shaped elbow 5 and U-shaped elbow 4 connected to the lower end of one of the first-pass tubes 1 , and the S-shaped elbow 5 and U-shaped elbow 4 connected to the lower end of the other of the first-pass tubes 1 are still respectively arranged at the two sides of the plane P in which all the three tubes are located (see FIGS. 3B and 3C ).
In one embodiment, viewed form a side view, a group of the S-shaped elbow 5 and U-shaped elbow 4 is in minor relationship with another group of the S-shaped elbow 5 and U-shaped elbow 4 with respect to the plane P (see FIG. 3C ). In one embodiment not shown, however, both groups of curved connectors may not be in mirror relationship with each other, in order to ensure the same length and weight between the elbows at the two sides.
Similarly, when the first-pass tubes 1 and the second-pass tube 2 are not arranged in a common plane, the curved connector can only comprise the U-shaped elbow 4 , while the S-shaped elbow 5 can be omitted.
FIGS. 4A , 4 B, and 4 C show a third embodiment according to the present disclosure. The third embodiment is different from the first embodiment in that the third embodiment involves a two-pass 4-1 type coil structure. As demonstrated by the Figures, both sides of the second-pass tube 2 are provided with two first-pass tubes 1 . The two first-pass tubes 1 in either side are first combined into one pipe via a manifold 6 , then connected to the S-shaped elbow 5 and the U-shaped elbow 4 , and finally connected to the manifold 3 positioned at the lower end of the second-pass tube 2 . In the embodiment, the manifold 6 is in the form of a Y-shaped pipe element having two input ends and one output end. In addition, according to the requirements in the process and mechanical design, the two first-pass tubes 1 in either side can first be combined into one pipe via one manifold 6 , then connected to the S-shaped elbow 5 and the U-shaped elbow 4 by connecting to one straight pipe, and finally connected to the manifold 3 arranged at the lower end of the second-pass tube 2 via one transition pipe (i.e., a straight pipe or an elbow).
It can be easily understood that in one embodiment not shown, the manifold 6 can be omitted. Meanwhile, the manifold 3 can be modified to have four input ends and one output end. In this case, the four first-pass tubes 1 can be directly connected to the four input ends via necessary elbows (i.e., U-shaped elbows 4 and S-shaped elbows 5 ), or via a transition pipe (i.e., a straight pipe or an elbow).
FIGS. 5A , 5 B, and 5 C show a fourth embodiment according to the present disclosure. The fourth embodiment is still a two-pass 2-1 type coil structure, which is designed in the same way as the first embodiment except that it comprises 8 second-pass tubes 2 arranged together side by side, and 16 first-pass tubes 1 which are divided into two groups with 8 tubes in each group respectively arranged at the two sides of the second-pass tubes 2 . The structure of the fourth embodiment is equivalent to a structure including 8 coils of the first embodiments arranged together in parallel with one another. As shown in FIG. 5B , all the 16 S-shaped elbows 5 are in parallel with one another. Furthermore, for each second-pass tube 2 , the corresponding two U-shaped elbows 4 are placed in one and the same line. Preferably, the corresponding U-shaped elbows 4 of each second-pass tube 2 are in parallel with one another.
In addition, preferably, at the two sides of the plane P, all connecting areas of the S-shaped elbows 5 and the U-shaped elbows 4 are located in a common plane Q, which is in parallel with the plane P.
FIGS. 6A , 6 B, and 6 C show a fifth embodiment according to the present disclosure. The fifth embodiment is substantially the same as the fourth embodiment except that not all the 16 S-shaped elbows 5 are in parallel with one another. Instead, they are divided into several groups and all elbows in a group are in parallel with one another. As indicated in the Figures, the S-shaped elbows 5 are grouped with an outer elbow and an inner elbow, and the two S-shaped elbows 5 in each group are parallel with each other.
FIGS. 7A , 7 B, and 7 C show a sixth embodiment according to the present disclosure. The sixth embodiment is substantially the same as the fourth embodiment except that the first-pass tubes 1 are not arranged to have a common plane with the second-pass tube 2 . As illustrated in FIG. 7C , the side view, a plane M in which eight first-pass tubes 1 are located at one side of the second-pass tube 2 , and a plane M′ in which the other eight first-pass tubes 1 are located at the other side of the second-pass tube 2 , form an acute angle respectively with respect to the plane P in which the second-pass tube 2 is located. Preferably, the planes M and M′ are in mirror relationship with respect to the plane P. In addition, as shown in FIG. 7B , the top view, each of the first-pass tubes 1 has an axis line L perpendicular to the plane P in which the second-pass tube 2 is located. It can be easily understood, in one specific embodiment, the planes M, M′ can be in parallel with the plane P. That is, either the plane M or M′ defines an angle of zero with the plane P. Furthermore, it would easily occur to one skilled in the art that this structure is applicable to any cases in which all the first-pass tubes are positioned at one and the same side of the second-pass tube 2 (for example in the second embodiment of the present disclosure).
FIGS. 8A , 8 B, and 8 C show a seventh embodiment according to the present disclosure. The seventh embodiment is substantially the same as the second embodiment except that it comprises five second-pass tubes 2 arranged together side by side, and 10 first-pass tubes 1 arranged at one and the same side of the second-pass tubes 2 . The structure of this embodiment is equivalent to five coils as illustrated in the first embodiment arranged together in parallel with one another. As shown in FIG. 8B , the S-shaped elbows 5 and U-shaped elbows 4 connected to the lower end of the first-pass tubes are staggered with each other with respect to the plane P in which the tubes are located, i.e., the S-shaped elbow 5 and U-shaped elbow 4 connected to a first tube of the first-pass tubes are arranged at one side of the plane P (an upper portion in the top view), while the S-shaped elbow 5 and U-shaped elbow 4 connected to a second tube of the first-pass tubes are arranged at the other side of the plane P (a lower portion in the top view), so on and so forth. Besides, all the S-shaped elbows 5 at the upper portion of the top view are in parallel with one another, and all the U-shaped elbows 4 thereof are also in parallel with one another. And all the S-shaped elbows 5 at the lower portion of the top view are in parallel with one another, and all the U-shaped elbows 4 thereof are also in parallel with one another.
Additionally, in this embodiment, viewed from the side view (see FIG. 8C ), the S-shaped elbows 5 and U-shaped elbows 4 respectively arranged at the two sides of the plane P are in mirror relationship with each other with respect to the plane P. In one embodiment not shown, however, the side projections thereof are not in symmetry in order to ensure the same pipe length of the two curved connectors connected to one and the same manifold.
FIGS. 9A , 9 B, and 9 C show an eighth embodiment according to the present disclosure. The eighth embodiment is substantially the same as the seventh embodiment except that the lower end of the first-pass tube 1 is first connected to the U-shaped elbow 4 , then to the S-shaped elbow 5 , and finally to the manifold 3 . That is, the layout order of the U-shaped elbow 4 and S-shaped elbow 5 are different from that in any one of the preceding embodiments. Preferably, the S-shaped elbows 5 respectively arranged at the two sides of the plane P in which the tubes are located are in mirror relationship with respect to the plane P in the top view. Still preferably, the pipe length of the connector connecting to the first-pass tube is the same as that of connecting to the second-pass tube (see FIG. 9B ).
FIGS. 10A , 10 B, and 10 C show a ninth embodiment according to the present disclosure. The ninth embodiment is substantially the same as the eighth embodiment except that all the U-shaped elbows are the same as one another, and the S-shaped elbows respectively positioned at the two sides of the plane P in which the tubes are located are not in mirror relationship with respect to plane P.
FIGS. 11A , 11 B, and 11 C show a tenth embodiment according to the present disclosure. The tenth embodiment, which is a two-pass 4-1 type coil structure, is substantially the same as the first embodiment except that it comprises four second-pass tubes 2 arranged together in parallel with one another, and 16 first-pass tubes 1 which are divided into two groups each group with eight tubes respectively arranged at the two sides of the second-pass tubes 2 . The structure of this embodiment is equivalent to four coils of the third embodiment arranged together in parallel with one another.
According to the present disclosure, an inner diameter of the first-pass tube 1 can be in the range from 40 to 65 mm, an inner diameter of the second-pass tube can be in the range from 55 to 130 mm, and an inner diameter of the connector connecting the first-pass and the second-pass tubes can be in the range from 40 to 90 mm Furthermore, the length of the first-pass tube 1 generally can be selected as within the range from 8 to 18 m, while the length of the second-pass tube 2 can be selected within the range from 6 to 14 m. The above parameters, and other parameters concerning the length and inner diameter of tubes and connectors are not limited in the above ranges but can be selected as specifically required, which is well known by one skilled in the art.
In one preferred embodiment, an intensified heat transfer member, such as the twisted tube as disclosed in CN 1260469, can be further provided in the radiant coil structure, in order to facilitate absorption of radiant heat.
Although the cracking furnace of the present disclosure is exemplarily described with the two-pass radiant coil structure, it however be understood that the present disclosure can also be used in a radiant coil structure having more than two passes. For example, in an 8-4-2-1 type four-pass coil structure, a manifold can be provided at a lower end of a second-pass or a fourth-pass tube. One skilled in the art would easily think of the above after reading the present disclosure.
Moreover, although in the foregoing the present disclosure is described with reference to one set of radiant coil arranged in one cracking furnace, it can be understood that a plurality of sets of radiant coils can be arranged in one single cracking furnace, dependent on the actual requirements. When one cracking furnace is provided with a plurality of radiant coils as described in the above embodiments, the radiant coils can be arranged in sequence. Alternatively, the plurality of radiant coils can be arranged in the form of manifolds. In this case, the coils should be arranged in a mirror-symmetric way.
Although the present disclosure is described in details with reference to some embodiments, it would be apparent to one skilled in the art that modifications and variations may be made to some features/components/structures of the present disclosure without departing from the spirit or scope of the invention. In particular, the features disclosed in one embodiment can be combined with those disclosed in other embodiments in arbitrary ways unless the combinations may cause conflicts. It is intended that the present disclosure covers all the modifications and variations thereof provided they come within the scope of the appended claims and their equivalents.
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The present disclosure provides an ethylene cracking furnace, comprising at least one radiant section provided with a bottom burner and/or a side burner, and at least one set of radiant coil arranged along a longitudinal direction of the radiant section. The radiant coil is an at least two-pass coil having an N−1 structure, wherein N is preferably a natural number from 2 to 8. A manifold is arranged at an inlet end of a downstream tube of said at least two-pass coil, and an outlet end of each upstream tube of said at least two-pass coil is connected to the manifold through a curved connector. The arrangement according to the present disclosure can effectively reduce the expansion differences between the upstream tubes and the downstream tubes, and therefore reduce the stress caused thereby. Consequently, bending of the radiant coil can be avoided, thereby extending the service life of the radiant coil.
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BACKGROUND OF THE INVENTION
The present invention relates to a sewing machine which includes a sewing-machine cutting device comprising a movable upper knife and a stationary bottom knife which cooperates therewith.
The prior art includes a number of sewing-material cutting devices of the general type mentioned above, in which a movable upper knife cooperates with a fixed bottom knife for cutting sewing material. All the known solutions have the feature in common that they have an upper knife of relatively complicated form; see, e.g., Federal Republic of Germany Utility Model 66 04 108, especially FIG. 21.
There is also known an upper knife having a carbide metal tip for edge trimming devices on sewing machines, see Federal Republic of Germany Utility Model 18 89 277, this knife also having a complicated structure.
As a result of these complicated prior art designs, the upper knives known up to the present time have all had the disadvantage of being expensive parts which are subject to wear. Accordingly, it has been the practice for decades to sharpen by regrinding dulled cutting edges which are no longer suitable for use. The regrinding requires a special knife-grinding apparatus which must be equipped with cutting stands for all or most of the different possible cutting angles. Since the regrinding must be carried out by skilled personnel, it is wage-intensive. Another disadvantage is that the reground upper knife must also be installed and adjusted for proper cutting by skilled personnel, in view of the displacement of the cutting edge which takes place by virtue of the regrinding.
SUMMARY OF THE INVENTION
Therefore, a primary object of the present invention is to provide an upper knife for a sewing-material cutting device which can be manufactured at low cost, has a longer life than the previously known upper knives, and can be replaced by the operator with a few turns of the hand.
In accordance with a broad aspect of the invention, this object is achieved by a sewing machine which includes a sewing-material cutting device, comprising a movable upper knife and a stationary bottom knife which cooperates therewith, wherein the upper knife includes a knife holder which holds a replaceable turnable cutting plate having a plurality of cutting edges.
With the upper knife of the invention, it is now possible, by using a turnable cutting plate having four cutting edges, for example, to obtain four times longer life than with a conventional upper knife. Furthermore, constant good cutting accuracy is assured since subsequent adjustment of the cutting edge after turning or replacing a turnable cutting plate is not necessary. Due to the relatively low price of the turnable cutting plate of the invention, subsequent regrinding is no longer worthwhile.
According to a further advantageous aspect of the invention, the turnable cutting plate is connected to the knife holder by an additional fastening element.
Preferably, the turnable cutting plate is provided with a polygonal protruding shaft, which permits the elimination of a stop edge on the knife holder for aligning the turnable cutting plate with the knife holder.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the invention will be seen from the following detailed description of two embodiments thereof, in which:
FIG. 1 is a perspective view of a complete assembly including an upper knife and an associated knife holder;
FIG. 2 is a cross-sectional view corresponding to FIG. 1;
FIG. 3 is a perspective view of the knife holder of FIG. 1;
FIG. 4 is a perspective view of a turnable cutting plate having a polygonal mounting extension;
FIG. 5 is a perspective view of a turnable cutting plate having a polygonal shaft; and
FIG. 6 is a perspective view of a conventional sewing machine having a sewing-material cutting device according to an embodiment of the invention mounted thereon.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 6 shows a conventional sewing machine 13 which has been provided with a sewing-material cutting device 14 according to an embodiment of the invention, the machine being made suitable thereby for the sewing and simultaneous cutting of the sewing material. Various known components, such as the needle bar, sewing needle, presser rod, and sewing foot have not been shown.
The cutting device 14 comprises a block 18 which can be moved up and down, and on which an upper knife 1 is mounted. The upper knife cooperates with a fixed bottom knife 20 for cutting sewing material, the bottom knife 20 being fastened preferably to the bottom of a foundation plate 15 and the cutting edge thereof being arranged preferably within a throat plate 16. Alternatively, the bottom knife 20 can also be mounted directly on the throat plate 16.
The cutting device 14 has a shift lever 17 for driving the driven upper knife 1 in up-and-down movement. The upper knife 1 includes two parts, a knife holder 2 which is fastened to the block 18, and a turnable cutting plate 3 mounted on the knife holder 2.
FIGS. 1-4 show a first embodiment of the invention, in which the turnable cutting plate 3 is mounted on the knife holder 2 by means of a screw 7 which is countersunk into the plate 3. In this embodiment, the cutting plate 3 has four cutting edges 4, which are preferably at an equal distance from an axis of symmetry 6. Each cutting edge 4 forms, with a front side 5 of the cutting plate 3, a cutting angle which is designed to be favorable for cutting.
On the side of the turnable cutting plate 3 which is opposite the front side 5, there is provided a polygonal mounting extension 10 (best seen in FIG. 4) which has as many resting edges 11 as the turnable cutting plate 3 has cutting edges 4. Since it is advantageous in many cases of use for the cutting edge 4 to form an angle with the horizontal, it is advisable to arrange the mounting extension 10, as shown in FIG. 4, in such a manner that each resting edge 11 forms a well-defined angle with the cutting edge 4 which faces it. As seen in FIG. 4, each resting edge 11 is at a distance a from the axis of symmetry 6.
The knife holder 2 has a threaded hole 9 to receive the countersunk screw 7, as well as a stop edge 8 which also is spaced the above-mentioned distance a from the center line of the threaded hole 9. The cutting plate 3 is secured to the knife holder by the screw 7 with a given resting edge 11 engaging the stop edge 8 of the knife holder 2, thus exposing for use the one of the cutting edges 4 which corresponds to the given resting edge 11.
Then, by loosening the countersunk screw 7, a different cutting edge 4 which is still sharp can, by suitable rotation of the turnable cutting plate 3, be brought into the position contemplated for dependable cutting by the upper knife 1. After the turnable cutting plate 3 is rotated, it is again fastened by tightening the countersunk screw 7. Since all cutting edges 4 of a given turnable cutting plate 3 are at the same distance from the axis of symmetry 6, no subsequent adjustment of the upper knife 1 is necessary. In this way, assurance is had that the operator can easily effect personally the replacement or rotation of a turnable cutting plate 3, in the same way as the replacement of a broken needle.
In another embodiment of the upper knife of the invention, shown in FIG. 5, the turnable cutting plate 3 has a protruding polygonal shaft 12. The shaft 12 is arranged at the axis of symmetry 6 of said cutting plate and can be introduced into an opening (not shown) in the knife holder, the opening having a shape corresponding to the cross-section of the shaft 12. The opening in the knife holder acts on the surfaces 19 to secure the cutting plate 3 in rotational position.
By means of the shaft 12, the turnable cutting plate 1 of FIG. 5 may be mounted on the knife holder in various alternative ways, such as in force-locked or form-locked manner, or by conventional holding or clamping means.
In order to permit economical manufacture of the turnable cutting plate 3, it is advisable that it be made as a precision casting of so-called knife steel, or as a sintered carbide part, for example. Both methods of manufacture result in finished parts which require no additional work except for the sharpening of the cutting edges 4. Alternatively, the turnable cutting plate 3 can also be made of compressed ceramic material.
Although illustrative embodiments of the invention have been described herein, it is to be understood that the invention is not limited to such embodiments, but rather that various modifications thereof may occur to one skilled in this art, still within the scope of the present invention.
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A sewing-material cutting device includes a movable upper knife and a stationary bottom knife which cooperates therewith. The upper knife includes a knife holder which holds a replaceable turnable cutting plate having a plurality of cutting edges. A polygonal fastener is provided on the cutting plate for selectively engaging the knife holder in a plurality of positions corresponding to respective cutting positions of the plurality of cutting edges.
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FIELD OF THE INVENTION
This relates to a method and apparatus for removing slitter skivings from a web that is moving through a conveyor system to be treated. The skivings are removed to avoid contamination to the web.
BACKGROUND OF THE INVENTION
In many systems of treating web material it is necessary to treat the web in a continuous fashion by conveying the web through various steps. A common step is to cut the web to a desired size. Thus a slitting step is included in many operations.
In these operations, such as the treatment of polyethylene coated paper webs for inducing photographic film or paper, the slitting operation produces skivings which when settling on the web, produces contaminants which adversely affect the final product.
Thus, in the photographic field, a high quality raw stock paper is sandwiched between two layers of high grade molten polyethylene in a continuous operation at a high rate of speed.
As the polyethylene is applied to the paper, it is squeezed between cooled rollers in a pressurized nip area. As a result, some of the polyethylene is forced past the edges of the paper, creating what is known in the trade as overcoat.
This overcoat is beneficial due to the fact that it can be used somewhat to control the caliper of the papers edges, as well as lock the paper into a sealed environment with a process called edge encapsulation.
It is this overcoat material that leads to the problem of the operation.
As desirable as the overcoat is, if left on in its entirety, it causes many problems downstream of the operation, for this reason as a step in the process, it is trimmed off in a final width slitting operation.
As the paper enters the winder area, it passes through a set of rotary slitter knives which are set to a pre determined width for the particular grade being run.
These knives turn at line speed and in fact, trim off the undesirable part of the overcoat. In doing so, a small amount of polyethylene is rubbed off of the trimmed edge, and left clinging to the rotary slitter knife. As the knives collect this material (known in the business as skivings) it is gradually thrown off by centrifugal force.
As the skivings become airborne, they are picked up by the static charge created by the moving web of polyethylene coated paper and carried onto the finished product where they are crushed into the surface by the nip pressure and the mass of the finished roll at the winding operation.
As a safeguard against sparking in the sensitizing operation the paper is generally treated with an antistatic coating on one side.
As the rolls sit in storage, they lose any static charge that was built up in the winding operation and as a result, when the rolls are unwound in the next operation, some of the skivings again become airborne, and now contaminate even more of the web instead of just the edges.
Even worse, as the paper conveys through the sensitizing machine, some of the embedded particles come free and contaminate the rest of the web.
An across the web system has existed for many years, and various other systems exist to clean moving webs, but however, poly skivings are a unique problem, because they have always existed but were never diagnosed before as a contaminant. With the increasing demand on higher quality products, and the thinner more surface sensitive emulsions coming onto the market they have become a defect that has stirred up a great amount of concern in finishing. In the business of creating an absolutely flat surface, any disruption in that surface can be a major problem, especially in the photographic industry where a minute surface disruption can actually change a color, or show up as a colored spot on a finished photo. An absolutely clean base is a must.
Poly skivings are a hard defect to deal with because by nature, they are light in weight, small in size, prone to static cling and once they are in a clean environment, they are all but impossible to get rid of.
The prior art has dealt with the slitter skiving problem in many ways. In U.S. Pat. No. 2,722,983, a device is shown for cutting wire and string products. In U.S. Pat. No. 4,875,398, a device is shown which collects saw dust for slitting sheets. The removal of slitting dust is described in U.S. Pat. Nos. 3,272,651; 4,704,930; 4,300,421; 3,795,164; 3,465,625; 3,691,888; 4,003,276; and 5,480,333. Although various methods are taught to remove contaminants, the problem still remains, especially in high speed operations.
SUMMARY OF THE INVENTION
It is an object of this invention to remove slitter skivings produced by slitting a continuously moving web at their source, before they can spread or be made more permanent by being compressed into a roll of the web.
It is a further object of this invention to eliminate the contamination of an entire web which results for cleaning only a small amount of the total width prior to the next treatment.
It is a still further object of the present invention to employ an operation for forming photographic webs including slitting of the webs and insuring that the skivings never make it into the sensitizing environment.
By using the edge vacuum system of this invention, the skivings are completely eliminated within a few feet of their source, thus insuring that they can not become airborne, and be wound into the finished roll to cause all of the problems described above.
The edge vacuum system consists of a dust collection system equipped with filter bags to allow for collection and analysis of the skivings being pulled off of the paper. The collector is coupled to hard piping under the machines frame. At the end of the hard pipes are flexible lines used to allow for different width positioning that connect to the vacuum heads.
The vacuum heads themselves are similar in shape to a clam shell and they are capable of engulfing, without actually touching the edges of the running web allowing for a stronger and more focused vacuum path as the paper runs through them at high line speeds of up to 1000 feet per minute.
The system is guarded by 1/2" screening so that in the event of a tear off of the line, nothing larger would be able to enter and plug up the hard piping.
The vacuum heads are mechanically fastened by way of adjustable brackets to pneumatically retractable slides that allow for the room necessary to thread up the line, or work in the crowded winder area for winding the web.
This apparatus for removing slitter skivings from a web running through a conveyor to carry a web of material through a treatment process including slicing comprises;
a slitter knife for cutting said web material as it is conveyed; and
an edge vacuum mechanism comprising at least two vacuum heads which are capable of engulfing but do not touch the edges of the moving web material wherein the web moves between said heads and slitting debris is removed by said vacuum heads.
BREIF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of the cutting and slitter removal for a continuously moving web.
FIG. 2 is a side and front view of web passing through the vacuum apparatus of the present invention.
For a better understanding of the present invention, together with other and further objects, advantages and capabilities thereof, reference is made to the following detailed description and appended claims in connection with the preceding drawings and description of some aspects of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the operation of photographic web material which includes slitting and winding into a roll, including the edge vacuum apparatus of this invention.
In FIG. 1, the paper web 12 is guided through the vacuum heads 7 idle rollers 1 and 14 and through slitter knife 3, supported by roll 2 and finally to roll 13.
The critical edge vacuum apparatus comprises vacuum heads 7 trimming removal chute 4, an edge vacuum slide mechanism 6, a reducer 8 to increase edge vacuum velocity, a flexible vacuum hose 9 to allow for variable widths of web, a dedicated vacuum source 10 and filter bags 11 for collecting debris.
The vacuum heads, 7 as shown in FIG 1 can be made from 21/2" long, 2" polyvinylchloride (PVC). One end is closed off with 1/8 sheet plastic glued permanently in place. A 3/4" slot is then cut 1" deep across the center of the closed off end forming a clamshell shape. This size was chosen for a vacuum pump with 12000 CFM draw because it would pick up the skivings, but stay far enough away from the paper to have the least chance of touching the finished product. Other sizes will work for particular vacuum pump being used. This shape allows both sides of the paper to be vacuumed with equal strength.
FIG. 2 illustrates the side and front view of the web 12 moving through vacuum head 7. Each edge of the web goes through clamshell shaped vacuum head 7 so as to remove the skivings without touching web 12.
The vacuum heads can be set into 2" PVC elbows which have their openings guarded by discs of 1/2 wire screening. This limits the size of debris allowed into the system. The elbows are fitted into 2" by 3" reducers 8 put in place to increase the air currents velocity at the vacuum heads. These are fitted to 4" wire reinforced flexible hosing 9 which is used in the system to allow for the flexibility needed in the variable widths of product run on the poly machines. The rest of the system consists of 3" PVC pipe and fittings, such as elbows, pipe, and a Tee fitting to allow for a center vacuum pickup when the paper is being center slit, needed to fit the physical constraints of the winder area. The vacuuming takes place, preferably as close to the slitters as possible (e.g. 2-4 ft.)
The whole system dumps into a 2HP dust collector 10 with cloth filter bags 11 for data collection. The vacuum heads are fitted to custom pneumatic retracting devices 5 and are attached to the poly machines trim chutes 4 but would work equally well mounted anywhere else.
The retracts 5 consist of custom built dovetail sliders fitted with small air cylinders 6 capable of allowing 3" of travel for the vacuum heads on each side of the web. These are installed to allow ease of thread up in the cramped winder/slitter area 2, 3.
The system runs on 230 volt single phase wiring, and is rated for continuous duty. It can however be turned on and off by using a switch provided with the unit (not shown).
This system being simple in nature is a very efficient and low-cost way of dealing with debris generated when using slitter knives. It can be fitted to almost any machine, and has the advantage of being moved out of the way when needed. It can be set up to handle any amount of slitters, and it removes the contamination at its source.
While the invention has been described with particular reference to a preferred embodiment, it will be understood by those skilled in the art the various changes can be made and equivalents may be substituted for elements of the preferred embodiment without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation in material to a teaching of the invention without departing from the essential teachings of the present invention.
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A method and apparatus for removing skivings generated by slicing a moving web comprises a slitter knife for cutting the web and an edge vacuum machine comprising at least two vacuum heads which engulf but do not touch the moving web. Skivings from the edges of the web are vacuumed away so that they do not contaminate the web during later treatment.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to equipment for cleaning steam generators, and particularly to an improved articulated fluid lance having an extension nozzle that is movable for bringing the fluid jet into close proximity with the broached holes in the support plates for a nuclear steam generator for more efficiently cleaning sludge from steam generators.
2. Description of the Related Art
In nuclear power stations, steam generators, such as recirculating steam generators and once-through steam generators, are used for heat exchange purposes in the generation of steam to drive the turbines. Primary fluid which is heated by the core of the nuclear reactor passes through a bundle of tubes in the steam generator. The secondary fluid, generally water, which is fed into the space surrounding the tubes receives heat from the tubes and is converted into steam for driving the turbines. After cooling and condensation has occurred, the secondary fluid is directed back into the space around the tubes to provide a continuous steam generation cycle. Due to the constant high temperature and severe operating conditions, sludge accumulates on the lower portions of the tubes, support plates, and on the tube sheet which supports same. The sludge which is mainly comprised of an iron oxide, such as magnetite, reduces the heat transfer efficiency of the tubes and can cause corrosion. Thus, the tubes must be cleaned periodically to remove the sludge and various types of apparatus and method are available to accomplish this task.
U.S. Pat. No. 4,980,120 which is assigned to the Assignee of the present invention, and hereby incorporated by reference, discloses an articulated sludge lance.
In addition, U.S. Pat. No. 4,980,120 in the background art section describes various other techniques found in U.S. Pat. Nos. 4,566,406; 4,079,701 and 4,700,662.
In addition to those references, U.S. Pat. No. 4,407,236 to Schukei, et al discloses a thin strip of spring steel which enters a tube lane for sludge lance cleaning for nuclear steam generators. The forward ends of the capillary tubes are directed downward for the jetting of fluid under high pressure.
U.S. Pat. No. 4,827,953 to Lee is directed to a flexible lance for steam generator secondary side sludge removal. This patent discloses a flexible lance having a plurality of hollow, flexible tubes extending lengthwise along the flexible member. There are a plurality of nozzles at an end of the flexible members with the flexible member being configured to go into the difficult to access geometry of the steam generator.
When using the articulated sludge lance, penetration into the steam generator must be at least seven inches below the individual support plates due to stress considerations. This means jetting water from seven inches away while moving the articulated sludge lance parallel to the support plate. It has been found that the effectiveness of the cleaning diminishes considerably with distance from the support plate. Of particular concern is the deposits blocking broached holes.
Because of the foregoing, it has become desirable to develop an improved articulated sludge lance which jets the fluid at close proximity to the broached support plate taking into consideration the stress factors.
SUMMARY OF THE INVENTION
The present invention solves the aforementioned problems associated with the prior art as well as others by providing a movable extension nozzle on an articulated sludge lance. The extension nozzle can be moved elastically with a tension cable to a predetermined curvature and height so as to place the nozzle in close proximity to a support plate. The improved articulated sludge lance of the present invention includes a bumper member attached to the flexible conduit of the nozzle to interact with the tubes in the tube lane as the lance moves therethrough creating a side-to-side motion so that the path of the fluid jet intersects as many of the broached holes as possible.
In an alternate embodiment, the improved articulated sludge lance includes actuating means to allow the extension nozzle to extend from a retracted position in the fluid distribution member after it is inserted in place in a tube lane. This facilitates the movement of the improved articulated sludge lance into a specific tube lane in a steam generator for cleaning thereof.
Accordingly, an object of the present invention is to provide an improved articulated sludge lance with a movable extension nozzle.
Another object of the present invention is to provide an improved articulated sludge lance with an extension nozzle that can be moved to a predetermined curvature and height so as to place the nozzle in close proximity to a support plate for more efficient cleaning.
A further object of the present invention is to provide an improved articulated sludge lance with a bumper member that causes the water jet from the lance to intersect as many broached holes as possible in a support plate by means of a side-to-side motion imparted to the extension nozzle.
Yet a further object of the present invention is to provide a retractable, movable extension nozzle for an articulated sludge lance.
Still, a further object of the present invention is to provide a device which is simple in design, rugged in construction, and economical to manufacture.
The various features of novelty characterizing the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, and the operating advantages attained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a front elevational view of an articulated sludge lance disclosed in U.S. Pat. No. 4,980,120;
FIG. 2 is a top plan view of the articulated sludge lance shown in FIG. 1;
FIG. 3 is a top plan view of the fluid distribution member utilized by the articulated sludge lance;
FIG. 4 is a top plan view of the articulated sludge lance employed in a steam generator;
FIG. 5 is an elevational sectional view of the fluid distribution member illustrating the extension nozzle in accordance with the present invention;
FIG. 6 is a view similar to FIG. 5 showing the tensioned cable moving the extension nozzle to a predetermined curvature and height;
FIG. 7 is a perspective view of the present invention illustrating the movable extension nozzle with the bumper member; and
FIG. 8 is a top sectional view of a broached tube support plate illustrating some of the tubes in section, and depicting the motion of the articulated sludge lance therethrough via several paths labeled A, B, C, in dashed line.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the figures generally, wherein like numerals designate the same element throughout the several drawings, and first to FIG. 1 in particular, there is shown the articulated sludge lance (10) as disclosed in U.S. Pat. No. 4,980,120, hereby incorporated into this application by reference. The sludge lance (10) is comprised of a manipulator member (12), a cam assembly (14) attached to one end of the manipulator member (12), a spring backing plate (16) attached to the underside of the manipulator member (12) adjacent to the opposite end thereof, and a water distribution member (18) positioned so that a portion thereof is interposed between the bottom surface of the manipulator member (12) and the top surface of the spring backing plate (16).
The manipulator member (12) is formed from a high impact strength plastic, is elongated and typically has a substantially rectangular cross-section. A plurality of radius blocks (20) each having a substantially rectangular cross-section of approximately the same size as the manipulating member (12) is attached to the opposite end of the manipulator (12) so as to be aligned therewith. Attachment is effected by means of the spring backing plate (16) which is attached to the bottom of the manipulator member (12) and to the bottom of each of the radius blocks (20) by fasteners (22). The radius blocks (20) are positioned in an abutting relationship to one another and to the end of the manipulator member (12).
As shown in FIG. 2, a wire cable (24) traverses through the length of the manipulator member (12) and through each of the radius blocks (20). One end of the cable (24) is connected to the outermost radius block (20) and the other end of the cable (24) is connected to a pin (26) (shown in phantom) within the cam assembly (14). A cam lever (28) is attached to the cam assembly (14) permitting rotation thereof. Rotation of the cam lever (28) in a clockwise direction causes the wire cable (24) to move to the left causing the radius blocks be drawn into an arc with respect to the manipulator member (12) as illustrated in FIG. 1. Subsequent rotation of the cam lever (28) back to its original position causes the wire cable (24) to move to the right resulting in the radius blocks (20) returning to their original position so as to be in the same plane as manipulator member (12). The spring backing plate (16) urges the radius blocks (20) to return to their original position.
The water distribution member (18) is elongated and has a substantially rectangular cross-section which is similar to, but smaller, than the rectangular cross-section of the manipulator member (12) and the radius blocks (20). The water distribution member (18) is received within a recess provided within the bottom of the manipulator member (12). The water distribution member (18) is similarly received within a recess provided within the bottom of each radius block (20) so as to be interposed between the spring backing plate (16) and the radius blocks (20). The length of the water distribution member (18) is greater than the combined length of the manipulator member (12) and the radius blocks (20) attached thereto causing the outer end of the water distribution member (18) to be exposed.
In the present invention, modifications have been made to the water distribution member (18) with particular emphasis on the water tubes (36).
Referring now to FIG. 5, there is shown a flexible fluid conduit (60) extending from the water distribution member (18). Referring back to FIG. 3, the articulated sludge lance as described in U.S. Pat. No. 4,980,120 provides for water tubes (36) terminating in a transverse passageway (38) located in a split manifold (40) at the outer end of the water distribution member (18). Now referring to FIG. 5, the flexible fluid conduit (60) is fluidly coupled to the transverse passageway (38) and receives fluid therefrom. Preferably, the flexible fluid conduit (60) is provided with at least one nozzle (62) for spraying a fluid in one or more directions from the outermost end of the flexible fluid conduit (60). To minimize wear, the nozzle (62) may be provided with a sapphire jewel or a ceramic insert. The flexible fluid conduit (60) is formed from a high impact strength plastic which is resilient in nature.
Attached to the outermost end of the flexible fluid conduit (60) is a wire cable (64) which runs lengthwise through a cable tube (66) through the water distribution member (18) traversing through the length of the manipulator member (12) to an actuating means (68) such as a knob or a cam assembly similar to cam assembly (14) which when pulled tensions the wire cable (64) from a first position substantially parallel to the fluid distribution member (18) as shown in FIG. 5 to a second position as shown in FIG. 6. In the second position, the flexible fluid conduit (60) is elastically curved upward to a predetermined curvature and height so as to place the nozzle (62) in close proximity to a support plate. Preferably, nozzle (62) would be within about 1/2 inch away from the support plate while the water distribution member (18) would be at least seven inches below. This will greatly improve the effectiveness of the articulated sludge lance in cleaning these hard to reach areas. FIG. 6 illustrates how the flexible fluid conduit (60) forms an arc which is planar to the fluid distribution member (18) and directs the fluid in a preset direction. In the case at hand, the direction is upwardly, however, any direction can be achieved and with a nozzle having more than one orifice in several directions a substantially large area may be cleaned all at one time. The flexible fluid conduit (60) is designed to be employed in conjunction with the outlet orifices (42) of the water distribution member (18) to efficiently clean the steam generator.
In a similar fashion, the tension cable (64) may be tensioned to direct the nozzle (62) downwards. While one wire cable (64) is depicted, it is envisionable that several cables may be employed in the manner previously described to direct nozzle (62) in a desired direction.
As described in U.S. Pat. No. 4,980,120, the sludge lance (10) is inserted through a hand hole (50) provided in a steam generator shell (52) and into a lane or space between tubes in a tube bundle (54) as shown in FIG. 4. The rotation of cam lever (28) adjusts an angular deflection of the radius blocks (20) to permit the sludge lance (10) to enter between the tubes within the tube bundle (54). At this point, the wire cable (64) is pulled tight to cause the flexible fluid conduit (60) to curve as illustrated in FIG. 6 to clean a support plate. As the sludge lance (10) is moved through the tube bundle (54) a fluid flow from the outlet orifices (42) in the water distribution member (18) as well as nozzle (62) in the flexible fluid conduit loosens and removes sludge from the tubes as well as the support plate with the sludge then being removed from the generator by a conventional suction system.
Next, referring to FIG. 7, the present invention advantageously provides a bumper member (70) which through a bumping interaction with the tubes in a tube bundle (54) causes the nozzle (62) to move in a side-to-side fashion as it travels through the lane. In this manner, the water or fluid jet intersects as many of the broached holes in the lane as possible as illustrated in FIG. 8.
There are three potential paths (A, B, C) shown in FIG. 8 in phantom line. The first path, A, describes the way the current lance would sweep across the support plate. As illustrated, the water jet depicted by the phantom line labeled A spends much of the time on the support plate (72), rather than removing the deposits blocking the broached holes (74). The addition of the bumper member (70) which may also be formed from a high impact strength plastic or polytetra fluoroethlene impacts the tubes in the steam generator thereby causing the nozzle (62) to travel with a side-to-side motion as the lance moves through the lane. This path is shown in phantom line labeled B in FIG. 8. The path labeled C illustrates what happens when the side-to-side motion caused by the bumper member (70) is not synchronized properly. It can be self defeating in that the water jet impinges only on the support plate while not cleaning the broached holes (74). This dilemma is easily overcome by adjusting the bumper member (70) along the length of the pressure fluid conduit (60) to achieve path B either by visual inspection or by calibration on a model or actual example.
Referring back to FIGS. 5 and 6, while a wire cable (64) with an actuating means (68) is described and shown, it should be understood that there are other positioning means which may be employed to move the flexible fluid conduit (60) to form an arc such as a rod. In addition, even though the flexible fluid conduit (60) is shown situated outside of the water distribution member (18), a further feature of the present invention allows the flexible fluid conduit (60) to be retracted so that substantially all of the flexible fluid conduit (60) is initially located in an opening or a passageway in the fluid distribution member (18) as shown by dashed lines in FIG. 5. This orientation facilitates the movement of the sludge lance (10) through the tube bundle to some preset starting point. When cleaning is to be commenced, a second actuating means such as a knob (76) or a cam assembly moves the flexible fluid conduit (60) out of the fluid distribution member passageway (78) so that an aperture (not shown) in the fluid distribution member (60) aligns with the transverse passageway (38) to receive fluid therefrom. Suitable rubber sealing means such as O-rings or gaskets are employed to prevent leaks and maintain a proper pressure tight seal.
While a specific embodiment of the invention has been shown and described in detail to illustrate the application and principles of the invention, certain modifications and improvements will occur to those skilled in the art upon reading the foregoing description. It is thus understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims.
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An improved articulated sludge lance with a retractable movable extension nozzle for cleaning a steam generator. The extension nozzle includes a flexible conduit adapted to be moved with a wire cable to place the nozzle in close proximity to a support plate for effectively cleaning the broached holes therein. A bumper member fastened to the flexible conduit provides a side-to-side motion from impact with the tubes when the lance is moved therethrough.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from Korean Patent Application No. 10-2006-0018210, filed Feb. 24, 2006, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
Systems and methods consistent with the present invention generally relate to a radio frequency (RF) communication system having a chaotic signal generator and a method of generating a chaotic signal, and more particularly, to an RF communication system having a chaotic signal generator which is less power-consuming, small in size and easy to construct and a method of generating a chaotic signal.
2. Description of the Related Art
A spread-spectrum communications technique transmits signal using a much wider band than the bandwidth of the signal. A representative example of using this technique is a code division multiple access (CDMA) which uses narrowband carriers. Additionally, there also is a way of using wideband carriers.
In order to use narrowband carriers, frequency of the data for transmission is modulated to be narrower than the frequency band of the carrier signal, while the frequency band of the data for transmission is modulated to be wider than the frequency band of the carrier signal in order to use wideband carriers.
Carriers in the spread-spectrum communications usually use sinuous waves and pulses. The sinuous waves or pulses are up-converted to a certain frequency to transmit data. To this end, a transmitter of a communication system needs components for up-converting the carriers from a baseband to a certain frequency band, while a receiver needs components to down-convert the received carriers back to the baseband.
More specifically, the transmitter includes a voltage controller oscillator (VCO) to generate a frequency to transmit data, and a phase locked loop (PLL) to lock the generated frequency from external influence. The transmitter also requires an up-mixer to up-convert the baseband carriers at the frequency generated by the VCO.
Accordingly, the receiver requires a down-mixer to down-convert the received carriers back to baseband.
Because the transmitter has components such as VCO, PLL, and up-mixer, power consumption increases. Additionally, components such an up-mixer is quite large and therefore, the size of the transmitter also increases. Likewise, there usually is a big and power-consuming receiver as the receiver uses components such as a down-mixer.
IEEE 802.15.4a standard has proposed the use of chaotic signals to transmit data.
IEEE 802.15.4a is the Task Group for the standardization of low-rate navigation sensor network, which proposed a next-generation communication incorporating a hybrid of IEEE 802.15.4 ZigBee and IEEE 802.15.3 Ultra Wide Band (UWB) communications with the functions of navigation and low-rate power consumption.
The chaotic signal modulation has been proposed in an attempt to achieve low-rate power consumption. The chaotic signal modulation can be designed in a simple RF structure at the hardware level, and circuits, which are generally required for an RF communication system such as VCO, PLL and mixer, are not necessary. Accordingly, power consumption can be reduced to 5 mW one-third of general power consumption, by using the chaotic signal modulation.
Therefore, a low-rate RF communication system will be achieved, if a chaotic signal modulation is appropriately applied.
SUMMARY OF THE INVENTION
Exemplary embodiments of the present invention overcome the above disadvantages and other disadvantages not described above. Also, the present invention is not required to overcome the disadvantages described above, and an exemplary embodiment of the present invention may not overcome any of the problems described above.
The present invention provides a low-rate RF communication system having a chaotic signal generator, and a method of generating chaotic signal.
According to one aspect of the present invention, the present invention provides an RF communication system comprising: a chaotic signal generator which generates a chaotic signal having a plurality of frequency components at a predetermined frequency band; a modulator which generates a chaotic carrier by combining the chaotic signal with a data signal which indicates information; and a transmission circuit which includes an antenna to transmit the chaotic carrier made at the modulator.
The chaotic signal generator may comprise an oscillator which converts a direct current (DC) bias power into a high frequency power, and a resonating unit which generates a wideband signal having a plurality of frequency components by passing a predetermined frequency band of the high frequency power signal.
The resonating unit may comprise a first filter which receives the high frequency power from the oscillator and passes at least a part of a harmonic signal of the high frequency power; and a second filter which generates a wideband signal having a plurality of frequency components of a predetermined range of frequency band by oscillating the filtered signal, and provides the oscillator with the wideband signal.
The oscillator may comprise a nonlinear element, and high frequency power of the nonlinear element is determined by:
f
(
z
)
=
M
[
z
+
e
1
-
z
′
-
e
1
+
z
-
e
2
-
z
+
e
2
2
]
where, M is an amplifier constant of the nonlinear element, and e 1 , e 2 are constants.
The nonlinear element comprises one of a transistor and a diode.
The signal generator may be oscillated when the conditions are met that the phase of a signal passing a loop of the nonlinear element, the first filter and the second filter is a multiple of 2π.
The signal generator may be oscillated when the conditions are met that a total gain of the loop is larger than 1.
The signal outputted from the first filter may be determined by:
Tx 1 ′+x 1 =f ( z N )
where, f(z N ) is the function of high frequency output from the nonlinear element, T is a time constant of the first filter, and x 1 is the initial signal outputted from the first filter.
The first filter may comprise a low pass filter (LPF), and the first filter may be a primary filter.
The second filter may comprise at least one band pass filter (BPF), and the BPF may preferably be a secondary filter.
A (N)th output from the BPF may be determined by:
z N ″+α BN z N ′+ω BN 2 z N =ω BN 2 z N-1′
where, z N-1 is an output from the (N−1)th BPF, that is, an input to the (N)th BPF, α BN is an attenuation constant, ω BN is a resonating frequency and z N is an output from the (N)th BPF.
The BPF may determine a resonating frequency band of the chaotic signal generator.
The second filter may comprise at least one LPF, and the LPF of the second filter may be a secondary filter.
The LPF of the second filter may be disposed between the first filter and the BPF.
An output from the (M)th LPF of the second filter may be determined by:
y M ″+α LM y M ′+ω LM 2 y M =ω LM 2 y M−1
where, y M-1 is an output from the (M−1)th LPF, that is, an input to the (M)th LPF, α LM is an attenuation constant, ω LM is a resonating frequency, and y M is an output from the (M)th LPF.
The LPF and the BPF of the second filter may have different delayed phase widths and gains, respectively.
The second filter may comprise a predetermined number of LPFs and BPFs so that a phase of a signal passing a loop of the nonlinear element, the first filter and the second filter corresponds to a multiple of 2π.
According to an aspect of the present invention, an RF communication system may be provided, comprising a nonlinear element which converts a DC bias power into a high frequency power; a first LPF which filters the high frequency power into a predetermined frequency band; one or more second LPFs which shift the filtered high frequency power according to a predetermined phase width; and one or more BPFs which have difference phase widths than the second LPFs, and filter the shifted signal into a predetermined frequency band.
The BPF may comprise first to third BPFs.
According to another aspect of the present invention an RF communication system may be provided, comprising an oscillator which converts a DC bias power into a high frequency power; and a resonating unit which generates a wideband signal having a plurality of frequency components by passing a predetermined frequency band of the high frequency power signal.
According to yet another aspect of the present invention, and RF communication system may be provided, comprising: a nonlinear element which converts a DC bias power into a high frequency power; a first filter which receives a high frequency power from the nonlinear element and passes at least a part of a harmonic signal of the high frequency power; and a second filter comprising one or more LPFs and one or more BPFs, which generate a wideband signal having a plurality of frequency components in a predetermined range of frequency band by oscillating a signal from the first filter, and provide the nonlinear element with the wideband signal.
According to yet another aspect of the present invention, a method of generating a chaotic signal in an RF communication system, comprising: converting a DC bias power into a high frequency power; generating an initial signal which meets initial conditions for oscillation using the high frequency power; and generating a wideband signal having a plurality of frequency components in a predetermined range of frequency band by oscillating the initial signal.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects of the present invention will be more apparent by describing certain exemplary embodiments of the present invention with reference to the accompanying drawings, in which:
FIG. 1 shows a block diagram of a transceiver of a RF communication system using chaotic signal, and graphical representations of signal waves in respective domains of the RF communication system;
FIG. 2A shows, in enlargement, waves of chaotic signals generated from a chaotic signal generator of FIG. 1 ;
FIG. 2B shows a graphical representation showing the chaotic signal of FIG. 2A based on frequency domain;
FIG. 2C is a graphical representation of an enlarged data signal;
FIG. 2D shows a graphical representation of chaotic carrier by modulating the chaotic signal of FIG. 2A and the data signal of FIG. 2C ;
FIG. 2E is a graphical representation of the chaotic carrier of FIG. 2D based on frequency domain;
FIG. 3 is a graphical representation of a frequency bandwidth of a chaotic signal region 1 T and a pulse region 3 T;
FIG. 4 is a block diagram of a chaotic signal generator according to an exemplary embodiment of the present invention;
FIG. 5 is a block diagram of a chaotic signal generator according to an exemplary embodiment of the present invention;
FIG. 6 is a graphical representation of chaotic signal generated from the chaotic signal generator based on the time domain;
FIG. 7 is a graphical representation of the result of measuring power spectrum density of chaotic signal according to an exemplary embodiment of the present invention;
FIG. 8A is a graphical representation of an example of a signal mask defined by the Federal Communications Commission (FCC);
FIG. 8B shows a power spectrum of chaotic signal generated by a chaotic signal generator based on the mask of FIG. 8A ;
FIG. 9A is a graphical representation of time domain of chaotic carrier which combines the chaotic signal of FIG. 6 with the data signal; and
FIG. 9B is a power spectrum of chaotic carrier of FIG. 9A .
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
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. The exemplary embodiments are described below in order to explain the present invention by referring to the figures.
The matters defined in the description such as the detailed construction and elements are provided to assist in a comprehensive understanding of the invention. Thus, it would be apparent to one skilled in the art that the present invention can be practiced out without those defined matters. Also, well-known functions or constructions are not described in detail since they would obscure the invention with unnecessary detail.
The present invention particularly relates to the structure and operational principle of a RF communication system using a chaotic signal, and a chaotic signal generator to generate the chaotic signal.
The ‘chaotic signal’ particularly refers to a carrier used in the transmission of data signal between a transceiver, and the chaotic signal is directly generated in the frequency band for data signal transmission.
FIG. 1 shows a block diagram of a transceiver of a RF communication system using a chaotic signal, along with the waves at points (a) to (g).
The transceiver of a RF communication system may include a transmission circuit 10 which transmits a chaotic carrier which is obtained by modulating a chaotic signal and data signal, and a reception circuit 20 which receives the chaotic carrier and evaluates the data signal. The transceiver may also include a transmission/reception antenna 5 , a switch 7 which connects one of the transmission circuit 10 and the reception circuit 20 to the antenna 5 , and a band pass filter (BPF) 6 which filters the transmitted or received chaotic carrier.
The transmission circuit 10 may include a chaotic signal generator 30 , a modulator 11 , and a power amplifier 15 .
The chaotic signal generator 30 may generate a chaotic signal which has a plurality of frequency components in a predetermined frequency band. With reference to point (d) of FIG. 1 , the chaotic signal is generated as a plurality of pulses with different periods and amplitudes in the time domain are successively generated. FIG. 2A shows an enlarged chaotic signal at point (d) of FIG. 1 . Based on the frequency domain, the chaotic signal is spread widely along the predetermined frequency band as show in FIG. 2B . The frequency band for the chaotic signal may vary according to the design of the chaotic signal generator 30 , and FIG. 2B shows the chaotic signal spreading along the UWB from about 3.1 GHz to about 5.1 GHz.
The frequency band of the chaotic signal is determined by the frequency bandwidth of the chaotic signal which is generated from the chaotic signal generator 30 , and is not related with the pulse region T of the chaotic signal. As shown in FIG. 3 , the frequency bandwidth Δf is almost identical as the wideband property of the carrier, either when the pulse region of the chaotic signal is 1 T or when it is 3 T. Because the same frequency bandwidth can be maintained irrespective of the variance of pulse region of the chaotic signal, there is no need for additional components such as filter or amplifier to change the pulse region. Furthermore, even the carrier of stronger energy can be transmitted and received by changing the pulse region of the chaotic signal. Accordingly, the communication range can be adequately controlled without having to change the peak of the transmission power, by increasing or decreasing the pulse region of the chaotic signal.
The structure of the chaotic signal generator 30 will be explained in detail below, with reference to FIG. 4 .
The modulator 11 generates a chaotic carrier by combining a chaotic signal from the chaotic signal generator 30 with a data signal. With reference to point (a) of FIG. 1 , ‘0s’ and ‘1s’ of binary data bits are provided to the modulator 11 in the form of pulse. By combining the data signal with the chaotic signal, a chaotic carrier, which has a chaotic signal only in the information region of the data signal, is generated (see point (e) of FIG. 1 ). FIG. 2D is a graphical representation showing an enlarged part of the chaotic carrier at point (e) of FIG. 1 . After the modulation, the frequency band of the chaotic carrier (see FIG. 2E ) is same as that of the chaotic signal (see FIG. 2B ). In other words, there is no relation between the pulse region of the chaotic signal and the frequency bandwidth.
The reception circuit 20 may include a low noise amplifier (LNA) 21 , a detector 23 , an automatic gain control (AGC) amplifier 25 , a LPF 27 , and an analogue-to-digital (A/D) converter 29 .
The LNA 21 may amplify the chaotic carrier which is received over the antenna 5 , and transmits the amplified signal to the detector 23 .
The detector 23 detects the chaotic carrier and extracts a data signal. The detector 23 may include a diode, and as the chaotic carrier passes the detector 23 , the chaotic carrier forms curvy signal waves as shown in the graphical representation of point (c) of FIG. 1 .
The AGC amplifier 25 may increase or decrease the rate of amplification, and amplifies the signal waves extracted by the detector 23 to a predetermined level. The LPF 27 may filter the amplified signal waves so that the waves can be converted into digital signal at the A/D converter 29 .
The A/D converter 29 converts the signal waves into digital signal, and therefore, extracts a data signal of pulse form as shown in FIG. 2B .
FIG. 4 is a block diagram of a chaotic signal generator of the RF communication system of FIG. 1 .
The chaotic signal generator 30 may include a loop of a nonlinear element 31 , a first filter 33 and one or more filters 35 , 37 .
The nonlinear element 31 is a main part of an oscillator and operates to amplify an input signal of small power to an output signal of high power. The output function f(z) of the nonlinear element 31 may be expressed by Equation 1 as follows:
f
(
z
)
=
M
[
z
+
e
1
-
z
-
e
1
+
z
-
e
2
-
z
+
e
2
2
]
(
1
)
where, M is an amplifier constant of the nonlinear element 31 , and e 1 , e 2 are constants.
A transistor or a diode may be used as the nonlinear element 31 . When the transistor is used, for example, a DC bias power to operate the transistor is converted to high frequency power, thereby resulting in amplification. The nonlinear element 31 of the chaotic signal generator 30 amplifies the noise inside the loop, and the amplified signal circulates along the loop and inputted back to the nonlinear element 31 . As the above process repeats, stable chaotic signal is outputted.
The first filter 33 receives high frequency power signal from the nonlinear element 31 , and processes the received high frequency power signal so that oscillation can occur. When a high frequency power signal is generated by amplifying a noise of the nonlinear element 31 , the high frequency power signal usually contains not only the frequency selected during the design process, but also a harmonic ingredient which is multiple times larger than the selected frequency. The first filter 33 may select from the high frequency power signal the range of harmonic ingredient to be used for the oscillation. That is, the first filter 33 may also operate to limit the frequency band of the chaotic signal, by selecting the frequency range to be used for the oscillation.
The first filter 33 may be a LPF. This will be explained below as one example of the present invention, and the first filter 33 will be referred to as the first LPF 33 . The first LPF 33 may be a primary filter, and the relation between the input and output of the first LPF 33 may be expressed by Equation 2 as follows:
Tx 1 ′+x 1 =f ( z N ) (2)
where, f(z N ) is the function of high frequency output from the nonlinear element 31 , that is, the function of signal inputted to the first LPF 33 , T is a time constant of the first LPF 33 , and x 1 is the initial signal outputted from the first LPF 33 .
The chaotic signal generator 30 has to meet the following two conditions as other general ring oscillators do. First, the signal passing the entire loop of the nonlinear element 31 , the first filter 33 and the second filter 35 , 37 should have a phase variance of 360 degrees, which is a multiple of 2π. Second, the gain of the entire loop should be greater than ‘1’. Both the first and the second filters 33 , 35 , 37 should meet the above conditions.
The second filter 35 , 37 may include a plurality of second LPFs 35 and a plurality of BPFs 37 , and like a resonator of the ring oscillator, the second filter 35 , 37 operates to determine the bandwidth of the resonating frequency. The only difference is that while the resonator selects and resonates one frequency, the second LPFs 35 and the BPFs 37 of the chaotic signal generator 30 cause a plurality of frequency components to be selected by passing the frequency of certain bandwidths. The BPFs 37 operate to determine resonating frequency band to generate a chaotic signal in the desired frequency band, and the second LPFs 35 , rather than determining the resonating frequency band, operate to enable oscillation by causing the signal passing the loop to have a phrase variance as a multiple of 2π in cooperation with the BPFs 37 .
The second LPFs 35 and the BPFs 37 are secondary filters, which have higher phase variance and larger and higher loop gains than the primary filters. Accordingly, the first LPF 33 may be employed as the primary filter, and the second LPFs 35 and the BPFs 37 may be employed as the secondary filters. By using the primary and the secondary filters appropriately, various frequency components can be selected. Additionally, because the second LPFs 35 and the BPFs 37 have different phase variances, and the respective frequency components vary phase differently, a wider frequency band is obtained.
In one example, the second filters 35 , 37 may include M number of second LPFs 35 . In this example, the first one 35 a of the second LPFs 35 receives input from the first LPF 33 . The relation between the input and output of the first one 35 a of the second LPFs 35 may be expressed by Equation 3 as follows:
y 1 ″+α L1 y 1 ′+ω L1 2 y 1 =ω L1 2 x 1 (3)
where, x 1 is an output from the first LPF 33 , that is, input to the first one 35 a of the second LPFs 35 , α L1 is an attenuation constant, ω L1 is a resonating frequency, and y 1 is an output from the first one 35 a of the second LPFs 35 .
The relation between the input and output of the (M)th LPF 35 m of the second LPFs 35 may be expressed by Equation 4 as follows:
y M ″+α LM y M ′+ω LM 2 y M =ω LM 2 y M-1 (4)
where, y M-1 is an output from the (M−1)th LPF of the second LPFs 35 , that is, an input to the (M)th LPF 35 m , and y M is an output from the (M)th LPF.
In another example, the second filters 35 , 37 may include (n) number of BPFs 37 . In this example, the first BPF 37 a receives a signal outputted from the (M)th LPF 35 m of the second LPFs 35 , and the relation between the input and output of the first BPF 37 a may be expressed by Equation 5 as follows:
z 1 ″+α B1 z 1 ′+ω B1 2 z 1 =ω B1 2 y′ M (5)
where, y M is an output from the (M)th LPF 35 m of the second LPFs, that is, an input to the first BPF 37 a, α B1 is an attenuation constant, ω B1 is a resonating frequency, and z 1 is an output from the first BPF 37 a.
The relation between the input and output of the (N)th BPF 37 n may be expressed by Equation 6 as follows:
z N ″+α BN z N ′+ω BN 2 z N =ω BN 2 z N-1 ′ (6)
where, z N-1 is an output from the (N−1)th BPF, that is, an input to the (N)th BPF 37 n , and z N is an output from the (N)th BPF 37 n.
The output signal from the BPFs 37 is inputted back to the nonlinear element 31 , and circulates along the loop of the first LPF 33 , the second LPFs 35 and the BPFs 374 of the nonlinear element 31 to finally become stable chaotic signal.
FIG. 5 is a block diagram of a chaotic signal generator according to an exemplary embodiment of the present invention. As shown, the chaotic signal generator according to one exemplary embodiment may include a nonlinear element 131 , a first LPF 133 , a second LPF 135 , and three BPFs 137 a , 137 b , 137 c.
The nonlinear element 131 amplifies a DC bias power to high frequency power, and the first LPF 133 filters the high frequency signal in the base band.
The resonating frequency band is determined when the high frequency signal filtered at the base band passes through the second LPF 135 and the three BPFs 137 a , 137 b , 137 c . When the resonating frequency band is determined, the signal is inputted back to the nonlinear element 131 , and processed repeatedly to become a chaotic signal having a plurality of frequency components.
The chaotic signal generated by the chaotic signal generator 130 shows a series of pulses of different amplitudes and periods in time domain (see FIG. 6 ).
FIG. 7 shows in a graphical representation the result of measuring a power spectrum density of the chaotic signal according to an exemplary embodiment of the present invention.
With reference to FIG. 7 , 99% of power of the power spectrum is focused around −20 dB, which means high energy rate and low power consumption.
FIG. 8A is a graphical representation of an example of a signal mask defined by the FCC, and FIG. 8B shows a power spectrum of chaotic signal generated by a chaotic signal generator based on the mask of FIG. 8A . As shown, the power spectrum of the chaotic signal from the chaotic signal generator 130 almost matches the FCC signal mask.
FIG. 9A is a graphical representation of time domain of chaotic carrier which combines the chaotic signal of FIG. 6 with the data signal, and FIG. 9B is a power spectrum of chaotic carrier of FIG. 9A .
While the chaotic signal of FIG. 6 is successively formed in time domain, the chaotic carrier of FIG. 9A shows a chaotic signal appearing and disappearing according to the data signal. Both of FIGS. 8B and 9B show almost no difference of power spectrum between before and after the chaotic signal is combined with the data signal.
Because there is almost no change in the power spectrum by the fact that the data signal is combined, or not combined with the chaotic signal, most of the RF communication system can still be utilized after the combination of signals.
As explained above, according to the exemplary embodiments of the present invention, a transmission circuit of an RF communication system does not need to use additional components such as VCO, PLL and up-mixer, and a reception circuit also does not need to employ components such as down-mixer. Additionally, a diode may be used as a detector in constructing a wideband RF communication system. Because the power consumption can be greatly reduced, a low rate RF communication system can be provided, and the size of the RF communication system is also reduced. Additionally, price can be reduced, and RF communication system becomes easy to construct. Also importantly, a power efficiency is high because the chaotic signal generator has 99% of power spectrum around −20 dB within the FCC standard mask.
The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the present invention. The present teaching can be readily applied to other types of apparatuses. Also, the description of the embodiments of the present invention is intended to be illustrative, and not to limit the scope of the claims, and many alternatives, modifications, and variations will be apparent to those skilled in the art.
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A radio frequency (RF) communication system having a chaotic signal generator and a method of generating a chaotic signal. The RF communication system includes a chaotic signal generator which generates a chaotic signal having a plurality of frequency components at a predetermined frequency band, a modulator which generates a chaotic carrier by combining the chaotic signal with a data signal which indicates information, and a transmission circuit which includes an antenna to transmit the chaotic carrier made at the modulator. The frequency signal generator comprises an oscillator which converts a DC bias power into a high frequency power, and a resonating unit which generates a wideband signal having a plurality of frequency components by passing a predetermined frequency band of the high frequency power signal.
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FIELD OF THE INVENTION
This application relates generally to the field of walkers and, more particularly, to a detachable backrest for a walker having a seat.
BACKGROUND
Walkers are commonly used by the elderly, persons with infirmities, and patients recovering from injuries or surgery. A variety of styles of walkers are available. Some have wheels, while others simply have legs tipped with rubber or a similar skid-resistant material.
Persons who use walkers often have a desire to sit down at certain times when they are using their walker. For example, the person may become tired and need to rest, or the person may have taken the walker to view an event, such as a sporting event or a parade, and wishes to use the walker as a seat while viewing the event. In this regard, it is desirable for the walker to have a backrest, to make the use of the seat more comfortable.
SUMMARY OF THE INVENTION
The present invention provides a backrest for use when the seat of the walker is deployed. The backrest is particularly adapted to be detachable for easy stowing. In one embodiment, the backrest conveniently attaches to the walker by inserting ends of the backrest into a housing. The backrest is secured in place, in one embodiment, by a spring-biased peg. The backrest may be padded, so as to provide greater comfort.
BRIEF DESCRIPTION OF THE DRAWINGS
The features, aspects, and advantages of the disclosed subject matter will become more fully apparent from the following Detailed Description and appended claims when taken in conjunction with accompanying illustrations in which:
FIG. 1 is an illustration of an elevated perspective view of an embodiment of a folding walker.
FIG. 2 is an illustration of an perspective view of an embodiment of a folding walker in the folded position.
FIG. 3 is an illustration of an exploded view of a detachable backrest in an embodiment of a folding walker.
FIG. 4 is an illustration of an elevated cross-sectional view of a portion of an attaching peg and peg housing in an embodiment of a folding walker.
FIG. 5 is a side cross-sectional view of an attaching peg and peg housing in an embodiment of a folding walker.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, for purposes of explanation and not limitation, specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that the present invention may be practiced in other embodiments that depart from these specific details. For example, those skilled in the art would understand that the present invention may be used in rollators, as well as walkers. In some instances, detailed descriptions of well-known methods and devices are omitted so as to not obscure the description of the present invention with unnecessary detail.
FIG. 1 is a perspective view of an embodiment of a folding walker in which the present invention has been incorporated. Walker 10 includes front frame 12 and rear frame 14 . Front frame 12 includes front upright members 13 . The length of front upright members 13 is telescopically adjustable, so as to accommodate users of varying height. In one embodiment, front cross braces 19 and 20 couple front upright members 13 .
Rear frame 14 includes rear upright members 15 . Rear cross brace 21 couples rear upright members 15 . Grips 18 are affixed to upright members 13 . A user holds grips 18 as he or she uses walker 10 to walk. In embodiments where walker 10 includes casters 16 , brakes 25 are included in walker 10 and may be applied to slow down or stop at least one of casters 16 from rolling.
In an embodiment, the posterior end of the underside of seat 24 is pivotally coupled to front cross brace 20 . The anterior end of the underside of seat 24 has two positions. In the first position, when seat 24 is down, the anterior end of the underside of seat 24 is detachably coupled to rear cross brace 21 . In the second position, when seat 24 is pulled up and walker 10 is collapsed for storage, the anterior end of seat 24 is detached from rear cross brace 21 . In one embodiment, the anterior end of seat 24 is coupled to rear cross brace 21 with two semi-ring clips (not shown).
In an embodiment, detachable backrest 30 is coupled with front frame 12 by inserting the ends of backrest 30 into housings 40 , which are coupled to front frame 12 . Detachable backrest 30 may include a single bar, or, in other embodiments, may comprise multiple transverse bars. In an embodiment, backrest 30 is made of a rigid material or materials. In other embodiments, backrest 30 may be made of a flexible material. Those skilled in the art will recognize that seat 24 may also be configured in a manner whereby the posterior end of seat 24 , rather than the anterior end, is detachably couple to rear cross brace 21 , and the anterior end of seat is pivotally couple to front cross brace 20 . Additionally, those skilled in the art will recognize that backrest member 30 may be coupled with rear frame 14 .
FIG. 2 is a perspective view of an embodiment of a folding walker in the folded position. Side support assembly 26 includes side support members 27 and 28 . Side support member 27 is pivotally coupled to front frame 12 , and side support member 28 is pivotally coupled to rear frame 14 . The ends of side support members 27 and 28 , which are not coupled to either front frame 12 or rear frame 14 , are coupled together. Pivot lever 29 is pivotally coupled with both side support assembly 26 and seat 24 . When seat 24 is pulled upward and detached from rear cross brace 21 , pivot lever 29 pulls side support members 27 and 28 upward, thus drawing front frame 12 and rear frame 14 together, thereby collapsing walker 10 , so that it may be easily stowed. In the folded position, backrest 30 may be used as a handle for carrying walker 10 or backrest 30 may be detached, so that folded walker 10 has an even smaller girth, and is more easily stowed.
FIG. 3 is an exploded view of detachable backrest 30 . Backrest 30 may be attached to front frame 12 by inserting attaching pegs 32 into peg housings 40 . When attaching peg 32 is inserted into peg housing 40 , knob 50 protrudes through lock pin hole 43 and into notch 34 , and secures backrest 30 in place. A spring (not shown) in peg housing 40 is biased so as to keep an inner portion of knob 50 protruding into notch 34 . Backrest 30 may be detached from walker 10 by pulling out knob 50 , and removing attaching peg 32 from peg housing 40 .
In an embodiment, padding sheath 31 covers a portion of backrest 30 . Padding sheath 31 is soft, and makes backrest 30 more comfortable to the seated user. In an embodiment, padding sheath 31 may only cover a portion of backrest 30 , but, in other embodiments, padding sheath 31 may cover all of backrest 30 . Padding sheath 31 may include multiple independent pieces of padding material, or, it may include only one piece of padding material. In an embodiment, padding sheath 31 includes foam rubber as a padding material. Those skilled in the art will recognize that various materials, soft or firm, will be suitable for padding sheath 31 , and the selection of the materials may depend on the particular characteristics or wishes of different users. As such, foam rubber is a representative padding material, and is not to be considered as limiting the scope of the subject matter described and claimed by the inventor.
Attaching pegs 32 are coupled to opposite ends of backrest 30 . In an embodiment, backrest 30 is a hollow, cylindrical bar. Also, in such an embodiment, attaching pegs 32 are coupled to backrest 30 by inserting a portion of attaching pegs 32 into opposite hollow ends of backrest 30 . The portions of attaching pegs 32 that are inserted into backrest 30 are secured to backrest 30 by rivets, in an embodiment. Attaching pegs 32 include notch 34 , in an embodiment. When attaching peg 32 is inserted into peg housing 40 , a portion of knob 50 protrudes through lock pin hole 43 into notch 34 , thereby keeping backrest bar 30 in a secure position. In an embodiment, attaching pegs 32 includes tapered ends 38 , which allows attaching pegs 32 to easily slide into peg housing 40 . Attaching peg 32 may also include rim 36 , which acts as a stopper, allowing only a specified length of attaching peg 32 to be inserted into receptacle 41 , and lining up notch 34 with lock pin hole 43 .
FIG. 4 is a detailed illustration of one embodiment of spring housing 42 . In an embodiment, spring housing 42 is coupled to peg housing 40 . Spring housing 42 contains a spring (not shown) that is used to bias knob 50 so as to pull knob 50 and lock pin 52 towards peg housing 40 when backrest 30 is attached for use. Lock pin 52 runs through spring housing 42 , and, when backrest 30 is attached to front frame 12 , forces lock pin head 54 (not shown) into notch 34 , thereby holding backrest 30 in a secure position.
Spring housing 42 includes engaging members 48 , which may engage with engaging members 56 of knob 50 when backrest 30 is attached to front frame 12 . Only when engaging members 48 are engaged with engaging members 56 , may lock pin 52 force lock pin head 54 through spring housing 42 and into notch 34 (not shown). FIG. 4 shows engaging members 56 disengaged from engaging members 48 . In the disengaged position, lock pin head 54 does not substantially enter notch 34 , and backrest 30 may be easily removed from peg housings 40 .
FIG. 5 is a detailed illustration of one embodiment of peg housing 40 and knob 50 . Each peg housing 40 includes receptacle 41 . Backrest 30 is attached to front frame 12 by inserting attaching pegs 32 into receptacle 41 of peg housing 40 .
In one embodiment, spring housing 42 is coupled to peg housing 40 . In other embodiments, spring housing 42 is part of peg housing 40 . Spring 44 is disposed inside spring housing 42 . Spring 44 biases lock pin 52 and lock pin head 54 toward peg housing 40 , so that, when backrest 30 is attached to front frame 12 , lock pin head 54 protrudes into notch 34 of attaching peg 32 , thus securing backrest 30 in the attached position.
Knob 50 , in an embodiment, includes lock pin 52 , lock pin head 54 , and engaging members 56 . In an embodiment, knob 50 is a quarter-turn-locking pin that has two positions. In the protruding position, lock pin head 54 protrudes into notch 34 of attaching peg 32 , thereby securing backrest 30 in the attached position. In another embodiment, knob 50 does not include lock pin head 54 , and lock pin 52 inserts protrudes into notch 34 .
In the non-protruding position, engaging members 48 on spring housing 42 do not engage with engaging members 56 of knob 50 . As such, the biasing in spring 44 is unable to pull lock pin head 54 into notch 34 . As such, in the non-protruding position of lock pin head 54 , backrest 30 is not secured. The non-protruding position of lock pin head 54 facilitates easy detachment of backrest 30 , or easy insertion of backrest 30 into peg housing 40 .
Those skilled in the art will recognize that other configurations may be used to secure attaching pegs 32 in receptacles 41 , and also fall under the subject matter disclosed herein. Likewise, those skilled in the art will also recognize that various structural configurations may be used to prevent lock pin head 54 from entering notch 34 in the non-protruding position, and also fall within the scope of the subject matter disclosed herein.
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A walker having a detachable backrest is described. The walker contains a seat, and a person may sit in the walker, and rest his or her back against the detachable backrest.
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BACKGROUND OF THE INVENTION
[0001] Synthesis of many retroviral protease and renin inhibitors containing a hydroxyethylamine, hydroxyethylurea or hydroxyethylsulfonamide isostere include the preparation of a key chiral amine intermediate. The synthesis of the key chiral amine requires a multi-step synthesis starting from a chiral amino acid such as L-phenylalanine. The key chiral amine intermediate can be prepared by diastereoselective reduction of an intermediate amino chloromethylketone or amine opening of a chiral epoxide intermediate. The present invention relates to a cost effective method of obtaining enantiomerically, diastereomerically and chemically pure chiral amine intermediate. This method is applicable for large scale (multikilogram) productions.
[0002] Roberts et al. ( Science, 248, 358 (1990)), Krohn et al. ( J. Med. Chem. 344, 3340 (1991)) and Getman et al. ( J. Med. Chem., 346, 288 (1993)) disclosed the synthesis of protease inhibitors containing the hydroxyethylamine or hydroxyethylurea isostere which include the opening of an epoxide generated in a multi-step synthesis starting from an amino acid. These methods also contain steps which include diazomethane and the reduction of an amino chloromethyl ketone intermediate to an amino alcohol prior to formation of the epoxide. The overall yield of these syntheses are low and the use of explosive diazomethane additionally prevents such methods from being commercially acceptable.
[0003] Tinker et al. (U.S. Pat. No. 4,268,688) disclosed a catalytic process for the asymmetric hydroformylation to prepare optically active aldehydes from unsaturated olefins. Similarly, Reetz et al. (U.S. Pat. No. 4,990,669) disclosed the formation of optically active alpha amino aldehydes through the reduction of alpha amino carboxylic acids or their esters with lithium aluminum hydride followed by oxidation of the resulting protected beta amino alcohol by dimethyl sulfoxide/oxalyl chloride or chromium trioxide/pyridine. Alternatively, protected alpha amino carboxylic acids or esters thereof can be reduced with diisobutylaluminum hydride to form the protected amino aldehydes.
[0004] Reetz et al. (Tet. Lett., 30, 5425 (1989) disclosed the use of sulfonium and arsonium ylides and their reactions of protected α-amino aldehydes to form aminoalkyl epoxides. This method suffers from the use of highly toxic arsonium compounds or the use of combination of sodium hydride and dimethyl sulfoxide which is extremely hazardous in large scale. Sodium hydride and DMSO are incompatible (Sax, N. I., “Dangerous Properties of Industrial Materials”, 6th Ed., Van Nostrand Reinhold Co., 1984, p. 433). Violent explosions have been reported on the reaction of sodium hydride and excess DMSO (“Handbook of Reactive Chemical Hazards”, 3rd Ed., Butterworths, 1985, p. 295).
[0005] Matteson et al. ( Synlett., 1991, 631) reported the addition of chloromethyllithium or bromomethyllithium to racemic aldehydes. J. Ng et al. (WO 93/23388 and PCT/US94/12201, both incorporated herein by reference in their entirety) disclose methods of preparing chiral epoxide, chiral cyanohydrin, chiral amine and other chiral intermediates useful in the preparation of retroviral protease inhibitors.
[0006] Various enzyme inhibitors, such as renin inhibitors and HIV protease inhibitors, have been prepared using the above described methods or variations thereof. EP 468641, EP 223437, EP 389898 and U.S. Pat. No. 4,599,198 for example describe the preparation of hydroxyethylamine isostere containing renin inhibitors. U.S. Pat. No. 5,157,041, WO 94/04492 and WO 92/08701 (each of which is incorporated herein by reference in its entirety) for example describe the preparation of hydroxyethylamine, hydroxyethylurea or hydroxyethylsulfonamide isostere containing retroviral protease inhibitors.
SUMMARY OF THE INVENTION
[0007] Human immunodeficiency virus (HIV), the causative agent of acquired immunodeficiency syndrome (AIDS), encodes three enzymes, including the well-characterized proteinase belonging to the aspartic proteinase family, the HIV protease. Inhibition of this enzyme is regarded as a promising approach for treating AIDS. One potential strategy for inhibitor design involves the introduction of hydroxyethylene transition-state analogs into inhibitors. Inhibitors adapting a hydroxyethylamine, hydroxyethylurea or hydroxyethylsulfonamide isostere are found to be highly potent inhibitors of HIV proteases. Despite the potential clinical importance of these compounds, the synthesis of these compounds are difficult and costly due to the number of chiral centers. Efficient processes for preparing large scale (multikilogram quantities) of such inhibitors is needed for development, clinical studies and cost effective pharmaceutical preparations.
[0008] This invention improves the synthesis of intermediates which are readily amenable to the large scale preparation of chiral hydroxyethylamine, hydroxyethylurea or hydroxyethylsulfonamide retroviral protease, renin or other aspartyl protease inhibitors.
[0009] Specifically, the method includes precipitating, crystallizing or recrystallizing a salt of the desired chiral amine intermediate.
DETAILED DESCRIPTION OF THE INVENTION
[0010] This invention relates to a method of preparation of retroviral protease inhibitor that allows the preparation of commercial quantities of intermediates of the formulae
[0011] wherein R 1 , R 3 , P 1 and P 2 are as defined below. Typical preparations of one diastereomer from enantiomerically pure starting materials, such as L-phenylalanine or D-phenylalanine, using methods as described herein and elsewhere result in enantiomeric mixtures of the alcohol containing carbon (—CHOH—) ranging from about 50:50 to about 90:10. Isolation of the desired enantiomer usually involves chromatographic separation. Alternatively, the enantiomeric mixture is used without separation and enantiomerically pure material is obtained at a later step in the synthesis of the inhibitors. These approaches increase the time and cost involved in the manufacture of a pharmaceutical preparation. Chromatographic separations increase the cost of manufacture. Using impure materials increases the amount of other reactants used in later steps of the inhibitor synthesis, and increases the amount of side products and waste produced in the later steps. Furthermore, these compounds often show indications of poor stability and may not be suitable for storage or shipment in large quantity (multikilograms) for long periods of time. Storage and shipment stability of such compounds is particularly important when the manufacture of the pharmaceutical preparation is carried out at different locations and/or in different environments. Alternatively, the amine can be protected with an amine protecting group, such as tert-butoxycarbonyl, benzyloxycarbonyl and the like, as described below and purified, such as by chromatography, crystallization and the like, followed by deprotection of the amine. This alternative adds more steps to the overall synthesis of the inhibitors and increases the manufacturing costs.
[0012] The present invention relates to a simple, economical process of isolating substantially enantiomerically and/or diastereomerically pure forms of Formula I. The process involves forming and isolating a salt of Formula I from crude reaction mixtures. The salt can be formed in the reaction mixture from which it precipitates. The precipitate can then be crystallized or recrystallized from the appropriate solvent system, such as ethanol, methanol, heptane, hexane, dimethylether, methyl-tert-butylether, ethyl acetate and the like or mixtures thereof. Alternatively, the reaction mixture solvent can be removed, such as in vacuo, and dissolved in a more appropriate solvent or mixture of solvents, such as methanol, ethanol, toluene, xylene, methylene chloride, carbon tetrachloride, hexane, heptane, petroleum ethers, dimethylether, ethyl acetate, methyl-tert-butylether, tetrahydrofuran, and the like or mixtures thereof. This may also permit removal, such as by filtration or extraction, of undesired materials from the reaction mixture, such as salts, side products, and the like. After the crude reaction mixture is dissolved, then the salt of Formula I can be precipitated or crystallized and recrystallized if desired or necessary. Formation, precipitation, crystallization and/or recrystallization of such salts can also be accomplished using water and water miscible or soluble organic solvent(s) mixtures, such as water/methanol, water/ethanol, and the like.
[0013] A salt of Formula I is prepared by the addition of an organic or inorganic acid, preferably in at least an equimolar quantities and more preferably in greater than equimolar quantities, directly to the reaction mixture or to the crude reaction mixture in solution as described above. Such salts may be monovalent, divalent or trivalent acid salts, may be monoprotic, diprotic, or triprotic, may be mixed or complex salts, or combinations thereof. Preferred organic acids which may be employed to form salts of Formula I include but are not limited to the following: acetic acid, aconitatoc acid, adipic acid, alginic acid, citric acid, aspartic acid, benzoic acid, benzenesulfonic acid, butyric acid, camphoric acid, camphorsulfonic acid, digluconic acid, isocitric acid, cyclopentylpropionic acid, undecanoic acid, malaic acid, dodecylsulfonic acid, ethanesulfonic acid, malic acid, glucoheptanoic acid, heptanoic acid, hexanoic acid, fumaric acid, 2-hydroxyethanesulfonic acid, lactic acid, maleic acid, mandelic acid, methanesulfonic acid, nicotinic acid, oxalacetic acid, 2-naphthalenesulfonic acid, oxalic acid, palmitic acid, pectinic acid, 3-phenylpropionic acid, picric acid, pivalic acid, propionic acid, succinic acid, glycerophosphoric acid, tannic acid, trifluoroacetic acid, toluenesulfonic acid, tartaric acid, diacetyltartaric acid, dibenzoyltartaric acid, ditoluyltartaric acid and the like. More preferred organic acids include acetic acid, camphorsulfonic acid, toluenesulfonic acid, methanesulfonic acid, malic acid, tartaric acid, mandelic acid, trifluoroacetic acid and oxalic acid. Most preferred organic acids include acetic acid, oxalic acid and tartaric acid. Racemic mixtures or optically pure isomers of an organic acid may be used, such as D, L, DL, meso, erythro, threo, and the like isomers. Preferred inorganic acids which may be employed to form salts of Formula I include but are not limited to the following: hydrochloric acid, hydrobromic acid, phosphoric acid, sulfurous acid, sulfuric acid and the like. A more preferred inorganic acid is hydrochloric acid.
[0014] The salts of Formula I and in particular crystalline salts of Formula I of the present invention are typically more stable under normal storage and shipping conditions than Formula I.
[0015] Formula I of the present invention means the formula
[0016] wherein R 1 represents alkyl, aryl, cycloalkyl, cycloalkylalkyl or aralkyl radicals, which are optionally substituted with alkyl, halogen, NO 2 , OR 9 or SR 9 , where R 9 represents hydrogen, alkyl, aryl or aralkyl. Preferably, R 1 is alkyl, cycloalkylalkyl or aralkyl radicals, which are optionally substituted with alkyl, halogen, NO 2 , OR 9 or SR 9 , where R 9 represents hydrogen, alkyl, aryl or aralkyl. Most preferably, R 1 is 2-(methylthio)ethyl, phenylthiomethyl, benzyl, (4-fluorophenyl)methyl, 2-naphthylmethyl or cyclohexylmethyl radicals.
[0017] R 3 represents hydrogen, alkyl, alkenyl, alkynyl, hydroxyalkyl, alkoxyalkyl, cycloalkyl, cycloalkylalkyl, heterocycloalkyl, heteroaryl, heterocycloalkylalkyl, aryl, aralkyl, heteroaralkyl, aminoalkyl or N-mono- or N,N-disubstituted aminoalkyl radicals, wherein said substituents are alkyl, aryl, aralkyl, cycloalkyl, cycloalkylalkyl, heteroaryl, heteroaralkyl, heterocycloalkyl, or heterocycloalkylalkyl radicals, or in the case of a disubstituted aminoalkyl radical, said substituents along with the nitrogen atom to which they are attached, form a heterocycloalkyl or a heteroaryl radical. Preferably, R 3 represents hydrogen, alkyl, cycloalkyl, cycloalkylalkyl or aralkyl radicals. More preferably, R 3 represents hydrogen, propyl, butyl, isobutyl, isoamyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclohexylmethyl, cyclopentylmethyl, phenylethyl or benzyl radicals. Most preferably, R 3 represents radicals as defined above which contain no alpha-branching, e.g., as in an isopropyl radical or a t-butyl radical. The preferred radicals are those which contain a —CH 2 — moiety between the nitrogen and the remaining portion of the radical. Such preferred groups include, but are not limited to, benzyl, isobutyl, n-butyl, isoamyl, cyclohexylmethyl, cyclopentylmethyl and the like.
[0018] p 1 and p 2 are each independently hydrogen or amine protecting groups, including but not limited to, aralkyl, substituted aralkyl, cycloalkenylalkyl and substituted cycloalkenylalkyl, allyl, substituted allyl, acyl, alkoxycarbonyl, aralkoxycarbonyl and silyl. Examples of aralkyl include, but are not limited to benzyl, 1-phenylethyl, ortho-methylbenzyl, trityl and benzhydryl, which can be optionally substituted with halogen, alkyl of C 1 -C 8 , alkoxy, hydroxy, nitro, alkylene, acylamino and acyl. Examples of aryl groups include phenyl, naphthalenyl, indanyl, anthracenyl, durenyl, 9-(9-phenylfluorenyl) and phenanthrenyl, which can be optionally substituted with halogen, alkyl of C 1 -C 8 , alkoxy, hydroxy, nitro, alkylene, acylamino and acyl. Suitable acyl groups include carbobenzoxy, t-butoxycarbonyl, iso-butoxycarbonyl, benzoyl, substituted benzoyl such as 2-methylbenzoyl, 2,6-dimethylbenzoyl 2,4,6-trimethylbenzoyl and 2,4,6-triisopropylbenzoyl, 1-naphthoyl, 2-naphthoyl butyryl, acetyl, tri-fluoroacetyl, tri-chloroacetyl, phthaloyl and the like.
[0019] Additionally, p 1 and p 2 protecting groups can form a heterocyclic ring system with the nitrogen to which they are attached, for example, 1,2-bis(methylene)benzene (i.e., 2-isoindolinyl), phthalimidyl, succinimidyl, maleimidyl and the like and where these heterocyclic groups can further include adjoining aryl and cycloalkyl rings. In addition, the heterocyclic groups can be mono-, di- or tri-substituted, e.g., nitrophthalimidyl.
[0020] Suitable carbamate protecting groups include, but are not limited to, methyl and ethyl carbamate; 9-fluorenylmethyl carbamate; 9-(2-Sulfo)fluorenylmethyl carbamate; 9-(2,7-dibromo)fluorenylmethyl carbamate; 2,7-di-t-butyl-[9-(10,10-dioxo-10,10,10-tetrahydrothioxanthyl)methyl carbamate; 4-methoxyphenacyl carbamate; 2,2,2-trichloroethyl carbamate; 2-trimethylsilylethyl carbamate; 2-phenylethyl carbamate; 1-(1-adamantyl)-1-methylethyl carbamate; 1,f-dimethyl-2-haloethyl carbamate; 1,1-dimethyl-2,2-dibromoethyl carbamate; 1,1-dimethyl-2,2,2-trichloroethyl carbamate; 1-methyl-1-(4-biphenylyl)-ethyl carbamate; 1-(3,5-di-t-butylphenyl)-1-methylethyl carbamate; 2-(2′-and 4′-pyridyl)ethyl carbamate; 2-(N,N-dicyclohexylcarboxamido) ethyl carbamate; t-butyl carbamate; 1-adamantyl carbamate; vinyl carbamate; allyl carbamate; 1-isopropylallyl carbamate; cinnamyl carbamate; 4-nitrocinnamyl carbamate; 8-quinolyl carbamate; N-hydroxypiperidinyl carbamate; alkyldithio carbamate; benzyl carbamate; p-methoxybenzyl carbamate; p-nitrobenzyl carbamate; p-bromobenzyl carbamate; p-chlorobenzyl carbamate; 2,4-dichlorobenzyl carbamate; 4-methylsulfinylbenzyl carbamate; 9-anthrylmethyl carbamate; diphenylmethyl carbamate; 2-methylthioethyl carbamate; 2-methylsulfonylethyl carbamate; 2-(p-toluenesulfonyl)ethyl carbamate; [2-(1,3-dithianyl)methyl carbamate; 4-methylthiophenyl-2,4-dimethylthiophenyl, 2-phosphonloethyl carbamate; 2-triphenylphosphonioisopropyl carbamate; 1,1-dimethyl-2-cyanoethyl carbamate; m-chloro-p-acyloxybenzyl carbamate; p-(dihydroxyboryl)benzyl carbamate; 5-benzoisoxazolylmethyl carbamate; 2-(trifluoromethyl)-6-chromonylmethyl carbamate; m-nitrophenyl carbamate; 3,5-dimethoxybenzyl carbamate; o-nitrobenzyl carbamate; 3,4-dimethoxy-6-nitrobenzyl carbamate; phenyl(o-nitrophenyl)methyl carbamate; phenothiazinyl-(10)-carbonyl derivative; N′-p-toluenesulfonylaminocarbonyl derivative; N′-phenylaminothiocarbonyl derivative t-amyl carbamate; S-benzyl thiocarbamate; p-cyanobenzyl carbamate; cyclobutyl carbamate; cyclohexyl carbamate; cyclopentyl carbamate; cyclopropylmethyl carbamate; p-decyloxybenzyl carbamate; diisopropylmethyl carbamate; 2,2-dimethoxycarbonylvinyl carbamate; o-(N,N-dimethylcarboxamido)benzyl carbamate; 1,1-dimethyl-3-(N,N-dimethylcarboxamido)propyl carbamate; 1,1-dimethylpropynyl carbamate; di(2-pyridyl)methyl carbamate; 2-furanylmethyl carbamate; 2-iodoethyl carbamate; isobornyl carbamate; isobutyl carbamate; isonicotinyl carbamate; p-(p′-methoxyphenylazo)benzyl carbamate; 1-methylcyclobutyl carbamate; 1-methylcyclohexyl carbamate; 1-methyl-1-cyclopropylmethyl carbamate; 1-methyl-1-(3,5-dimethoxyphenyl)ethyl carbamate; 1-methyl-1-(p-phenylazophenyl)ethyl carbamate; and 1-methyl-1-phenylethyl carbamate. T. Greene and P. Wuts (“Protective Groups In Organic Synthesis,” 2nd Ed., John Wiley & Sons, Inc. (1991)) describe the preparation and cleavage of such carbamate protecting groups.
[0021] The term silyl refers to a silicon atom substituted by one or more alkyl, aryl and aralkyl groups. Suitable silyl protecting groups include, but are not limited to, trimethylsilyl, triethylsilyl, tri-isopropylsilyl, tert-butyldimethylsilyl, dimethylphenylsilyl, 1,2-bis(dimethylsilyl)benzene, 1,2-bis(dimethylsilyl)ethane and diphenylmethylsilyl. Silylation of the amine functions to provide mono- or bis-disilylamine can provide derivatives of the aminoalcohol, amino acid, amino acid esters and amino acid amide. In the case of amino acids, amino acid esters and amino acid amides, reduction of the carbonyl function provides the required mono- or bis-silyl aminoalcohol. Silylation of the amino-alcohol can lead to the N,N,O-tri-silyl derivative. Removal of the silyl function from the silyl ether function is readily accomplished by treatment with, for example, a metal hydroxide or ammonium fluoride reagent, either as a discrete reaction step or in situ during the preparation of the amino aldehyde reagent. Suitable silylating agents are, for example, trimethylsilyl chloride, tert-buty-dimethylsilyl chloride, phenyldimethylsilyl chloride, diphenylmethylsilyl chloride or their combination products with imidazole or DMF. Methods for silylation of amines and removal of silyl protecting groups are well known to those skilled in the art. Methods of preparation of these amine derivatives from corresponding amino acids, amino acid amides or amino acid esters are also well known to those skilled in the art of organic chemistry including amino acid/amino acid ester or aminoalcohol chemistry.
[0022] Preferably p 1 is aralkyl, substituted aralkyl, alkylcarbonyl, aralkylcarbonyl, arylcarbonyl, alkoxycarbonyl or aralkoxycarbonyl, and p 2 is aralkyl or substituted aralkyl. Alternatively, when p 1 is alkoxycarbonyl or aralkoxycarbonyl, p 2 can be hydrogen. More preferably, p 1 is t-butoxycarbonyl, phenylmethoxycarbonyl, (4-methoxyphenyl)methoxycarbonyl or benzyl, and p 2 is hydrogen or benzyl.
[0023] Because the same synthetic and purification procedures are applicable to the preparation of each of the four possible diastereomers of Formula I, provided the proper chiral amino acid starting material is utilized, Formula I though shown in one configuration is intended to encompass all four diastereomers individually. Thus, the preparation procedures described herein and the definitions of R 1 , R 3 , p 1 and p 2 also apply to the other three configurational isomers
[0024] Protected amino epoxides of the formula
[0025] protected amino alpha-hydroxycyanides and acids of the formula
[0026] wherein X is —CN, —CH 2 NO 2 or —COOH, protected alpha-aminoaldehyde intermediates of the formula
[0027] and protected chiral alpha-amino alcohols of the formula
[0028] wherein p 1 , p 2 and R 1 are as defined above, are also described herein.
[0029] As utilized herein, the term “amino epoxide” alone or in combination, means an amino-substituted alkyl epoxide wherein the amino group can be a primary, or secondary amino group containing substituents selected from hydrogen, alkyl, aryl, aralkyl, alkenyl, alkoxycarbonyl, aralkoxycarbonyl, cycloalkenyl, silyl, cycloalkylalkenyl radicals and the like and the epoxide can be alpha to the amine. The term “amino aldehyde” alone or in combination, means an amino-substituted alkyl aldehyde wherein the amino group can be a primary, or secondary amino group containing substituents selected from hydrogen, alkyl, aryl, aralkyl, alkenyl, aralkoxycarbonyl, alkoxycarbonyl, cycloalkenyl, silyl, cycloalkylalkenyl radicals and the like and the aldehyde can be alpha to the amine. The term “alkyl”, alone or in combination, means a straight-chain or branched-chain alkyl radical containing from 1 to 10, preferably from 1 to 8, more preferably from 1 to 5 carbon atoms. Examples of such radicals include methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, tert-butyl, pentyl, iso-amyl, hexyl, octyl and the like. The term “alkenyl”, alone or in combination, means a straight-chain or branched-chain hydrocarbon radial having one or more double bonds and containing from 2 to, 10 carbon atoms, preferably from 2 to 8, more preferably from 2 to 5 carbon atoms. Examples of suitable alkenyl radicals include ethenyl, propenyl, allyl, 1,4-butadienyl and the like. The term “alkynyl”, alone or in combination, means a straight-chain hydrocarbon radical having one or more triple bonds and containing from 2 to about 10, preferably from 2 to 8, more preferably from 2 to 5 carbon atoms. Examples of alkynyl radicals include ethynyl, propynyl, (propargyl), butynyl and the like. The term “alkoxy”, alone or in combination, means an alkyl ether radical wherein the term alkyl is as defined above. Examples of suitable alkyl ether radicals include methoxy, ethoxy, n-propoxy, isopropoxy, n-butoxy, iso-butoxy, sec-butoxy, tert-butoxy and the like. The term “cycloalkenyl”, alone or in combination, means an alkyl radical which contains from 5 to 8, preferably 5 to 6 carbon atoms, is cyclic and contains at least one double bond in the ring which is non-aromatic in character. Examples of such cycloalkenyl radicals include cyclopropenyl, cyclobutenyl, cyclopentenyl, cyclohexenyl, dihydrophenyl and the like. The term “cycloalkenylalkyl” means cycloalkenyl radical as defined above which is attached to an alkyl radical as defined above. The term “cycloalkyl”, alone or in combination, means a cyclic alkyl radical which contains from about 3 to about 8, preferably 3 to 6, more preferably 5 to 6 carbon atoms. The term “cycloalkylalkyl” means an alkyl radical as defined above which is substituted by a cycloalkyl radical as defined above. Examples of such cycloalkyl radicals include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl and the like. The term “aryl”, alone or in combination, means a phenyl or naphthyl radical either of which is optionally substituted by one or more alkyl, alkoxy, halogen, hydroxy, amino, nitro and the like, as well as p-tolyl, 4-methoxyphenyl, 4-(tert-butoxy)phenyl, 4-fluorophenyl, 4-chlorophenyl, 4-hydroxyphenyl, 1-naphthyl, 2-naphthyl, and the like. The term “aralkyl”, alone or in combination, means an alkyl radical as defined above substituted by an aryl radical as defined above, such as benzyl, 1-phenylethyl and the like. Examples of substituted aralkyl include 3,5-dimethoxybenzyl, 3,4-dimethoxybenzyl, 2,4-dimethoxybenzyl, 3,4,5-trimethoxybenzyl, 4-nitrobenzyl, 2,6-dichlorobenzyl, 4-(chloromethyl)benzyl, 2-(bromomethyl)benzyl, 3-(chloromethyl)benzyl, 4-chlorobenzyl, 3-chlorobenzyl, 2-(chloromethyl)benzyl, 6-chloropiperonyl, 2-chlorobenzyl, 4-chloro-2-nitrobenzyl, -chloro-6-fluorobenzyl, 2-(chloromethyl)-4,5-dimethylbenzyl, 6-(chloromethyl)duren-3-ylmethyl, 10-(chloromethyl)anthracen-9-ylmethyl, 4-(chloromethyl)-2,5-dimethylbenzyl, 4-(chloromethyl)-2,5-dimethoxybenzyl, 4-(chloromethyl)anisol-2-ylmethyl, 5-(chloromethyl)-2,4-dimethylbenzyl, 4-(chloromethyl)mesitylen-2-ylmethyl, 4-acetyl-2,6-dichlorobenzyl, 2-chloro-4-methylbenzyl, 3,4-dichlorobenzyl, 6-chlorobenzo-1,3-dioxan-8-ylmethyl, 4-(2,6-dichlorobenzylsulphonyl)benzyl, 4-chloro-3-nitrobenzyl, 3-chloro-4-methoxybenzyl, 2-hydroxy-3-(chloromethyl)-5-methylbenzyl and the like. The term aralkoxycarbonyl means an aralkoxyl group attached to a carbonyl. Carbobenzoxy is an example of aralkoxycarbonyl. The term “heterocyclic” means a saturated or partially unsaturated monocyclic, bicyclic or tricyclic heterocycle having 5 to 6 ring members in each ring and which contains one or more heteroatoms as ring atoms, selected from nitrogen, oxygen, silicon and sulphur, which is optionally substituted on one or more carbon atoms by halogen, alkyl, alkoxy, oxo, and the like, and/or on a secondary nitrogen atom (i.e., —NH—) by alkyl, aralkoxycarbonyl, alkanoyl, phenyl or phenylalkyl or on a tertiary nitrogen atom (i.e. ═N—) by oxido. “Heteroaryl” means an aromatic monocyclic, bicyclic, or tricyclic heterocycle which contains the heteroatoms and is optionally substituted as defined above with respect to the definition of aryl. Examples of such heterocyclic groups are pyrrolidinyl, piperidinyl, piperazinyl, morpholinyl, thiamorpholinyl, pyrrolyl, phthalimide, succinimide, maleimide, and the like. Also included are heterocycles containing two silicon atoms simultaneously attached to the nitrogen and joined by carbon atoms. The term “alkylamino” alone or in combination, means an amino-substituted alkyl group wherein the amino group can be a primary, or secondary amino group containing substituents selected from hydrogen, alkyl, aryl, aralkyl, cycloalkyl, cycloalkylalkyl radicals and the like. The term “halogen” means fluorine, chlorine, bromine or iodine. The term dihaloalkyl means two halogen atoms, the same or different, substituted on the same carbon atom. The term “oxidizing agent” includes a single agent or a mixture of oxidizing reagents. Examples of mixtures of oxidizing reagents include sulfur trioxide-pyridine/dimethylsulfoxide, oxalyl chloride/dimethyl sulfoxide, acetyl chloride/dimethyl sulfoxide, acetyl anhydride/dimethyl sulfoxide, trifluoroacetyl chloride/dimethyl sulfoxide, toluenesulfonyl bromide/dimethyl sulfoxide, phosphorous pentachloride/dimethyl sulfoxide and isobutylchloroformate/dimethyl sulfoxide.
[0030] A general Scheme for the preparation of amino epoxides, useful as intermediates in the synthesis of HIV protease inhibitors is shown in Scheme 1 below.
[0031] An economical and safe large scale method of preparation of protease inhibitors of the present invention can alternatively utilize amino acids or amino alcohols to form N,N-protected alpha aminoalcohol of the formula
[0032] wherein p 1 , p 2 and R 1 are described above.
[0033] Whether the compounds of Formula II are formed from amino acids or aminoalcohols, such compounds have the amine protected with groups p 1 and p 2 as previously identified. The nitrogen atom can be alkylated such as by the addition of suitable alkylating agents in an appropriate solvent in the presence of base.
[0034] Alternate bases used in alkylation include sodium hydroxide, sodium bicarbonate, potassium hydroxide, lithium hydroxide, potassium carbonate, sodium carbonate, cesium hydroxide, magnesium hydroxide, calcium hydroxide or calcium oxide, or tertiary amine bases such as triethyl amine, diisopropylethylamine, pyridine, N-methylpiperidine, dimethylaminopyridine and azabicyclononane. Reactions can be homogenous or heterogenous. Suitable solvents are water and protic solvents or solvents miscible with water, such as methanol, ethanol, isopropyl alcohol, tetrahydrofuran and the like, with or without added water. Dipolar aprotic solvents may also be used with or without added protic solvents including water. Examples of dipolar aprotic solvents include acetonitrile, dimethylformamide, dimethyl acetamide, acetamide, tetramethyl urea and its cyclic analog, dimethylsulfoxide, N-methylpyrrolidone, sulfolane, nitromethane and the like. Reaction temperature can range between about −20° to 100° C. with the preferred temperature of about 25-85° C. The reaction may be carried out under an inert atmosphere such as nitrogen or argon, or normal or dry air, under atmospheric pressure or in a sealed reaction vessel under positive pressure. The most preferred alkylating agents are benzyl bromide or benzyl chloride or monosubstituted aralkyl halides or polysubstituted aralkyl halides. Sulfate or sulfonate esters are also suitable reagents to provide the corresponding benzyl analogs and they can be preformed from the corresponding benzyl alcohol or formed in situ by methods well known to those skilled in the art. Trityl, benzhydryl, substituted trityl and substituted benzhydryl groups, independently, are also effective amine protecting groups [p 1 ,p 2 ] as are allyl and substituted allyl groups. Their halide derivatives can also be prepared from the corresponding alcohols by methods well known to those skilled in the art such as treatment with thionyl chloride or bromide or with phosphorus tri- or pentachloride, bromide or iodide or the corresponding phosphoryl trihalide. Examples of groups that can be substituted on the aryl ring include alkyl, alkoxy, hydroxy, nitro, halo and alkylene, amino, mono- and dialkyl amino and acyl amino, acyl and water solubilizing groups such as phosphonium salts and ammonium salts. The aryl ring can be derived from, for example, benzene, napthelene, indane, anthracene, 9-phenylfluorenyl, durene, phenanthrene and the like. In addition, 1,2-bis (substituted alkylene) aryl halides or sulfonate esters can be used to form a nitrogen containing aryl or non-aromatic heterocyclic derivative [with p 1 and p 2 ] or bis-heterocycles. Cycloalkylenealkyl or substituted cyloalkylene radicals containing 6-10 carbon atoms and alkylene radicals constitute additional acceptable class of substituents on nitrogen prepared as outlined above including, for example, cyclohexylenemethylene.
[0035] Compounds of Formula II can also be prepared by reductive alkylation by, for example, compounds and intermediates formed from the addition of an aldehyde with the amine and a reducing agent, reduction of a Schiff Base, carbinolamine or enamine or reduction of an acylated amine derivative. Reducing agents include metals [platinum, palladium, palladium hydroxide, palladium on carbon, platinum oxide, rhodium and the like] with hydrogen gas or hydrogen transfer molecules such as cyclohexene or cyclohexadiene or hydride agents such as lithium aluminum hydride, sodium borohydride, lithium borohydride, sodium cyanobqrohydride, diisobutylaluminum hydride or lithium tri-tert-butoxyaluminum hydride.
[0036] Additives such as sodium or potassium bromide, sodium or potassium iodide can catalyze or accelerate the rate of amine alkylation, especially when benzyl chloride was used as the nitrogen alkylating agent.
[0037] Phase transfer catalysis wherein the amine to be protected and the nitrogen alkylating agent are reacted with base in a solvent mixture in the presence of a phase transfer reagent, catalyst or promoter. The mixture can consist of, for example, toluene, benzene, ethylene dichloride, cyclohexane, methylene chloride or the like with water or a aqueous solution of an organic water miscible solvent such as THF. Examples of phase transfer catalysts or reagents include tetrabutylammonium chloride or iodide or bromide, tetrabutylammonium hydroxide, tri-butyloctylammonium chloride, dodecyltrihexylammonium hydroxide, methyltrihexylammonium chloride and the like.
[0038] A preferred method of forming substituted amines involves the aqueous addition of about 3 moles of organic halide to the amino acid or about 2 moles to the aminoalcohol. In a more preferred method of forming a protected amino alcohol, about 2 moles of benzylhalide in a basic aqueous solution is utilized. In an even more preferred method, the alkylation occurs at 50° C. to 80° C. with potassium carbonate in water, ethanol/water or denatured ethanol/water. In a more preferred method of forming a protected amino acid ester, about 3 moles of benzylhalide is added to a solution containing the amino acid.
[0039] The protected amino acid ester is additionally reduced to the protected amino alcohol in an organic solvent. Preferred reducing agents include lithium aluminum hydride, lithium borohydride, sodium borohydride, borane, lithium tri-tert-butoxyaluminum hydride, borane.THF complex. Most preferably, the reducing agent is diisobutylaluminum hydride (DiBAL-H) in toluene. These reduction conditions provide an alternative to a lithium aluminum hydride reduction.
[0040] Purification by chromatography is possible. In the preferred purification method the alpha amino alcohol can be purified by an acid quench of the reaction, such as with hydrochloric acid, and the resulting salt can be filtered off as a solid and the amino alcohol can be liberated such as by acid/base extraction.
[0041] The protected alpha amino alcohol is oxidized to form a chiral amino aldehyde of the formula
[0042] Acceptable oxidizing reagents include, for example, sulfur trioxide-pyridine complex and DMSO, oxalyl chloride and DMSO, acetyl chloride or anhydride and DMSO, trifluoroacetyl chloride or anhydride and DMSO, methanesulfonyl chloride and DMSO or tetrahydrothiaphene-S-oxide, toluepesulfonyl bromide and DMSO, trifluoromethanesulfonyl anhydride (triflic anhydride) and DMSO, phosphorus pentachloride and DMSO, dimethylphosphoryl chloride and DMSO and isobutylchloroformate and DMSO. The oxidation conditions reported by Reetz et al [ Angew Chem., 99, p. 1186, (1987)], Angew Chem. Int. Ed. Engl., 26, p. 1141, 1987) employed oxalyl chloride and DMSO at −78° C.
[0043] The preferred oxidation method described in this invention is sulfur trioxide pyridine complex, triethylamine and DMSO at room temperature. This system provides excellent yields of the desired chiral protected amino aldehyde usable without the need for purification i.e., the need to purify kilograms of intermediates by chromatography is eliminated and large scale operations are made less hazardous. Reaction at room temperature also eliminated the need for the use of low temperature reactor which makes the process more suitable for commercial production.
[0044] The reaction may be carried out under an inert atmosphere such as nitrogen or argon, or normal or dry air, under atmospheric pressure or in a sealed reaction vessel under positive pressure. Preferred is a nitrogen atmosphere. Alternative amine bases include, for example, tri-butyl amine, tri-isopropyl amine, N-methylpiperidine, N-methyl morpholine, azabicyclononane, diisopropylethylamine, 2,2,6,6-tetramethylpiperidine, N,N-dimethylaminopyridine, or mixtures of these bases. Triethylamine is a preferred base. Alternatives to pure DMSO as solvent include mixtures of DMSO with non-protic or halogenated solvents such as tetrahydrofuran, ethyl acetate, toluene, xylene, dichloromethane, ethylene dichloride and the like. Dipolar aprotic co-solvents include acetonitrile, dimethylformamide, dimethylacetamide, acetamide, tetramethyl urea and its cyclic analog, N-methylpyrrolidone, sulfolane and the like. Rather than N,N-dibenzylphenylalaminol as the aldehyde precursor, the phenylalaminol derivatives discussed above can be used to provide the corresponding N-monosubstituted [either p 1 or p 2 =H] or N,N-disubstituted aldehyde.
[0045] In addition, hydride reduction of an amide or ester derivative of the corresponding alkyl, benzyl or cycloalkenyl nitrogen protected phenylalanine, substituted phenylalanine or cycloalkyl analog of phenyalanine derivative can be carried out to provide a compound of Formula III. Hydride transfer is an additional method of aldehyde synthesis under conditions where aldehyde condensations are avoided, cf, Oppenauer Oxidation.
[0046] The aldehydes of this process can also be prepared by methods of reducing protected phenylalanine and phenylalanine analogs or their amide or ester derivatives by, e.g., sodium amalgam with HCl in ethanol or lithium or sodium or potassium or calcium in ammonia. The reaction temperature may be from about −20° C. to about 45° C., and preferably from abut 5° C. to about 25° C. Two additional methods of obtaining the nitrogen protected aldehyde include oxidation of the corresponding alcohol with bleach in the presence of a catalytic amount of 2,2,6,6-tetramethyl-1-pyridyloxy free radical. In a second method, oxidation of the alcohol to the aldehyde is accomplished by a catalytic amount of tetrapropylammonium perruthenate in the presence of N-methylmorpholine-N-oxide.
[0047] Alternatively, an acid chloride derivative of a protected phenylalanine or phenylalanine derivative as disclosed above can be reduced with hydrogen and a catalyst such as Pd on barium carbonate or barium sulphate, with or without an additional catalyst moderating agent such as sulfur or a thiol (Rosenmund Reduction).
[0048] An important aspect of the present invention is a reaction involving the addition of chloromethyllithium or bromomethyllithium to the α-amino aldehyde. Although addition of chloromethyllithium or bromomethyllithium to aldehydes is known, the addition of such species to racemic or chiral amino aldehydes to form aminoepoxides of the formula
[0049] is novel. The addition of chloromethyllithium or bromomethyllithium to a chiral amino aldehyde with appropriate amino protecting groups is highly diastereoselective. Preferably, the chloromethyllithium or bromomethyllithium is generated in-situ from the reaction of the dihalomethane and n-butyl lithium. Acceptable methyleneating halomethanes include chloroiodomethane, bromochloromethane, dibromomethane, diiodomethane, bromofluoromethane and the like. The sulfonate ester of the addition product of, for example, hydrogen bromide to formaldehyde is also a methyleneating agent. Tetrahydrofuran is the preferred solvent, however alternative solvents such as toluene, dimethoxyethane, ethylene dichloride, methylene chloride can be used as pure solvents or as a mixture. Dipolar aprotic solvents such as acetonitrile, DMF, N-methylpyrrolidone are useful as solvents or as part of a solvent mixture. The reaction can be carried out under an inert atmosphere such as nitrogen or argon. Other organometallic reagents can be substituted for n-butyl lithium, such as methyl lithium, tert-butyl lithium, sec-butyl lithium, phenyl lithium, phenyl sodium, lithium diisopropylamide, lithium bis(trimethylsilyl)amide, other amide bases, and the like. The reaction can be carried out at temperatures of between about −80° C. to 0° C. but preferably between about −80° C. to −20° C. The most preferred reaction temperatures are between −40° C. to −15° C. Reagents can be added singly but multiple additions are preferred in certain conditions. The preferred pressure of the reaction is atmospheric however a positive pressure is valuable under certain conditions such as a high humidity environment.
[0050] Alternative methods of conversion to the epoxides of this invention include substitution of other charged methylenation precursor species followed by their treatment with base to form the analogous anion. Examples of these species include trimethylsulfoxonium tosylate or triflate, tetramethylammonium halide, methyldiphenylsulfoxonium halide wherein halide is chloride, bromide or iodide.
[0051] The conversion of the aldehydes of this invention into their epoxide derivative can also be carried out in multiple steps. For example, the addition of the anion of thioanisole prepared from, for example, a butyl or aryl lithium reagent, to the protected aminoaldehyde, oxidation of the resulting protected aminosulfide alcohol with well known oxidizing agents such as hydrogen peroxide, tert-butyl hypochlorite, bleach or sodium periodate to give a sulfoxide. Alkylation of the sulfoxide with, for example, methyl iodide or bromide, methyl tosylate, methyl mesylate, methyl triflate, ethyl bromide, isopropyl bromide, benzyl chloride or the like, in the presence of an organic or inorganic base Alternatively, the protected aminosulfide alcohol can be alkylated with, for example, the alkylating agents above, to provide a sulfonium salts that are subsequently converted into the subject epoxides with tert-amine or mineral bases.
[0052] The desired epoxides form, using most preferred conditions, diastereoselectively in ratio amounts of at least about an 85:15 ratio (S:R). The product can be purified by chromatography to give the diastereomerically and enantiomerically pure product but it is more conveniently used directly without purification to prepare HIV protease inhibitors.
[0053] The epoxide is then reacted, in a suitable solvent system, with an equal amount, or preferably an excess of, with R 3 NH 2 to form the amino alcohol of Formula I
[0054] wherein R 3 is as defined above.
[0055] The reaction can be conducted over a wide range of temperatures, e.g., from about 10° C. to about 100° C., but is preferably, but not necessarily, conducted at a temperature at which the solvent begins to reflux. Suitable solvent systems include those wherein the solvent is an alcohol, such as methanol, ethanol, isopropanol, and the like, ethers such as tetrahydrofuran, dioxane and the like, and toluene, N,N-dimethylformamide, dimethyl sulfoxide, and mixtures thereof. A preferred solvent is isopropanol. Exemplary amines corresponding to the formula R 3 NH 2 include benzylamine, isobutylamine, n-butyl amine, isopentylamine, isoamylamine, cyclohexylmethylamine, cyclopentylmethylamine, naphthylmethylamine and the like. In some cases, R 3 NH 2 can be used as the solvent, such as iso-butylamine.
[0056] Alternatively, the protected amino aldehyde of Formula III can also be reacted with a cyanide salt, such as sodium cyanide or potassium cyanide to form a chiral cyanohydrin of the formula
[0057] Preferably, a reaction rate enhancer, such as sodium bisulfite, is used to enhance the rate of cyanohydrin formation. Alternatively, trimethylsilylnitrile can be used to form a trimethylsilyloxycyano intermediate, which can be readily hydrolyzed to the cyanohydrin.
[0058] The reaction can be carried out at temperatures of between about −5° C. to 5° C. but preferably between about 0° C. to 5° C. The desired cyanohydrins form, using sodium cyanide and sodium bisulfite, diastereoselectively in ratio amounts of at least about an 88:12 ratio (S:R). The product can be purified by chromatography to give the diastereomerically and enantiomerically pure product.
[0059] The cyano group can be reduced to the amine of Formula V
[0060] The reduction can be accomplished using a variety of reducing reagents, such as hydride transfer, metal reductions and catalytic hydrogenation which are well known to those skilled in the art. Examples of hydride reagents with and without heavy metal(s) or heavy metal salts as adjunct reagents include, for example, lithium aluminum hydride, lithium tri-tert-butoxyaluminum hydride, lithium trimethoxy-aluminum hydride, aluminum hydride, diborane (or borane), borane/THF, borane/dimethyl sulfide, borane/pyridine, sodium borohydride, lithium borohydride, sodium borohydride/cobalt salts, sodium borohydride/Raney-nickel, sodium borohydride/acetic acid and the like. Solvents for the reaction include, for the more reactive hydrides, THF, diethyl ether, dimethoxy ethane, diglyme, toluene, heptane, cyclohexane, methyl tert-butyl ether and the like. Solvents or solvent mixtures for reductions using reagents such as sodium borohydride, in addition to the non-protic solvents listed above, can include ethanol, n-butanol, tert-butyl alcohol, ethylene glycol and the like. Metal reductions include, for example, sodium and ethanol. Reaction temperatures can vary between solvent reflux and −20° C. An inert atmosphere such as nitrogen or argon is usually preferred especially where the possibility of flammable gas or solvent production/evolution is possible. Catalytic hydrogenation (metal catalyst plus hydrogen gas) can be carried out in the same solvents as above with metals or metal salts such a nickel, palladium chloride, platinum, rhodium, platinum oxide or palladium on carbon or other catalysts known to those skilled in the art. These catalysts can also be modified with, for example, phosphine ligands, sulfur or sulfur containing compounds or amines such as quinoline. Hydrogenations can be carried out at atmospheric pressure or at elevated pressures to about 1500 psi at temperatures between 0° to about 250° C. The most preferred reducing reagent is diborane-tetrahydrofuran, preferably at room temperature under an atmosphere of nitrogen and atmospheric pressure.
[0061] The amine of Formula V can then be reacted with R 3 L, wherein L is a leaving group selected from halo, tosylate, mesolate and the like, and R 3 represents alkyl, alkenyl, alkynyl, hydroxyalkyl, alkoxyalkyl, cycloalkyl, cycloalkylalkyl, heterocycloalkyl, heterocycloalkylalkyl, aralkyl or heteroaralkyl. Alternatively, the primary amino group of Formula V can be reductively alkylated with an aldehyde to introduce the R 3 group. For example, when R 3 is an isobutyl group, treatment of Formula V with isobutyraldehyde under reductive amination conditions affords the desired Formula I. Similarly, when R 3 is an isoamyl group, treatment of Formula V with isovaleraldehyde under reductive amination conditions affords the desired Formula I. Other aldehydes can be used to introduce various R 3 groups. Reductive amination can be performed using a variety of reaction conditions well-known to those skilled in the art. For example, the reductive amination of Formula V with an aldehyde can be carried out with a reducing agent such as sodium cyanoborohydride or sodium borohydride in a suitable solvent, such as methanol, ethanol, tetrahydrofuran and the like. Alternatively, the reductive amination can be carried out using hydrogen in the presence of a catalyst such as palladium or platinum, palladium on carbon or platinum on carbon, or various other metal catalysts known to those skilled in the art, in a suitable solvent such as methanol, ethanol, tetrahydrofuran, ethyl acetate, toluene and the like.
[0062] Alternatively, the amine of Formula I can be prepared by reduction of the protected amino acid of formula
[0063] (commercially available from Nippon Kayaku, Japan) to the corresponding alcohol of formula
[0064] The reduction can be accomplished using a variety of reducing reagents and conditions. A preferred reducing reagent is diborane.tetrahydrofuran. The alcohol is then converted into a leaving group (L′) by tosylation, mesylation or conversion into a halo group, such as chloro or bromo:
[0065] Finally, the leaving group (L′) is reacted with R 3 NH 2 as described above to form amino alcohol of Formula I. Alternatively, base treatment of the alcohol can result in the formation of the amino epoxide of Formula IV.
[0066] The above preparation of amino alcohol of Formula I is applicable to mixtures of optical isomers as well as resolved compounds. If a particular optical isomer is desired, it can be selected by the choice of starting material, e.g., L-phenylalanine, D-phenylalanine, L-phenylalaminol, D-phenylalaminol, D-hexahydrophenyl alaminol and the like, or resolution can occur at intermediate or final steps. Chiral auxiliaries such as one or two equivalents of camphor sulfonic acid, citric acid, camphoric acid, 2-methoxyphenylacetic acid and the like can be used to form salts, esters or amides of the compounds of this invention. These compounds or derivatives can be crystallized or separated chromatographically using either a chiral or achiral column as is well known to those skilled in the art.
[0067] A further advantage of the present process is that materials can be carried through the above steps without purification of the intermediate products. However, if purification is desired, the intermediates disclosed can be prepared and stored in a pure state.
[0068] The practical and efficient synthesis described here has been successfully scaled up to prepare large quantity of intermediates for the preparation of HIV protease inhibitors. It offers several advantages for multikilogram preparations: (1) it does not require the use of hazardous reagents such as diazomethane, (2) it requires no purification by chromatography, (3) it is short and efficient, (4) it utilizes inexpensive and readily available commercial reagents, (5) it produces enantiomerically pure alpha amino epoxides. In particular, the process of the invention produces enantiomerically-pure epoxide as required for the preparation of enantiomerically-pure intermediate for further synthesis of HIV protease inhibitors.
[0069] The amino epoxides were prepared utilizing the following procedure as disclosed in Scheme IT below.
[0070] In Scheme II, there is shown a synthesis for the epoxide, chiral N,N,α-S-tris(phenylmethyl)-2S-oxiranemethan-amine. The synthesis starts from L-phenylalanine. The aldehyde is prepared in three steps from L-phenylalanine or phenylalaminol. L-Phenylalanine is converted to the N,N-dibenzylamino acid benzyl ester using benzyl bromide under aqueous conditions. The reduction of benzyl ester is carried out using diisobutylaluminum hydride (DIBAL-H) in toluene. Alternatively, lithium aluminum hydride may be used. Instead of purification by chromatography, the product is purified by an acid (hydrochloric acid) quench of the reaction, the hydrochloride salt is filtered off as a white solid and then liberated by an acid/base extraction. After one recrystallization, chemically and optically pure alcohol is obtained. Alternately, and preferably, the alcohol can be obtained in one step in 88% yield by the benzylation of L-phenylalaminol using benzylbromide under aqueous conditions. The oxidation of alcohol to aldehyde is also modified to allow for more convenient operation during scaleup. Instead of the standard Swern procedures using oxalyl chloride and DMSO in methylene chloride at low temperatures (very exothermic reaction), sulfur trioxide-pyridine/DMSO was employed (Parikh, J., Doering, W., J. Am. Chem. Soc., 89, p. 5505, 1967) which can be conveniently performed at room temperature to give excellent yields of the desired aldehyde with high chemical and enantiomer purity which does not require purification.
[0071] An important reaction involves the addition of chloromethyllithium or bromomethyllithium to the aldehyde. Although addition of chloromethyllithium or bromomethyllithium to aldehydes has been reported previously, the addition of such species to chiral α-amino aldehydes to form chiral-aminoepoxides is believed to be novel. Now, chloromethyllithium or bromomethyllithium is generated in-situ from chloroiodomethane(or bromochloromethane) or dibromomethane and n-butyl lithium at a temperature in a range from about −78° C. to about −10° C. in THF in the presence of aldehyde. The desired chlorohydrin or bromohydrin is formed as evidenced by TLC analyses. After warming to room temperature, the desired epoxide is formed diastereoselectively in a 85:15 ratio (S:R). The product can be purified by chromatography to give the diastereomerically pure product as a colorless oil but it is more conveniently used directly without purification.
[0072] Scheme III illustrates the preparation of the aminopropylurea (9) utilizing mixed protected amine of phenylalaminol, where BOC is t-butoxycarbonyl and Bn is benzyl.
[0073] Scheme IV illustrates an alternative preparation of the amino epoxide (5) utilizing a sulfur ylide.
[0074] The aminopropylurea (9) was also prepared utilizing the procedure as disclosed in Scheme V below.
[0075] In Scheme V a mixed protected amine of phenylalaninal, where BOC is t-butoxycarbonyl and Bn is benzyl, was reacted with potassium cyanide to form the desired stereoisomeric cyanohydrin (12) in high yield. In additional to the stereospecificity of the cyanohydrin reaction, this process has the added advantage of being easier and less expensive because the temperature of the reactions need not be less than −5° C.
[0076] The aminourea (9) was also prepared utilizing the procedure as disclosed in Scheme VI below.
[0077] The procedure in Scheme VI required only one protecting group, BOC, for the amine of the hydroxyamino acid. This procedure has the advantage of having the desired stereochemistry of the benzyl and hydroxy groups established in the starting material. Thus the chirality does not need to be introduced with the resulting loss of material due to preparation of diastereomers.
EXAMPLE 1
[0078] β-2-[Bis(phenylmethyl)amino]benzenepropanol
[0079] METHOD 1: βS-2-[Bis(phenylmethyl)amino]benzenepropanol from the DIBAL Reduction of N,N-bis(phenylmethyl)-L-Phenylalanine Phenylmethyl Ester
[0080] Step 1:
[0081] A solution of L-phenylalanine (50.0 g, 0.302 mol), sodium hydroxide (24.2 g, 0.605 mol) and potassium carbonate (83.6 g, 0.605 mol) in water (500 mL) was heated to 97° C. Benzyl bromide (108.5 mL, 0.605 mol) was then slowly added (addition time −25 min). The mixture was stirred at 97° C. for 30 minutes under a nitrogen atmosphere. The solution was cooled to room temperature and extracted with toluene (2×250 mL). The combined organic layers were washed with water and brine, dried over magnesium sulfate, filtered and concentrated to an oil. The identity of the product was confirmed as follows. Analytical TLC (10% ethyl acetate/hexane, silica gel) showed major component at Rf value=0.32 to be the desired tribenzylated compound, N,N-bis(phenylmethyl)-L-phenylalanine phenylmethyl ester. This compound can be purified by column chromatography (silica gel, 15% ethyl acetate/hexane). Usually the product is pure enough to be used directly in the next step without further purification. 1 H NMR spectrum was in agreement with published literature. 1 H NMR (CDCL 3 ) ∂, 3.00 and 3.14 (ABX-system, 2H, J AB =14.1 Hz, J AX =7.3 Hz and J BX =5.9 Hz), 3.54 and 3.92 (AB-System, 4H, J AB =13.9 Hz), 3.71 (t, 1H, J=7.6 Hz), 5.11 and 5.23 (AB-System, 2H, J AB =12.3 Hz,), and 7.18 (m, 20H). ETMS: m/z 434 (M−1).
[0082] Step 2:
[0083] The benzylated phenylalanine phenylmethyl ester (0.302 mol) from the previous reaction was dissolved in toluene (750 mL) and cooled to −55° C. A 1.5 M solution of DIBAL in toluene (443.9 mL, 0.666 mol) was added at a rate to maintain the temperature between −55 to −50° C. (addition time −1 hr). The mixture was stirred for 20 minutes under a nitrogen atmosphere and then quenched at −55° C. by the slow addition of methanol (37 ml). The cold solution was then poured into cold (5° C.) 1.5 N HCl solution (1.8 L). The precipitated solid (approx. 138 g) was filtered off and washed with toluene. The solid material was suspended in a mixture of toluene (400 mL) and water (100 ml). The mixture was cooled to 5° C. and treated with 2.5 N NaOH (186 mL) and then stirred at room temperature until solid dissolved. The toluene layer was separated from the aqueous phase and washed with water and brine, dried over magnesium sulfate, filtered and concentrated to a volume of 75 mL (89 g). Ethyl acetate (25 mL) and hexane (25 mL) were added to the residue upon which the desired alcohol product began to crystallize. After 30 min, an additional 50 mL hexane were added to promote further crystallization. The solid was filtered off and washed with 50 mL hexane to give 34.9 g of first crop product. A second crop of product (5.6 g) was isolated by refiltering the mother liquor. The two crops were combined and recrystallized from ethyl acetate (20 mL) and hexane (30 mL) to give 40 g of ES-2-[Bis(phenylmethyl)amino]benzenepropanol, 40% yield from L-phenylalanine. An additional 7 g (7%) of product can be obtained from recrystallization of the concentrated mother liquor. TLC of product Rf=0.23 (10% ethyl acetate/hexane, silica gel); 1 H NMR (CDCl 3 ) ∂ 2.44 (m, 1H,), 3.09 (m, 2H), 3.33 (m, 1H), 3.48 and 3.92 (AB-System, 4H, J AB =13.3 Hz), 3.52 (m, 1H) and 7.23 (m, 15H); [α] D 25+42.4 (c 1.45, CH 2 Cl 2 ); DSC 77.67° C.; Anal. Calcd. for C 23 H 25 ON: C, 83.34; H, 7.60; N, 4.23. Found: C, 83.43; H, 7.59; N, 4.22. HPLC on chiral stationary phase: Cyclobond I SP column (250×4.6 mm I.D.), mobile phase: methanol/triethyl ammonium acetate buffer pH 4.2 (58:42, v/v), flow-rate of 0.5 ml/min, detection with detector at 230 nm and a temperature of 0° C. Retention time: 11.25 min., retention time of the desired product enantiomer: 12.5 min.
[0084] METHOD 2: Preparation of βS-2-[Bis(phenylmethyl)amino]benzene-propanol from the N,N-Dibenzylation of L-Phenylalaminol
[0085] L-phenylalaminol (176.6 g, 1.168 mol) was added to a stirred solution of potassium carbonate (484.6 g, 3.506 mol) in 710 mL of water. The mixture was heated to 65° C. under a nitrogen atmosphere. A solution of benzyl bromide (400 g, 2.339 mol) in 3A ethanol (305 mL) was added at a rate that maintained the temperature between 60-68° C. The biphasic solution was stirred at 65° C. for 55 min and then allowed to cool to 10° C. with vigorous stirring. The oily product solidified into small granules. The product was diluted with 2.0 L of tap water and stirred for 5 minutes to dissolve the inorganic by products. The product was isolated by filtration under reduced pressure and washed with water until the pH is 7. The crude product obtained was air dried overnight to give a semi-dry solid (407 g) which was recrystallized from 1.1 L of ethyl acetate/heptane (1:10 by volume). The product was isolated by filtration (at −8° C.), washed with 1.6 L of cold (−10° C.) ethyl acetate/heptane (1:10 by volume) and air-dried to give 339 g (88% yield) of ES-2-[Bis(phenylmethyl)amino]benzene-propanol, Mp=71.5-73.0° C. More product can be obtained from the mother liquor if necessary. The other analytical characterization was identical to compound prepared as described in Method 1.
EXAMPLE 2
[0086] αS-[Bis(phenylmethyl)amino]benzenepropanaldehyde
[0087] METHOD 1:
[0088] βS-2-[Bis(phenylmethyl)amino]benzene-propanol (200 g, 0.604 mol) was dissolved in triethylamine (300 mL, 2.15 mol). The mixture was cooled to 12° C. and a solution of sulfur trioxide/pyridine complex (380 g, 2.39 mol) in DMSO (1.6 L) was added at a rate to maintain the temperature between 8-17° C. (addition time −1.0 h). The solution was stirred at ambient temperature under a nitrogen atmosphere for 1.5 hour at which time the reaction was complete by TLC analysis (33% ethyl acetate/hexane, silica gel). The reaction mixture was cooled with ice water and quenched with 1.6 L of cold water (10-15° C.) over 45 minutes. The resultant solution was extracted with ethyl acetate (2.0 L), washed with 5% citric acid (2.0 L), and brine (2.2 L), dried over MgSO 4 (280 g) and filtered. The solvent was removed on a rotary evaporator at 35-40° C. and then dried under vacuum to give 198.8 g of αS-[Bis-(phenylmethyl)amino]-benzenepropanaldehyde as a pale yellow oil (99.9%). The crude product obtained was pure enough to be used directly in the next step without purification. The analytical data of the compound were consistent with the published literature. [α] D 25=−92.9° (c 1.87, CH 2 Cl 2 ); 1 H NMR (400 MHz, CDCl 3 ) ∂, 2.94 and 3.15 (ABX-System, 2H, J AB =130.9 Hz, J AX =7.3 Hz and J BX =6.2 Hz), 3.56 (t, 1H, 7.1 Hz), 3.69 and 3.82 (AB-System, 4H, J AB =13.7 Hz), 7.25 (m, 15H) and 9.72 (s, 1H); HRMS Calcd for (M+1) C 23 H 24 NO 330.450, found: 330.1836. Anal. Calcd. for C 23 H 23 ON: C, 83.86; H, 7.04; N, 4.25. Found: C, 83.64; H, 7.42; N, 4.19. HPLC on chiral stationary phase:(S,S) Pirkle-Whelk-O 1 column (250×4.6 mm I.D.), mobile phase: hexane/isopropanol (99.5:0.5, v/v), flow-rate: 1.5 ml/min, detection with UV detector at 210 nm. Retention time of the desired S-isomer: 8.75 min., retention time of the R-enantiomer 10.62 min.
[0089] METHOD 2:
[0090] A solution of oxalyl chloride (8.4 ml, 0.096 mol) in dichloromethane (240 ml) was cooled to −74° C. A solution of DMSO (12.0 ml, 0.155 mol) in dichloromethane (50 ml) was then slowly added at a rate to maintain the temperature at −74° C. (addition time ˜1.25 hr). The mixture was stirred for 5 min. followed by addition of a solution of βS-2-[bis(phenylmethyl)amino]benzene-propanol (0.074 mol) in 100 ml of dichloromethane (addition time −20 min., temp. −75° C. to −68° C.). The solution was stirred at −78° C. for 35 minutes under a nitrogen atmosphere. Triethylamine (41.2 ml, 0.295 mol) was then added over 10 min. (temp. −78° to −68° C.) upon which the ammonium salt precipitated. The cold mixture was stirred for 30 min. and then water (225 ml) was added. The dichloromethane layer was separated from the aqueous phase and washed with water, brine, dried over magnesium sulfate, filtered and concentrated. The residue was diluted with ethyl acetate and hexane and then filtered to further remove the ammonium salt. The filtrate was concentrated to give αS-[bis(phenylmethyl)amino] benzenepropanaldehyde. The aldehyde was carried on to the next step without purification.
[0091] METHOD 3:
[0092] To a mixture of 1.0 g (3.0 mmoles) of βS-2-[bis(phenylmethyl)amino]benzenepropanol 0.531 g (4.53 mmoles) of N-methyl morpholine, 2.27 g of molecular sieves (4A) and 9.1 mL of acetonitrile was added 53 mg (0.15 mmoles) of tetrapropylammonium perruthenate (TPAP). The mixture was stirred for 40 minutes at room `temperature and concentrated under reduced pressure. The residue was suspended in 15 mL of ethyl acetate, filtered through a pad of silica gel. The filtrate was concentrated under reduced pressure to give a product containing approximately 50% of αS-2-[bis(phenylmethyl)amino]benzene propanaldehyde as a pale yellow oil.
[0093] METHOD 4:
[0094] To a solution of 1.0 g (3.02 mmoles) of ES-2-[bis(phenylmethyl)amino]benzenepropanol in 9.0 mL of toluene was added 4.69 mg (0.03 mmoles) of 2,2,6,6-tetramethyl-1-piperidinyloxy, free radical (TEMPO), 0.32 g (3.11 mmoles) of sodium bromide, 9.0 mL of ethyl acetate and 1.5 mL of water. The mixture was cooled to 0° C. and an aqueous solution of 2.87 mL of 5% household bleach containing 0.735 g (8.75 mmoles) of sodium bicarbonate and 8.53 mL of water was added slowly over 25 minutes. The mixture was stirred at 0° C. for 60 minutes. Two more additions (1.44 mL each) of bleach was added followed by stirring for 10 minutes. The two phase mixture was allowed to separate. The aqueous layer was extracted twice with 20 mL of ethyl acetate. The combined organic layer was washed with 4.0 mL of a solution containing 25 mg of potassium iodide and water (4.0 mL), 20 mL of 10% aqueous sodium thiosulfate solution and then brine solution. The organic solution was dried over magnesium sulfate, filtered and concentrated under reduced pressure to give 1.34 g of crude oil containing a small amount of the desired product aldehyde, αS-[bis(phenylmethyl)amino] benzenepropanaldehyde.
[0095] METHOD 5:
[0096] Following the same procedures as described in Example 2 (Method 1) except 3.0 equivalents of sulfur trioxide pyridine complex was used and αS-[bis(phenylmethyl)amino]benzenepropanaldehyde was isolated in comparable yields.
EXAMPLE 3
[0097] N,N,αS-Tris(phenylmethyl)-2S-oxiranemethanamine
[0098] METHOD 1:
[0099] A solution of αS-[Bis (phenylmethyl)amino]benzenepropanaldehyde (191.7 g, 0.58 mol) and chloroiodomethane (56.4 mL, 0.77 mol) in tetrahydrofuran (1.8 L) was cooled to −30 to −35° C. (colder temperature such as −70° C. also worked well but warmer temperatures are more readily achieved in large scale operations) in a stainless steel reactor under a nitrogen atmosphere. A solution of n-butyl lithium in hexane (1.6 M, 365 mL, 0.58 mol) was then added at a rate that maintained the temperature below −25° C. After addition the mixture was stirred at −30 to −35° C. for 10 minutes. More additions of reagents were carried out in the following manner: (1) additional chloroiodomethane (17 mL) was added, followed by n-butyl lithium (110 mL) at <−25° C. After addition the mixture was stirred at −30 to −35° C. for 10 minutes. This was repeated once. (2) Additional chloroiodomethane (8.5 mL, 0.11 mol) was added, followed by n-butyl lithium (55 mL, 0.088 mol) at <−25° C. After addition the mixture was stirred at −30 to −35° C. for 10 minutes. This was repeated 5 times. (3) Additional chloroiodomethane (8.5 mL, 0.11 mol) was added, followed by n-butyl lithium (37 mL, 0.059 mol) at <−25° C. After addition the mixture was stirred at −30 to −35° C. for 10 minutes. This was repeated once. The external cooling was stopped and the mixture warmed to ambient temp. over 4 to 16 hours when TLC (silica gel, 20% ethyl acetate/hexane) indicated that the reaction was completed. The reaction mixture was cooled to 10° C. and quenched with 1452 g of 16% ammonium chloride solution (prepared by dissolving 232 g of ammonium chloride in 1220 mL of water), keeping the temperature below 23° C. The mixture was stirred for 10 minutes and the organic and aqueous layers were separated. The aqueous phase was extracted with ethyl acetate (2×500 mL). The ethyl acetate layer was combined with the tetrahydrofuran layer. The combined solution was dried over magnesium sulfate (220 g), filtered and concentrated on a rotary evaporator at 65° C. The brown oil residue was dried at 70° C. in vacuo (0.8 bar) for 1 h to give 222.8 g of crude material. (The crude product weight was >100%. Due to the relative instability of the product on silica gel, the crude product is usually used directly in the next step without purification). The diastereomeric ratio of the crude mixture was determined by proton NMR: (2S)/(2R): 86:14. The minor and major epoxide diastereomers were characterized in this mixture by tlc analysis (silica gel, 10% ethyl acetate/hexane), Rf=0.29 & 0.32, respectively. An analytical sample of each of the diastereomers was obtained by purification on silica-gel chromatography (3% ethyl acetate/hexane) and characterized as follows:
[0100] N,N,αS-Tris(phenylmethyl)-2S-oxiranemethanamine
[0101] [0101] 1 H NMR (400 MHz, CDCl 3 ) ∂ 2.49 and 2.51 (AB-System, 1H, J AB =2.82), 2.76 and 2.77 (AB-System, 1H, J AB =4.03), 2.83 (m, 2H), 2.99 & 3.03 (AB-System, 1H, J AB =10.1 Hz), 3.15 (m, 1H), 3.73 & 3.84 (AB-System, 4H, J AB =14.00), 7.21 (m, 15H); 13 C NMR (400 MHz,CDCl 3 ) ∂ 139.55, 129.45, 128.42, 128.14, 128.09, 126.84, 125.97, 60.32, 54.23, 52.13, 45.99, 33.76; HRMS Calcd for C 24 H 26 NO (M+1) 344.477, found 344.2003.
[0102] N,N,αS-Tris(phenylmethyl)-2R-oxiranemethanamine
[0103] [0103] 1 H NMR (300 MHz, CDCl 3 ) ∂ 2.20 (m, 1H), 2.59 (m, 1H), 2.75 (m, 2H), 2.97 (m, 1H), 3.14 (m, 1H), 3.85 (AB-System, 4H), 7.25 (m, 15H).HPLC on chiral stationary phase: Pirkle-Whelk-O 1 column (250×4.6 mm I.D.), mobile phase: hexane/isopropanol (99.5:0.5, v/v), flow-rate: 1.5 ml/min, detection with UV detector at 210 nm. Retention time of (8): 9.38 min., retention time of enantiomer of (4): 13.75 min.
[0104] METHOD 2:
[0105] A solution of the crude aldehyde 0.074 mol and chloroiodomethane (7.0 ml, 0.096 mol) in tetrahydrofuran (285 ml) was cooled to −78° C., under a nitrogen atmosphere. A 1.6 M solution of n-butyl lithium in hexane (25 ml, 0.040 mol) was then added at a rate to maintain the temperature at −75° C. (addition time −15 min.). After the first addition, additional chloroiodomethane (1.6 ml, 0.022 mol) was added again, followed by n-butyl lithium (23 ml, 0.037 mol), keeping the temperature at −75° C. The mixture was stirred for 15 min. Each of the reagents, chloroiodomethane (0.70 ml, 0.010 mol) and n-butyl lithium (5 ml, 0.008 mol) were added 4 more times over 45 min. at −75° C. The cooling bath was then removed and the solution warmed to 22° C. over 1.5 hr. The mixture was poured into 300 ml of saturated aq. ammonium chloride solution. The tetrahydrofuran layer was separated. The aqueous phase was extracted with ethyl acetate (1×300 ml). The combined organic layers were washed with brine, dried over magnesium sulfate, filtered and concentrated to give a brown oil (27.4 g). The product could be used in the next step without purification. The desired diastereomer can be purified by recrystallization at a subsequent step. The product could also be purified by chromatography.
[0106] METHOD 3:
[0107] A solution of αS-[Bis(phenylmethyl)amino]benzenepropanaldehyde (178.84 g, 0.54 mol) and bromochloromethane (46 mL, 0.71 mol) in tetrahydrofuran (1.8 L) was cooled to −30 to −35° C. (colder temperature such as −70° C. also worked well but warmer temperatures are more readily achieved in large scale operations) in a stainless steel reactor under a nitrogen atmosphere. A solution of n-butyl lithium in hexane (1.6 M, 340 mL, 0.54 mol) was then added at a rate that maintained the temperature below −25° C. After addition the mixture was stirred at −30 to −35° C. for 10 minutes. More additions of reagents were carried out in the following manner: (1) additional bromochloromethane (14 mL) was added, followed by n-butyl lithium (102 mL) at <−25° C. After addition the mixture was stirred at −30 to −35° C. for 10 minutes. This was repeated once. (2) Additional bromochloromethane (7 mL, 0.11 mol) was added, followed by n-butyl lithium (51 mL, 0.082 mol) at <−25° C. After addition the mixture was stirred at −30 to −35° C. for 10 minutes. This was repeated 5 times. (3) Additional bromochloromethane (7 mL, 0.11 mol) was added, followed by n-butyl lithium (51 mL, 0.082 mol) at <−25° C. After addition the mixture was stirred at −30 to −35° C. for 10 minutes. This was repeated once. The external cooling was stopped and the mixture warmed to ambient temp. over 4 to 16 hours when TLC (silica gel, 20% ethyl acetate/hexane) indicated that the reaction was completed. The reaction mixture was cooled to 10° C. and quenched with 1452 g of 16% ammonium chloride solution (prepared by dissolving 232 g of ammonium chloride in 1220 mL of water), keeping the temperature below 23° C. The mixture was stirred for 10 minutes and the organic and aqueous layers were separated. The aqueous phase was extracted with ethyl acetate (2×500 mL). The ethyl acetate layer was combined with the tetrahydrofuran layer. The combined solution was dried over magnesium sulfate (220 g), filtered and concentrated on a rotary evaporator at 65° C. The brown oil residue was dried at 70° C. in vacuo (0.8 bar) for 1 h to give 222.8 g of crude material.
[0108] METHOD 4:
[0109] Following the same procedures as described in Example 3 (Method 3) except the reaction temperatures were at −20° C. The resulting N,N,αS-tris(phenylmethyl)-2S-oxiranemethanamine was a diastereomeric mixture of lesser purity then that of Method 3.
[0110] METHOD 5:
[0111] Following the same procedures as described in Example 3 (Method 3) except the reaction temperatures were at −70-78° C. The resulting N,N,αS-tris(phenylmethyl)-2S-oxiranemethanamine was a diastereomeric mixture, which was used directly in the subsequent steps without purification.
[0112] METHOD 6:
[0113] Following the same procedures as described in Example 3 (Method 3) except a continuous addition of bromochloromethane and n-butyl lithium was used at −30 to −35° C. After the reaction and work up procedures as described in Example 3 (Method 3), the desired N,N,αS-tris(phenylmethyl)-2S-oxiranemethanamine was isolated in comparable yields and purities.
[0114] METHOD 7:
[0115] Following the same procedures as described in Example 3 (Method 2) except dibromomethane was used instead of chloroiodomethane. After the reaction and work up procedures as described in Example 3 (Method 2), the desired N,N,αS-tris(phenylmethyl)-2S-oxiranemethanamine was isolated.
EXAMPLE 4
[0116] N-[3(S)-[N,N-bis(phenylmethyl)amino]-2(R)-hydroxy-4-phenylbutyl]-N-isobutylamine
[0117] To a solution of crude N,N-dibenzyl-3(S)-amino-1,2(S)-epoxy-4-phenylbutane (388.5 g, 1.13 mol) in isopropanol (2.7 L) (or ethyl acetate) was added isobutylamine (1.7 kgm, 23.1 mol) over 2 min. The temperature increased from 25° C. and to 30° C. The solution was heated to 82° C. and stirred at this temperature for 1.5 h. The warm solution was concentrated under reduced pressure at 65° C. The brown oil residue was transferred to a 3-L flask and dried in vacuo (0.8 mm Hg) for 16 h to give 450 g of 3S-[N,N-bis(phenylmethyl)amino-4-phenylbutan-2R-ol as a crude oil.
[0118] An analytical sample of the desired major diastereomeric product was obtained by purifying a small sample of crude product by silica gel chromatography (40% ethyl acetate/hexane). Tlc analysis: silica gel, 40% ethyl acetate/hexane; Rf=0.28; HPLC analysis: ultrasphere ODS column, 25% triethylamino-/phosphate buffer pH 3-acetonitrile, flow rate 1 mL/min, UV detector; retention time 7.49 min.; HRMS Calcd for C 28 H 27 N 2 O (M+1) 417.616, found 417.2887. An analytical sample of the minor diastereomeric product, 3S-[N,N-bis(phenylmethyl)amino]1-(2-methylpropyl)amino-4-phenylbutan-2S-ol was also obtained by purifying a small sample of crude product by silica gel chromatography (40% ethyl acetate/hexane).
EXAMPLE 5
[0119] N-[3(S)-[N,N-bis(phenylmethyl)amino]-2(R)-hydroxy-4-phenylbutyl]-N-isobutylamine-oxalic Acid Salt
[0120] To a solution of oxalic acid (8.08 g, 89.72 mmol) in methanol (76 mL) was added a solution of crude 3(S)-[N,N-bis(phenylmethyl)amino]-1-(2-methylpropyl)amino-4-phenylbutan-2(R)-ol (39.68 g, which contains about 25.44 g (61.06 mmol) of 3(S),2(R) isomer and about 4.49 g (10.78 mmol) of 3(S),2(S) isomer) in ethyl acetate (90 mL) over 15 minutes. The mixture was stirred at room temperature for about 2 hours. Solid was isolated by filtration, washed with ethyl acetate (2×20 mL) and dried in vacuo for about 1 hour to yield 21.86 g (70.7% isomer recovery) of 97% diastereomerically pure salt (based on HPLC peak areas). HPLC analysis: Vydec-peptide/protein C18 column, UV detector 254 nm, flow rate 2 mL/min., gradient (A=0.05% trifluoroacetic acid in water, B=0.05% trifluoroacetic acid in acetonitrile, 0 min. 75% A/25% B, 30 min. 10% A/90% B, 35 min. 10% A/90% B, 37 min. 75% A/25% B); Retention time 10.68 min. (3(S),2(R) isomer) and 9.73 min. (3(S),2(S) isomer). Mp=174.99° C.; Microanalysis: Calc.: C 71.05%, H 7.50%, N 5.53%; Found: C 71.71%, H 7.75%, N 5.39%.
[0121] Alternatively, oxalic acid dihydrate (119 g, 0.94 mole) was added to a 5000 mL round bottom flask fitted with a mechanical stirrer and a dropping funnel. Methanol (1000 ml) was added and the mixture stirred until dissolution was complete. A solution of crude 3(S)-[N,N-bis(phenylmethyl)amino]-1-(2-methylpropyl) amino-4-phenylbutan-2(R)-ol in ethyl acetate (1800 ml, 0.212 g amino alcohol isomers/mL, 0.9160 moles) was added over a twenty minute period. The mixture was stirred for 18 hours and the solid product was isolated by centrifugation in six portions at 400G. Each portion was washed with 125 mL of ethyl acetate. The salt was then collected and dried overnight at 1 torr to yield 336.3 g of product (71% based upon total amino alcohol). HPLC/MS (electrospray) was consistent with the desired product (m/z 417 [M+H] + ).
[0122] Alternatively, crude 3(S)-[N,N-bis(phenylmethyl) amino]-1-(2-methylpropyl)amino-4-phenylbutan-2(R)-ol (5 g) was dissolved in methyl-tert-butylether (MTBE) (10 mL) and oxalic acid (1 g) in methanol (4 mL) was added. The mixture was stirred for about 2 hours. The resulting solid was filtered, washed with cold MTBE and dried to yield 2.1 g of white solid of about 98.9% diastereomerically pure (based on HPLC peak areas).
EXAMPLE 6
[0123] N-[3(S)-[N,N-bis(phenylmethyl)amino]-2(R)-hydroxy-4-phenylbutyl]-N-isobutylamine-acetic Acid Salt
[0124] To a solution of crude 3(S)-[N,N-bis(phenylmethyl) amino]-1-(2-methylpropyl)amino-4-phenylbutan-2(R)-ol in methyl-tert-butylether (MTBE) (45 mL, 1.1 g amino alcohol isomers/mL) was added acetic acid (6.9 mL) dropwise. The mixture was stirred for about 1 hour at room temperature. The solvent was removed in vacuo to yield a brown oil about 85% diastereomerically pure product (based on HPLC peak areas). The brown oil was crystallized as follows: 0.2 g of the oil was dissolved in the first solvent with heat to obtain a clear solution, the second solvent was added until the solution became cloudy, the mixture was heated again to clarity, seeded with about 99% diastereomerically pure product, cooled to room temperature and then stored in a refrigerator overnight. The crystals were filtered, washed with the second solvent and dried. The diastereomeric purity of the crystals was calculated from the HPLC peak areas. The results are shown in Table 1.
TABLE 1 Diastereo- First Second Solvent Recovery meric Solvent Solvent Ratio Weight (g) Purity (%) MTBE Heptane 1:10 0.13 98.3 MTBE Hexane 1:10 0.03 99.6 Methanol Water 1:1.5 0.05 99.5 Toluene Heptane 1:10 0.14 98.7 Toluene Hexane 1:10 0.10 99.7
[0125] Alternatively, crude 3(S)-[N,N-bis(phenylmethyl) amino]-1-(2-methylpropyl)amino-4-phenylbutan-2(R)-ol (50.0 g, which contains about 30.06 g (76.95 mmol) of 3(S),2(R) isomer and about 5.66 g (13.58 mmol) of 3(S),2(S) isomer) was dissolved in methyl-tert-butylether (45.0 mL). To this solution was added acetic acid (6.90 mL, 120.6 mmol) over a period of about 10 min. The mixture was stirred at room temperature for about 1 hour and concentrated under reduced pressure. The oily residue was purified by recrystallization from methyl-tert-butylether (32 mL) and heptane (320 mL). Solid was isolated by filtration, washed with cold heptane and dried in vacuo for about 1 hour to afford 21.34 g (58.2% isomer recovery) of 96% diastereomerically pure monoacetic acid salt (based on HPLC peak areas). Mp=105-106° C.; Microanalysis: Calc.: C 75.53%, H 8.39%, N 5.87%; Found: C 75.05%, H 8.75%, N 5.71%.
EXAMPLE 7
[0126] N-[3(S)-[N,N-bis(phenylmethyl)amino]-2(R)-hydroxy-4-phenylbutyl]-N-isobutylamine.L-tartaric Acid Salt
[0127] Crude 3(S)-[N,N-bis(phenylmethyl)amino]-1-(2-methylpropyl)amino-4-phenylbutan-2(R)-ol (10.48 g, which contains about 6.72 g (16.13 mmol) of 3(S),2(R) isomer and about 1.19 g (2.85 mmol) of 3(S),2(S) isomer) was dissolved in tetrahydrofuran (10.0 mL). To this solution was added a solution of L-tartaric acid (2.85 g, 19 mmol) in methanol (5.0 mL) over a period of about 5 min. The mixture was stirred at room temperature for about 10 min. and concentrated under reduced pressure. Methyl-tert-butylether (20.0 mL) was added to the oily residue and the mixture was stirred at room temperature for about 1 hour. Solid was isolated by filtration to afford 7.50 g of crude salt. The crude salt was purified by recrystallization from ethyl acetate and heptane at room temperature to yield 4.13 g (45.2% isomer recovery) of 95% diastereomerically pure L-tartaric acid salt (based on HPLC peak areas). Microanalysis: Calc.: C 67.76%, H 7.41%, N 4.94%; Found: C 70.06%, H 7.47%, N 5.07%.
EXAMPLE 8
[0128] N-[3(S)-[N,N-bis(phenylmethyl)amino]-2(R)-hydroxy-4-phenylbutyl]-N-isobutylamine-dihydrochloric Acid Salt
[0129] Crude 3(S)-[N,N-bis(phenylmethyl) amino]-1-(2-methylpropyl)amino-4-phenylbutan-2(R)-ol (10.0 g, which contains about 6.41 g (15.39 mmol) of 3(S),2(R) isomer and about 1.13 g (2.72 mmol) of 3(S),2(S) isomer} was dissolved in tetrahydrofuran (20.0 mL). To this solution was added hydrochloric acid (20 mL, 6.0 N) over a period of about 5 min. The mixture was stirred at room temperature for about 1 hour and concentrated under reduced pressure. The residue was recrystallized from ethanol at 0° C. to yield 3.20 g (42.7% isomer recovery) of 98% diastereomerically pure dihydrochloric acid salt (based on HPLC peak areas). Microanalysis: Calc.: C 68.64%, H 7.76%, N 5.72%; Found: C 68.79%, H 8.07%, N 5.55%.
EXAMPLE 9
[0130] N-[3(S)-[N,N-bis(phenylmethyl)amino]-2(R)-hydroxy-4-phenylbutyl]-N-isobutylamine.toluenesulfonic Acid Salt
[0131] Crude 3(S)-[N,N-bis(phenylmethyl) amino]-1-(2-methylpropyl)amino-4-phenylbutan-2(R)-ol (5.0 g, which contains about 3.18 g (7.63 mmol) of 3(S),2(R) isomer and about 0.56 g (1.35 mmol) of 3(S),2(S) isomer) was dissolved in methyl-tert-butylether (10.0 mL). To this solution was added a solution of toluenesulfonic acid (2.28 g, 12 mmol) in methyl-tert-butylether (2.0 mL) and methanol (2.0 mL) over a period of about 5 min. The mixture was stirred at room temperature for about 2 hours and concentrated under reduced pressure. The residue was recrystallized from methyl-tert-butylether and heptane at 0° C., filtered, washed with cold heptane and dried in vacuo to yield 1.85 g (40.0% isomer recovery) of 97% diastereomerically pure monotoluenesulfonic acid salt (based on HPLC peak areas).
EXAMPLE 10
[0132] N-[3(S)-[N,N-bis(phenylmethyl)amino]-2(R)-hydroxy-4-phenylbutyl]-N-isobutylamine.methanesulfonic Acid Salt
[0133] Crude 3(S)-[N,N-bis(phenylmethyl) amino]-1-(2-methylpropyl)amino-4-phenylbutan-2(R)-ol (10.68 g, which contains about 6.85 g (16.44 mmol) of 3(S),2(R) isomer and about 1.21 g (2.90 mmol) of 3(S),2(S) isomer) was dissolved in tetrahydrofuran (10.0 mL). To this solution was added methanesulfonic acid (1.25 mL, 19.26 mmol). The mixture was stirred at room temperature for about 2 hours and concentrated under reduced pressure. The oily residue was recrystallized from methanol and water at 0° C., filtered, washed with cold methanol/water (1:4) and dried in vacuo to yield 2.40 g (28.5% isomer recovery) of 98% diastereomerically pure monomethanesulfonic acid salt (based on HPLC peak areas).
EXAMPLE 11
[0134] 3S-[N,N-Bis(phenylmethyl)amino]-1-(3-methylbutyl)amino-4-phenylbutan-2R-ol
[0135] Example 4 was followed using isoamylamine instead of isobutylamine to prepare 3S-[N,N-Bis(phenylmethyl)amino]-1-(3-methylbutyl)amino-4-phenylbutan-2R-ol and 3S-[N,N-Bis(phenylmethyl)amino]-1-(3-methylbutyl)amino-4-phenylbutan-2S-ol in comparable yields to that of Example 4. The crude amine was used in the next step without further purification.
EXAMPLE 12
[0136] N-[3S-[N,N-Bis(phenylmethyl)amino]-2R-hydroxy-4-phenyl butyl]-N′-(1,1-dimethylethyl)-N-(2-methylpropyl)urea
[0137] A solution of the crude 3S-[N,N-bis(phenylmethyl) amino]-1-(2-methylpropyl)amino-4-phenylbutan-2R-ol (446.0 g, 1.1 mol) from Example 4 in tetrahydrofuran (6 L) (or ethyl acetate) was cooled to 8° C. t-Butyl isocyanate (109.5 g, 1.1 mol) was then added to the solution of the amine from an addition funnel at a rate that maintained the temperature between 10-12° C. (addition time was about 10 min). The external cooling was stopped and the reaction was warmed to 18° C. after 30 min. The solution was transferred directly from the reactor to a rotary evaporator flask (10 L) through a teflon tube using vacuum and then concentrated. The flask was heated in a 50° C. water bath during the 2 hours required for the distillation of the solvent. The brown residue was dissolved in ethyl acetate (3 L), washed with 5% aq citric acid solution (1×1.2 L), water (2×500 mL), brine (1×400 mL), dried over magnesium sulfate (200 g) and filtered. The volume of product solution was reduced to 671 mL over 2 h on a rotary evaporator at 50° C. The concentrate was stirred and diluted with 1.6 L of hexane. The mixture was cooled to 12° C. and stirred for 15 hours. The product crystals were isolated by filtration, washed with 10% ethyl acetate/hexane (1×500 mL), hexane (1×200 mL) and dried in vacuo (2 mm) at 50° C. for 1 hour to give 248 g of N-[3S-[N,N-bis-(phenylmethyl)amino]-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(2-methylpropyl)-urea. The mother liquor and washes were combined and concentrated on a rotary evaporator to give 270 g of a brown oil. This material was dissolved in ethyl acetate (140 mL) at 50° C. and diluted with hexane (280 mL) and seeded with crystals of the first crop product (20 mg). The mixture was cooled in an ice bath and stirred for 1 h. The solid was isolated by filtration, washed with 10% ethyl acetate/hexane (1×200 mL) and dried in vacuo (2 mm) at 50° C. for 1 h to give 55.7 g of 11 as the second crop (49% overall yield). Mp 126° C.; [α] D 25=−59.0° (c 1.0, CH 2 Cl 2 ), TLC: Rf 0.31 (silica gel, 25% ethyl acetate/hexane).
[0138] An analytical sample of the minor diastereomer, N-[3S-[N,N-bis(phenylmethyl)amino]-2S-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(2-methylpropyl)urea was isolated by silica-gel chromatography (10-15% ethyl acetate/hexane) in an earlier experiment and characterized.
EXAMPLE 13
[0139] N-[3S-[N,N-Bis(phenylmethyl)amino]-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(3-methylbutyl)urea
[0140] The crude product from Example 11 was reacted with t-butylisocyanate following the method of Example 12 to prepare N-[3S-[N,N-Bis(phenylmethyl)amino]-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(3-methylbutyl)urea and N-[3S-[N,N-Bis(phenylmethyl)amino]-2S-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(3-methylbutyl)urea in comparable yields to that of Example 12.
EXAMPLE 14
[0141] N-[3S-Amino-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(2-methylpropyl)urea
[0142] N-[3S-[N,N-Bis(phenylmethyl)amino]-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(2-methylpropyl) urea (125.77 g, 0.244 mol) from Example 12 was dissolved in ethanol (1.5 L) (or methanol) and 20% palladium hydroxide on carbon (18.87 g) (or 4% palladium on carbon) was added to the solution under nitrogen. The mixture was stirred at ambient temperature under a hydrogen atmosphere at 60 psi for approximately 8 hours. The catalyst was removed by filtration and the filtrate was concentrated to give 85 g of N-[3S-Amino-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(2-methylpropyl)urea as a colorless oil.
EXAMPLE 15
[0143] N-[3S-Amino-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(3-methylbutyl)urea
[0144] N-[3S-[N,N-Bis(phenylmethyl)amino]-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(3-methylbutyl)urea from Example 13 was hydrogenated following the method of Example 14 to prepare N-[3S-Amino-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(3-methylbutyl)urea in comparable yields to Example 14.
EXAMPLE 16
[0145] N-benzyl-L-phenylalaminol
[0146] METHOD 1:
[0147] L-Phenylalaminol (89.51 g, 0.592 moles) was dissolved in 375 mL of methanol under inert atmosphere, 35.52 g (0.592 moles) of glacial acetic acid and 50 mL of methanol was added followed by a solution of 62.83 g (0.592 moles) of benzaldehyde in 100 mL of methanol. The mixture was cooled to approximately 15° C. and a solution of 134.6 g (2.14 moles) of sodium cyanoborohydride in 700 mL of methanol was added in approximately 40 minutes, keeping the temperature between 15° C. and 25° C. The mixture was stirred at room temperature for 18 hours. The mixture was concentrated under reduced pressure and partitioned between 1 L of 2M ammonium hydroxide solution and 2 L of ether. The ether layer was washed with 1 L of 1M ammonium hydroxide solution, twice with 500 mL water, 500 mL of brine and dried over magnesium sulfate for 1 hour. The ether layer was filtered, concentrated under reduced pressure and the crude solid product was recrystallized from 110 mL of ethyl acetate and 1.3 L of hexane to give 115 g (81% yield) of N-benzyl-L-phenylalaminol as a white solid.
[0148] METHOD 2:
[0149] L-Phenylalaminol (5 g, 33 mmoles) and 3.59 g (33.83 mmoles) of benzaldehyde were dissolved in 55 mL of 3A ethanol under inert atmosphere in a Parr shaker and the mixture was warmed to 60° C. for 2.7 hours. The mixture was cooled to approximately 25° C. and 0.99 g of 5% platinum on carbon was added and the mixture was 20. hydrogenated at 60 psi of hydrogen and 40° C. for 10 hours. The catalyst was filtered off, the product was concentrated under reduced pressure and the crude solid product was recrystallized from 150 mL of heptane to give 3.83 g (48% yield) of N-benzyl-L-phenylalaminol as a white solid.
EXAMPLE 17
[0150] N-(t-Butoxycarbonyl)-N-benzyl-L-phenylalaminol
[0151] N-benzyl-L-phenylalaminol (2.9 g, 12 mmoles) from Example 16 was dissolved in 3 mL of triethylamine and 27 mL of methanol and 5.25 g (24.1 mmoles) of di-tert-butyl dicarbonate was added. The mixture was warmed to 60° C. for 35 minutes and concentrated under reduced pressure. The residue was dissolved in 150 mL of ethyl acetate and washed twice with 10 ML of cold (0-5° C.), dilute hydrochloric acid (pH 2.5 to 3), 15 mL of water, 10 mL of brine, dried over magnesium sulfate, filtered and concentrated under reduced pressure The crude product oil was purified by silica gel chromatography (ethyl acetate:hexane, 12:3 as eluting solvent) to give 3.98 g (97% yield) of colorless oil.
EXAMPLE 18
[0152] N-(t-Butoxycarbonyl)-N-benzyl-L-phenylalaninal
[0153] METHOD 1:
[0154] To a solution of 0.32 g (0.94 mmoles) of N-(t-Butoxycarbonyl)-N-benzyl-L-phenylalaminol from Example 17 in 2.8 mL of toluene was added 2.4 mg (0.015 mmoles) of 2,2,6,6-tetramethyl-1-piperidinyloxy, free radical (TEMPO), 0.1 g (0.97 mmoles) of sodium bromide, 2.8 mL of ethyl acetate and 0.34 mL of water. The mixture was cooled to 0° C. and an aqueous solution of 4.2 mL of 5% household bleach containing 0.23 g (3.0 mL, 2.738 mmoles) of sodium bicarbonate was added slowly over 30 minutes. The mixture was stirred at 0° C. for 10 minutes. Three more additions (0.4 mL each) of bleach was added followed by stirring for 10 minutes after each addition to consume all the stating material. The two phase mixture was allowed to separate. The aqueous layer was extracted twice with 8 mL of toluene. The combined organic layer was washed with 1.25 mL of a solution containing 0.075 g of potassium iodide, sodium bisulfate (0.125 g) and water (1.1 mL), 1.25 mL of 10% aqueous sodium thiosulfate solution, 1.25 mL of pH 7 phosphate buffer and 1.5 mL of brine solution. The organic solution was dried over magnesium sulfate, filtered and concentrated under reduced pressure to give 0.32 g (100% yield) of N-(t-Butoxycarbonyl)-N-benzyl-L-phenylalaninal.
[0155] METHOD 2:
[0156] To a solution of 2.38 g (6.98 mmoles) of N-(t-butoxycarbonyl)-N-benzyl-L-phenylalaminol from Example 17 in 3.8 mL (27.2 mmoles) of triethylamine at 10° C. was added a solution of 4.33 g (27.2 mmoles) of sulfur trioxide pyridine complex in 17 mL of dimethyl sulfoxide. The mixture was warmed to room temperature and stirred for one hour. Water (16 mL) was added and the mixture was extracted with 20 mL of ethyl acetate. The organic layer was washed with 20 mL of 5% citric acid, 20 mL of water, 20 mL of brine, dried over magnesium sulfate and filtered. The filtrate was concentrated under reduced pressure to give 2.37 g (100% yield) of N-(t-Butoxycarbonyl)-N-benzyl-L-phenylalaninal.
EXAMPLE 19
[0157] N,αs-Bis(phenylmethyl)-N-(t-butoxycarbonyl)-2S-oxiranemethanamine
[0158] METHOD 1:
[0159] A solution of 2.5 g (7.37 mmoles) of N-(t-butoxycarbonyl)-N-benzyl-L-phenylalaninal from Example 18 and 0.72 mL of chloroiodomethane in 35 mL of THF was cooled to −78° C. A 4.64 mL of a solution of n-butyllithium (1.6 M in hexane, 7.42 mmoles) was added slowly, keeping the temperature below −70° C. The mixture was stirred for 10 minutes between −70 to −75° C. Two additional portions of 0.22 mL of chloroiodomethane and 1.4 mL of n-butyllithium was added sequentially and the mixture was stirred for 10 minutes between −70 to −75° C. after each addition. Four additional portions of 0.11 mL of chloroiodomethane and 0.7 mL of n-butyllithium was added sequentially and the mixture was stirred for 10 minutes between −70 to −75° C. after each addition. The mixture was warmed to room temperature for 3.5 hours. The product was quenched at below −5° C. with 24 mL of ice-cold water. The biphasic layers were separated and the aqueous layer was extracted twice with 30 mL of ethyl acetate. The combined organic layers was washed three times with 10 mL water, then with 10 mL brine, dried over sodium sulfate, filtered and concentrated under reduced pressure to give 2.8 g of a yellow crude oil. This crude oil (>100% yield) is a mixture of the diastereomeric epoxides N,αS-bis(phenylmethyl)-N-(t-butoxycarbonyl)-2S-oxiranemethanamine and N,αS-bis(phenylmethyl)-N-(t-butoxycarbonyl)-2R-oxiranemethanamine. The crude mixture is used directly in the next step without purification.
[0160] METHOD 2:
[0161] To a suspension of 2.92 g (13.28 mmoles) of trimethylsulfoxonium iodide in 45 mL of acetonitrile was added 1.49 g (13.28 mmoles) of potassium t-butoxide. A solution of 3.0 g (8.85 mmoles) of N-(t-butoxycarbonyl)-N-benzyl-L-phenylalaninal from Example 18 in 18 mL of acetonitrile was added and the mixture was stirred at room temperature for one hour. The mixture was diluted with 150 mL of water and extracted twice with 200 mL of ethyl acetate. The organic layers were combined and washed with 100 mL water, 50 mL brine, dried over sodium sulfate, filtered and concentrated under reduced pressure to give 3.0 g of a yellow crude oil. The crude product was purified by silica gel chromatography (ethyl acetate/hexane: 1:8 as eluting solvent) to give 1.02 g (32.7% yield) of a mixture of the two diastereomers N,αS-bis(phenylmethyl)-N-(t-butoxycarbonyl)-2S-oxiranemethanamine and N,αS-bis(phenylmethyl)-N-(t-butoxycarbonyl)-2R-oxiranemethanamine.
[0162] METHOD 3:
[0163] To a suspension of 0.90 g (4.42 mmoles) of trimethylsulfonium iodide in 18 mL of acetonitrile was added 0.495 g (4.42 mmoles) of potassium t-butoxide. A solution of 1.0 g (2.95 mmoles) of N-(t-butoxycarbonyl)-N-benzyl-L-phenylalaninal from Example 18 in 7 mL of acetonitrile was added and the mixture was stirred at room temperature for one hour. The mixture was diluted with 80 mL of water and extracted twice with 80 mL of ethyl acetate. The organic layers were combined and washed with 100 mL water, 30 mL brine, dried over sodium sulfate, filtered and concentrated under reduced pressure to give 1.04 g of a yellow crude oil. The crude product was a mixture of the two diastereomers N,αS-bis(phenylmethyl)-N-(t-butoxycarbonyl)-2S-oxiranemethanamine and N,αS-bis(phenylmethyl)-N-(t-butoxycarbonyl)-2R-oxiranemethanamine.
EXAMPLE 20
[0164] 3S-[N-(t-Butoxycarbonyl)-N-(phenylmethyl)amino]-1-(2-methylpropyl)amino-4-phenylbutan-2R-ol
[0165] To a solution of 500 mg (1.42 mmoles) of the crude epoxide from Example 19 in 0.98 mL of isopropanol was added 0.71 mL (7.14 mmoles) of isobutylamine. The mixture was warmed to reflux at 85° C. to 90° C. for 1.5 hours. The mixture was concentrated under reduced pressure and the product oil was purified by silica gel chromatography (chloroform:methanol, 100:6 as eluting solvents) to give 330 mg of 3S-[N-(t-butoxycarbonyl)-N-(phenylmethyl)amino]-1-(2-methylpropyl)amino-4-phenylbutan-2R-ol as a colorless oil (54.5% yield). 3S-[N-(t-Butoxycarbonyl)-N-(phenylmethyl)amino]1-1(2-methylpropyl)amino-4-phenylbutan-2S-ol was also isolated. When purified N,αS-bis(phenylmethyl)-N-(t-butoxycarbonyl)-2S-oxiranemethanamine was used as starting material, 3S-[N-(t-butoxycarbonyl)-N-(phenylmethyl)amino]-1-(2-methylpropyl)amino-4-phenylbutan-2R-ol was isolated after purification by chromatography in an 86% yield.
EXAMPLE 21
[0166] N-[3S-[N-(t-Butoxycarbonyl)-N-(phenylmethyl)amino]-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(2-methylpropyl)urea
[0167] To a solution of 309 mg (0.7265 mmoles) of 3S-[N-(t-butoxycarbonyl)-N-(phenylmethyl)amino]-1-(2-methylpropyl)amino-4-phenylbutan-2R-ol from Example 20 in 5 mL of THF was added 0.174 mL (1.5 mmoles) of t-butylisocyanate. The mixture was stirred at room temperature for 1.5 hours. The product was concentrated under reduced pressure to give 350 mg (92% yield) of a white solid crude product. The crude product was purified by silica gel chromatography (ethyl acetate/hexane: 1:4 as eluting solvents) to give 324 mg of N-[3S-[N-(t-butoxycarbonyl)-N-(phenylmethyl)amino]-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(2-methylpropyl)urea as a white solid (85.3% yield).
EXAMPLE 22
[0168] 3S-[N-(t-Butoxycarbonyl)-N-(phenylmethyl)amino]-2S-hydroxy-4-phenylbutyronitrile
[0169] A solution of 7.0 g (20.65 mmoles) of N-(t-butoxycarbonyl)-N-benzyl-L-phenylalaninal from Example 18 in 125 mL of THF was cooled to −5° C. A solution of 12.96 g of sodium bisulfite in 68 mL of water was added over 40 minutes, keeping the temperature below 5° C. The mixture was stirred for 3 hours at 0 to 5° C. An additional 1.4 g of sodium bisulfite was added and the mixture was stirred for another two hours. Sodium cyanide (3.3 g, 82.56 mmoles) was added to the bisulfite product at 0 to 5° C. and the mixture was stirred at room temperature for 16 hours. The biphasic mixture was extracted with 150 mL of ethyl acetate. The aqueous layer was extracted twice each with 100 mL of ethyl acetate. The combined organic layers was washed twice with 30 mL water, twice with 25 mL brine, dried over sodium sulfate, filtered and concentrated under reduced pressure to give 7.5 g (100% crude yield of both diastereomers) of crude oil. The crude oil was purified by silica gel chromatography (ethyl acetate:hexane, 1:4 as eluting solvents) to give 5.725 g (76% yield) of 3S-[N-(t-butoxycarbonyl)-N-(phenylmethyl)amino]-2S-hydroxy-4-phenylbutyronitrile as the major later eluting diastereomer and 0.73 g (9.6% yield) of 3S-[N-(t-butoxycarbonyl)-N-(phenylmethyl)amino]-2R-hydroxy-4-phenylbutyronitrile as the minor diastereomer. The combined yields of both isomers of cyanohydrins is 85.6% yield.
EXAMPLE 23
[0170] 3S-[N-(t-Butoxycarbonyl)-N-(phenylmethyl)amino]-1-amino-4-phenylbutan-2R-ol
[0171] To a solution of 205.5 mg (0.56 mmoles) of 3S-[N-(t-butoxycarbonyl)-N-(phenylmethyl)amino]-2S-hydroxy-4-phenylbutyronitrile from Example 22 in 4 mL of THF was added 2.4 mL of a solution of borane in THF (1.0 M, 4 mmoles). The mixture was stirred at room temperature for 30 minutes. An additional 1.4 mL of borane in THF was added and the mixture was stirred for another 30 minutes. The mixture was cooled to 0° C. and 2.0 mL of cold (0-5° C.) water was added slowly. The mixture was warmed to room temperature and stirred for 30 minutes. The product was extracted twice with 30 mL of ethyl acetate. The organic layers were combined and washed with 4 mL water, 4 mL brine, dried over sodium sulfate, filtered and concentrated under reduced pressure to give 200 mg of 3S-[N-(t-butoxycarbonyl)-N-(phenylmethyl)amino]-1-amino-4-phenylbutan-2R-ol as a white solid (96.4% yield).
EXAMPLE 24
[0172] 3S-[N-(t-Butoxycarbonyl)-N-(phenylmethyl)amino]-1-(2-methylpropyl)amino-4-phenylbutan-2R-ol
[0173] To a solution of 2.41 g (6.522 mmoles) of 3S-[N-(t-butoxycarbonyl)-N-(phenylmethyl)amino]-1-amino-4-phenylbutan-2R-ol from Example 23 in 40 mL of methanol was added 0.592 mL (6.522 mmoles) of isobutyraldehyde and 0.373 mL (6.522 mmoles) of acetic acid. The mixture was stirred for 10 minutes. Sodium cyanoborohydride (1.639 g, 26 mmoles) was added and the mixture was stirred for 16 hours at room temperature. The product mixture was concentrated under reduced pressure and partitioned between 150 mL of ethyl acetate and 50 mL of 1.5M ammonium hydroxide. The organic layer was washed twice with 20 mL water, twice with 20 mL brine, dried over sodium sulfate, filtered and concentrated to an yellow oil. The crude product was purified by silica gel chromatography (chloroform:methanol, 100:6 as eluting solvents) to give 2.326 g of 3S-[N-(t-butoxycarbonyl)-N-(phenylmethyl)amino]-1-(2-methylpropyl)amino-4-phenylbutan-2R-ol as a colorless oil (88.8% yield).
EXAMPLE 25
[0174] N-[3S-[N-(t-Butoxycarbonyl)-N-(phenylmethyl)amino]-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(2-methylpropyl)urea
[0175] To a solution of 309 mg (0.7265 mmoles) of 3S-[N-(t-butoxycarbonyl)-N-(phenylmethyl)amino]-1-(2-methylpropyl)amino-4-phenylbutan-2R-ol from Example 24 in 5 mL of THF was added 0.174 mL (1.5 mmoles) of t-butylisocyanate. The mixture was stirred at room temperature for 1.5 hours. The product was concentrated under reduced pressure to give 350 mg (92% yield) of a white solid crude product. The crude product was purified by silica gel chromatography (ethyl acetate/hexane: 1:4 as eluting solvents) to give 324 mg of N-[3S-[N-(t-butoxycarbonyl)-N-(phenylmethyl)amino]-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(2-methylpropyl)urea as a white solid (85.3% yield).
EXAMPLE 26
[0176] N-[3S-[N-(Phenylmethyl)amino]-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(2-methylpropyl)urea
[0177] To a solution of 210 mg (0.4 mmoles) of N-[3S-[N-(t-Butoxycarbonyl)-N-(phenylmethyl)amino]-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(2-methylpropyl)urea from Example 25 in 5.0 mL of THF was added 5 mL of 4N hydrochloric acid. The mixture was stirred at room temperature for two hours. The solvents were removed under reduced pressure to give 200 mg (100%) of N-[3S-[N-(phenylmethyl)amino]-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(2-methylpropyl)urea as a white solid.
EXAMPLE 27
[0178] N-[3S-Amino-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(2-methylpropyl)urea
[0179] To a solution of 200 mg (0.433 mmoles) of N-[3S-[N-(phenylmethyl)amino]-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(2-methylpropyl)urea from Example 26 in 7 mL of 3A ethanol was added 0.05 g of 20% palladium on carbon. The mixture was hydrogenated at 40° C. for 1.8 hours at 5 psi followed by hydrogenation at 60 psi at room temperature for 22 hours. The catalyst was filtered and the solvent and by-product were removed under reduced pressure to give 150 mg (93.4% yield) of N-[3S-amino-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(2-methylpropyl)urea as a white solid.
EXAMPLE 28
[0180] 3S-(N-t-Butoxycarbonyl)amino-4-phenylbutan-1,2R-diol
[0181] To a solution of 1 g (3.39 mmoles) of 2S-(N-t-butoxycarbonyl)amino-1S-hydroxy-3-phenylbutanoic acid (commercially available from Nippon Kayaku, Japan) in 50 mL of THF at 0° C. was added 50 mL of borane-THF complex (liquid, 1.0 M in THF), keeping the temperatures below 5° C. The reaction mixture was warmed to room temperature and stirred for 16 hours. The mixture was cooled to 0° C. and 20 mL of water was added slowly to destroy the excess BH 3 and to quench the product mixture, keeping the temperature below 12° C. The quenched mixture was stirred for 20 minutes and concentrated under reduced pressure. The product mixture was extracted three times with 60 mL of ethyl acetate. The organic layers were combined and washed with 20 mL of water, 25 mL of saturated sodium chloride solution and concentrated under reduced pressure to give 1.1 g of crude oil. The crude product was purified by silica gel chromatography (chloroform/methanol, 10:6 as eluting solvents) to give 900 mg (94.4% yield) of 3S-(N-t-butoxycarbonyl)amino-4-phenylbutan-1,2R-diol as a white solid.
EXAMPLE 29
[0182] 3S-(N-t-Butoxycarbonyl)amino-2R-hydroxy-4-phenylbut-1-yl Toluenesulfonate
[0183] To a solution of 744.8 mg (2.65 mmoles) of 3S-(N-t-butoxycarbonyl)amino-4-phenylbutan-1,2R-diol from Example 28 in 13 mL of pyridine at 0° C. was added 914 mg of toluenesulfonyl chloride in one portion. The mixture was stirred at 0° C. to 5° C. for 5 hours. A mixture of 6.5 mL of ethyl acetate and 15 mL of 5% aqueous sodium bicarbonate solution was added to the reaction mixture and stirred for 5 minutes. The product mixture was extracted three times with 50 mL of ethyl acetate. The organic layers were combined and washed with 15 mL of water, 10 mL of saturated sodium chloride solution and concentrated under reduced pressure to give about 1.1 g of a yellow chunky solid. The crude product was purified by silica gel chromatography (ethyl acetate/hexane 1:3 as eluting solvents) to give 850 mg (74% yield) of 3S-(N-t-butoxycarbonyl)amino-2R-hydroxy-4-phenylbut-1-yl toluenesulfonate as a white solid.
EXAMPLE 30
[0184] 3S-[N-(t-Butoxycarbonyl)amino]-1-(2-methylpropyl)amino-4-phenylbutan-2R-ol
[0185] To a solution of 90 mg (0.207 mmoles) of 3S-(N-t-butoxycarbonyl)amino-2R-hydroxy-4-phenylbut-1-yl toluenesulfonate from Example 29 in 0.143 mL of isopropanol and 0.5 mL of toluene was added 0.103 mL (1.034 mmoles) of isobutylamine. The mixture was warmed to 80 to 85° C. and stirred for 1.5 hours. The product mixture was concentrated under reduced pressure at 40 to 50° C. and purified by silica gel chromatography (chloroform/methanol, 10:1 as eluting solvents) to give 54.9 mg (76.8% yield) of 3S-[N-(t-butoxycarbonyl)amino]-1-(2-methylpropyl)amino-4-phenylbutan-2R-ol as a white solid.
EXAMPLE 31
[0186] N-[3S-[N-(t-Butoxycarbonyl)amino]-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(2-methylpropyl)urea
[0187] To a solution of 0.1732 g (0.516 mmoles) of 3S-[N-(t-butoxycarbonyl)amino]-1-(2-methylpropyl)amino-4-phenylbutan-2R-ol from Example 30 in 5 mL of ethyl acetate at 0° C. was added 1.62 mL (12.77 mmoles) of t-butylisocyanate and the mixture was stirred for one hour. The product was concentrated under reduced pressure and purified by silica gel chromatography (chloroform/methanol, 100:1.5 as eluting solvents) to give 96 mg (42.9% yield) of N-[3S-[N-(t-butoxycarbonyl)amino]-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(2-methylpropyl)urea as a white solid.
EXAMPLE 32
[0188] N-[3S-amino-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(2-methylpropyl)urea
[0189] To a solution of 10 mg (0.023 mmoles) of N-[3S-[N-(t-butoxycarbonyl)amino]-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(2-methylpropyl)urea from Example 31 in 1 mL of methanol at 0° C. was added 1.05 mL of a 4M hydrogen chloride in methanol and the mixture was stirred at room temperature for 45 minutes. The product was concentrated under reduced pressure. The residue was dissolved 5 mL of methanol and concentrated under reduced pressure. This operation was repeated three times to remove water form the product, after which 8.09 mg (95.2% yield) of N-[3S-amino-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(2-methylpropyl)urea hydrochloride salt was obtained as a white solid.
EXAMPLE 33
[0190] 3S-(N,N-Dibenzyl)amino-2S-hydroxy-4-phenylbutyronitrile, O-trimethylsilyl Ether
[0191] To a solution of 24.33 g (73.86 mmol) of 2S-(N,N-dibenzyl)amino-3-phenylpropanal in 740 mL of anhydrous methylene chloride at −20 C under a nitrogen atmosphere, was added 11.8 mL (8.8 g, 88.6 mmol) of trimethylsilylcyanide, then 19.96 g (88.6 mmol) of anhydrous zinc bromide. After 4 hours at −15 C, and 18 hours at room temperature, the solvent was removed under reduced pressure, ethyl acetate was added, washed with water, brine, dried over magnesium sulfate, filtered and concentrated to afford 31.3 g of a brown oil, which was identified as a 95:5 mixture of 3S-(N,N-dibenzyl)amino-2S-hydroxy-4-phenylbutyronitrile, O-trimethylsilyl ether, m/e=429(M+H) and 3S-(N,N-dibenzyl)amino-2R-hydroxy-4-phenylbutyronitrile, O-trimethylsilyl ether, respectively.
EXAMPLE 34
[0192] 3S-(N,N-Dibenzyl)amino-2S-hydroxy-4-phenylbutyronitrile
[0193] A solution of 10.4 g (24.3 mmol) of the crude 95:5 mixture of 3S-(N,N-dibenzyl)amino-2S-hydroxy-4-phenylbutyronitrile, O-trimethylsilyl ether, and 3S-(N,N-dibenzyl)amino-2R-hydroxy-4-phenylbutyronitrile, O-trimethylsilyl ether from Example 33 in 40 mL of methanol, was added to 220 mL of 1N hydrochloric acid with vigorous stirring. The resulting solid was collected, dissolved in ethyl acetate, washed with aqueous sodium bicarbonate, brine, dried over anhydrous magnesium sulfate, filtered and concentrated to afford 8.04 g of crude product. This was recrystallized from ethyl acetate and hexane to afford pure 3S-(N,N-dibenzyl) amino-2S-hydroxy-4-phenylbutyronitrile, m/e=357 (M+H).
EXAMPLE 35
[0194] 3S-(N,N-Dibenzyl)amino-2R-hydroxy-4-phenylbutylamine
[0195] METHOD 1:
[0196] A solution of 20.3 g (47.3 mmol) of the crude 95:5 mixture of 3S-(N,N-dibenzyl)amino-2S-hydroxy-4-phenylbutyronitrile, O-trimethylsilyl ether, and 3S-(N,N-dibenzyl)amino-2R-hydroxy-4-phenylbutyronitrile, O-trimethylsilyl ether from Example 34 in 20 mL of anhydrous diethyl ether, was added to 71 mL (71 mmol) of a 1M solution of lithium aluminum hydride in diethyl ether at reflux. After the addition, the reaction was refluxed for 1 hour, cooled to 0C, and quenched by the careful addition of 2.7 mL of water, 2.7 mL of 15% aqueous sodium hydroxide, and 8.1 mL of water. The resulting solids were removed by filtration and the filtrate washed with water, brine, dried over magnesium sulfate, filtered and concentrated to afford 13.8 g of crude material, which was recrystallized from tetrahydrofuran and isooctane to afford 10.6 g of 3S-(N,N-dibenzyl)amino-2R-hydroxy-4-phenylbutylamine, Mp=46-49 C, m/e=361 (M+H), which was contaminated by approximately 2% of 3S-(N,N-dibenzyl)amino-2S-hydroxy-4-phenylbutylamine.
[0197] METHOD 2:
[0198] To 15.6 mL (60.4 mmol) of 70% sodium bis(methoxyethoxy)aluminum hydride in toluene, was added 15 mL of anhydrous toluene, and then after cooling to 0C, a solution of 20.0 g (46 mmol) of the crude 95:5 mixture of 3S-(N,N-dibenzyl)amino-2S-hydroxy-4-phenylbutyronitrile, O-trimethylsilyl ether, and 3S-(N,N-dibenzyl)amino-2R-hydroxy-4-phenylbutyronitrile, O-trimethylsilyl ether from Example 34 in 10 mL of anhydrous toluene, at a rate so as to maintain the temperature below 15° C. After 2.5 hours at room temperature, the reaction was quenched by the careful addition of 200 mL of 5% aqueous sodium hydroxide. The solution was diluted with ethyl acetate, washed with 5% sodium hydroxide, sodium tartrate solution, brine, dried over magnesium sulfate, filtered and concentrated to afford 16.6 g of crude product, which was assayed by HPLC and shown to contain 87% of 3S-(N,N-dibenzyl)amino-2R-hydroxy-4-phenylbutylamine
EXAMPLE 36
[0199] N-[3S-(N,N-Dibenzyl)amino-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(3-methylbutyl)urea
[0200] Step 1:
[0201] To a solution of 1.0 g (2.77 mmol) of 3S-(N,N-dibenzyl)amino-2R-hydroxy-4-phenylbutylamine from Example 35 in 4.6 mL of ethanol, was added 0.3 mL (0.24 g, 2.77 mmol) of isovaleraldehyde. After 1 hour at room temperature, the ethanol was removed under reduced pressure, 4 mL of ethyl acetate was added and the solution purged with nitrogen. To the solution was added 360 mg of 5% platinum on carbon catalyst, the solution purged with 40 psig of hydrogen and then maintained under 40 psig of hydrogen for 20 hours. The solution was purged with nitrogen, the catalyst removed by filtration and the solvent removed under reduced pressure to afford 473 mg of the crude product.
[0202] Step 2:
[0203] The crude product from Step A was directly dissolved in 5.4 mL of ethyl acetate and 109 mg (1.1 mmol) of tertiary-butyl isocyanate was added. After 1 hour at room temperature, the solution was washed with 5% citric acid, brine, dried over magnesium sulfate, filtered and concentrated to afford 470 mg of crude product. The crude product was recrystallized from ethyl acetate and isooctane to afford 160 mg of N-[3S-(N,N-Dibenzyl)amino-2R-hydroxy-4-phenylbutyl]-N′-(1,1-dimethylethyl)-N-(3-methylbutyl)urea, Mp=120.4-121.7° C., m/e=530 (M+H).
[0204] From the foregoing detailed description, one skilled in the art can easily ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various uses and conditions.
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Chiral hydroxyethylamine, hydroxyethylurea or hydroxyethylsulfonamide isostere containing retroviral protease and renin inhibitors can be prepared by multi-step syntheses that utilize key chiral amine intermediates. This invention is a cost effective method of obtaining such key chiral amine intermediates enantiomerically, diastereomerically and chemically pure. The method is suitable for large scale (multikilogram) productions. This invention also encompasses organic acid and inorganic acid salts of the amine intermediates.
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FIELD OF THE INVENTION
This application deals with exercise, fitness and therapeutic massage devices that may be held in one hand or both hands and used for a wide range of wrist, forearm and shoulder manipulation, massage and total body fitness exercises.
BACKGROUND OF THE INVENTION
Club-like exercise devices have been used for exercise, training and rehabilitation dating back for hundreds of years, if not longer. One country of origin for these club-like exercise devices was India. British colonialists brought these training tools back from India to England and they came to be called “Indian Clubs.” Indian Clubs became very popular in the late 1800's and into the early 1900's in England and then the United States. Indian Clubs were often made of wood and came in a wide variety of shapes and sizes. They were used by military soldiers for exercise and training, as well as by the general population for exercise. Modern club-like devices are generally made of wood, hard plastic composites or metal. Today Indian Clubs are making a resurgence but their popularity is limited in part because of the unforgiving hard materials used to construct them, and the associated risks of injury. Because Indian Clubs are constructed of a hard material they are dangerous, their application to total body exercise routines is limited for most people.
Juggling clubs resemble Indian Clubs but are usually lighter. The lighter construction of juggling clubs enables users to throw and catch them more easily whereas Indian Clubs are generally heavier and are not thrown, but rather swung about the body. Some juggling clubs are designed more specifically for training and incorporate a soft padded surface to prevent injury when a juggler misses a catch and the club hits his/her (hereafter referred to as his for convenience) body. While these training juggling clubs are similar to the present invention in that they incorporate soft padding on the clubs, their design is distinctly different from the present invention so that they can facilitate juggling as opposed to swinging them for exercise. Juggling clubs are designed with a balanced weight distribution that enables them to turn or rotate about a central axis for even and fluid rotations through the air to facilitate juggling. The present apparatus and method taught in the present invention have an uneven weight distribution between the club handles which are light and the club heads which are heavier making them unsuitable for throwing and catching but rather optimizes them for swinging exercises. The weight distribution between the handle and head of the present invention helps encourage and teaches a user to articulate the wrists and shoulders through a greater range of motion than when manipulating a more evenly weighted club.
Similar devices having extended handles such as sledgehammers are being used for exercise, primarily in the form of hitting truck tires in a gym. This exercise develops the coordination between the hands where one hand starts at the upper distal end adjacent to the head and slides down to the lower end of the handle during the swinging process, then connecting to a rigid object. Hammers and mallets with rubberized hammer heads are used as tools to hammer objects without denting or defacing them such as wooden furniture. Because many of these devices are constructed of hard materials with a rigid handle and metal hammer head, they are dangerous if not used with extreme caution. These hammers and mallets with rubberized heads are not suitable for many total body exercise routines because the rubberized hammer heads are still hard enough to cause injury if one happens to inadvertently strike his body. The act of hitting a rigged object with a limited cushioning effect provided by the present invention has additional benefits in some exercise routines.
The present Hand Held Exercise and Fitness Devices disclosed within this application and method taught enable a wider population of people with many fitness levels enjoy the benefits of exercise routines with less risk of injury and far wider application to total body exercise.
Numerous innovations for various hand held exercise and devices have been provided in the prior art that are described as follows. Even though these innovations may be suitable for the specific individual purposes to which they address, they differ from the present design as hereinafter contrasted. The following is a summary of those prior art patents most relevant to this application at hand, as well as a brief description outlining the difference between the features of the Hand Held Exercise Device and the prior art.
U.S. Pat. No. 7,179,210 of John E. Soukeras describes an exercise club, which may be held comfortably in one hand. Two of these clubs may be used, one in each hand, to execute a series of planned movements, which result in a full body workout. The weight of the clubs may be easily adjusted, to alter the intensity of the workout as desired. Virtually any person can use the clubs to improve their strength, health and fitness. This club can be made preferably of enforced polypropylene for rapid and quick volume production through injection molding.
This patent describes an exercise club with a head that is adjustable in position along the length of the handle but does not have the head with the unique capabilities of a club with a variety of soft polymer flexible heads that can be filled with varying quantities of a variety of granular substances including but not limited to ball bearings (commonly referred to as bb's), sand, gravel and variable density urethane foams or the additional inflatable head that will be capable of accommodating different air pressures.
U.S. Pat. No. 4,279,416 of Oliver D. Finnigan describes a juggling club which is composed of a sturdy hollow one-piece molded plastic body formed with a bulged end for receiving a tapered resilient knob, and also formed with a notched end for receiving a resilient tip. The body is formed of, for example, polyethylene, and it is inexpensive in its construction since it does not include a dowel pin, or the like, extending through the club for supporting the knob and tip at the opposite ends of the body.
This patent describes a juggling club which is composed of a sturdy hollow one-piece molded plastic body with a centralized weight distribution and does not incorporate the light weight handle along with not having the ability of a soft polymer flexible head.
U.S. Pat. No. 4,466,610 of Terry P. Israel describes a light weight exerciser or club adapted to assist the user to perform stretching, isometric, isotonic, and isokinetic exercises and to combine them with various aerobic exercises of walking or jogging. The exercise club has the shape of an elongate cylindrical shaft terminated in coaxially mounted end knobs serving as hand grips and has a length corresponding to the width of the chest of the user. The end knobs are dimensioned to be gripped by the hand with the palm resting against their outer ends with the fingers curving around the edges of the knob. The knobs are rounded in peripheral dimension and continuous to an inner wall which continues smoothly to and joins with the shaft so that the finger tips can lie along and grip the inwardly facing walls of the knob. Means are provided for forming various hand, finger, and thumb gripping surfaces. When the exerciser is constructed of wood such means can comprise grooves formed in the parts by scoring together with scallops formed in the rounded peripheral portions of the end knobs.
This patent describes a light weight exerciser or club adapted to assist the user to perform stretching, isometric, isotonic, and isokinetic exercises with hand knobs at both ends of a tubular member. It does not resemble the conventional Indian Club and does not indicate a club with a variety of soft polymer flexible heads that can be partially filled with a varying quantities of a variety of granular substances such as bb's, sand, gravel and low density urethane foam or the additional inflatable head that will be capable to different air pressures.
U.S. Pat. No. 4,696,468 of Brian J. Dube describes a juggling club that is formed of a hollow, unitary molded plastic body having a bulged portion, a relatively heavy knob and handle portion, and a center of gravity located at between 55 and 59 percent of the length of the longitudinal axis toward the bulged end of the club. The thickness of the body wall of the club is substantially greater at the handle and knob portions than at the bulged portion.
This patent describes another juggling club which is composed of a unitary molded plastic body having a bulged portion, a relatively heavy knob and handle portion with a centralized weight distribution and does not incorporate the light weight handle along with not having the ability of a number of soft polymer flexible heads.
There are no devices in the prior art that exists that would address the needs and create the specific advantages and benefits attendant with the Apparatus and Method for total body exercise routines using a sledgehammer-like device. The present design is a new, useful and non-obvious combination of method steps and component elements, with the use of a minimum number of functioning parts, at a reasonable cost to manufacture, and by employing readily available materials.
None of these previous efforts, however, provides the benefits attendant with the Hand Held Exercise and Fitness Devices disclosed within this application. The present designs achieve their intended purposes, objects and advantages over the prior art devices through a new, useful and non-obvious combination of method steps and component elements at a reasonable cost to manufacture, and by employing readily available materials.
In this respect, before explaining at least one embodiment of the Hand Held Exercise and Fitness Devices as a method for more effective exercise in detail, it is to be understood that the design is not limited in its application to the details of construction and to the arrangement, of the components set forth in the following description or illustrated in the drawings. The Hand Held Exercise and Fitness Devices used as a method for total body exercise are capable of other embodiments and of being practiced and carried out in various ways. In addition, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for designing of other structures, methods and systems for carrying out the several purposes of the present design. It is important, therefore, that the claims be regarded as including such equivalent construction insofar as they do not depart from the spirit and scope of the present application.
SUMMARY OF THE INVENTION
The principal advantage of the preferred embodiment of the Hand Held Exercise Device is having an exercise club with a light weight handle and spherical head.
An advantage is the Hand Held Exercise Device in the configuration of a club will have a head made from a soft polymer flexible very durable material.
Another advantage of the Hand Held Exercise Device in the configuration of a club would be being able to use two of the devices, one in each hand.
Another advantage of the Hand Held Exercise Device in the configuration of a club is having a soft polymer flexible head that can be partially filled with a variety of granular substances such as bb's, sand or gravel that will shift position to the front of the head on impact.
Another advantage of the Hand Held Exercise Device is that it is safer when swinging around the body.
Another advantage of the Hand Held Exercise Device is that it is suitable for percussive exercises where a user intentionally taps his body with the Hand Held Exercise Device.
Another advantage of the Hand Held Exercise Device in the configuration of a club is having soft polymer flexible head that can be filled with a liquid.
Another advantage of the Hand Held Exercise Device in the configuration of a club is having soft polymer flexible head that can be filled with compressed air to produce different degrees of firmness.
Another advantage of the Hand Held Exercise Device in the configuration of a club is having a soft polymer flexible head that can be filled with a urethane foam material.
Another advantage of the Hand Held Exercise Device in the configuration of a club is that it can be used to exercise the wrist by holding and rotating the wrist, the forearm by raising and lowering at the elbow, and shoulder by rotating the full arm.
Another advantage of the Hand Held Exercise Device in the configuration of a club is that it can be used to massage body parts where the granular material inside the head produces a soft but firm impact conforming to the part of the body impacted.
An alternate embodiment of the Hand Held Exercise Device will have an extended handle and a head resembling a sledgehammer made from a soft polymer flexible very durable material.
Another advantage of the Hand Held Exercise Device resembling a sledgehammer is that the head may be filled with a soft urethane foam material.
Another advantage of the Hand Held Exercise Device resembling a sledgehammer is that it may be swung like a conventional sledgehammer without the possibility of damaging things.
Another advantage of the Hand Held Exercise Device resembling a sledgehammer is that it can be used to train individuals how to properly and safely swing a sledgehammer.
Another advantage of the Hand Held Exercise Device resembling a sledgehammer is that the head may be partially filled with a variety of granular substances including but not limited to granular metal, steel shot, bb's, sand or gravel.
Another advantage of the Hand Held Exercise Device resembling a sledgehammer is that the head may be partially filled with compressed air.
Another advantage of the Hand Held Exercise Device resembling a sledgehammer is that it is safer when swinging around the body.
Another advantage of the Hand Held Exercise Device resembling a sledgehammer is that it provides ideal rebound reaction when hitting hard surfaces to stimulate the muscles involved in decelerating the rebounding hammer.
Another advantage of the Hand Held Exercise Device resembling a sledgehammer is that the rebound “bounce” it creates is easier on joints and more effectively exercises the muscles, ligaments and tendons.
The preferred embodiment of the Hand Held Exercise Device would be in the configuration of a club with a lightweight ridged injection molded two part handle having restraining elements holding the spherical head made from a soft polymer flexible very durable material. The handle will be held together by the means of conventional screw type fasteners. A lanyard may be attached through an orifice in the lower distal end of the handle. The spherical head will have a groove around the mounting section with indentions on two opposing sides that engage with two restraining elements within the handle. The rib around the circumference of the inner surface lip of the two part handle engage within a groove in the spherical head, additionally restricting the movement within the device. Another style of head will have a thread on the insert section to engage within a threaded orifice in a one piece handle to be locked in place by the means of a single dowel pin. At this time it must be made clear that the spherical shape to the head of the device may have a wide variety of geometric shapes and sizes and still remain within the scope of this application.
The spherical head made from a soft flexible very durable polymer material may incorporate a tubular orifice in the mounting end to insert a variety of different materials such as granular elements or liquid to be sealed with a compressive plug or a urethane foam material that can be inserted within the internal cavity. Additionally self-skinning foam can be molded to form the club head. The amount and weight of the material within the head section can greatly affect the unique operations of the device. The spherical head may also be sealed with a needle valve orifice in the flat portion for a pressurized inflation.
An alternate embodiment of the Hand Held Exercise Device will have an extended fiber glass handle and a head made from a soft polymer flexible and very durable polymer material in a variety of shapes, with the preferred being of a sledgehammer. One design will have a weighted object, preferably steel, in the center of the head attached to the handle. The head would be filled with urethane foam or either using self-skinning foam molded for the outside covering.
A second design would additionally be made from a soft polymer flexible very durable polymer material with a mounting cavity on the upper and lower surfaces. A lower steel retainer will be permanently affixed to a light weight fiberglass handle. An upper steel retainer attached to the handle will have screw type fasteners extending through the head engaging in the lower steel retainer. The size of the steel retainers can vary depending on the desired weight of the device head. The head may incorporate an orifice in the upper mounting cavity to insert a variety of elements effecting the weight and balance. The head may also be sealed with a needle valve orifice for a pressurized inflation. Additionally the head may have a sealed inner cavity that has been filled with low density urethane foam.
In this respect, before explaining at least one embodiment of the preferred embodiment and alternate embodiment of the Hand Held Exercise Device application in detail, it is to be understood that the design is not limited in its application to the details of construction and to the arrangement of the components set forth in the following description or illustrated in the drawings. The Hand Held Exercise Device is capable of other embodiments and of being practiced and carried out in various ways. In addition, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the Hand Held Exercise and Fitness Device and together with the description, serve to explain the principles of this application.
FIG. 1 depicts a perspective view of a person holding two of the preferred embodiments of the Hand Held Exercise Device.
FIG. 2 depicts a perspective view of an exploded view of the preferred embodiments of the Hand Held Exercise Device.
FIG. 3 depicts a cross section through the preferred embodiments of the Hand Held Exercise Device.
FIG. 4 depicts a front view of the spherical head of the preferred embodiments of the Hand Held Exercise Device.
FIG. 5 depicts a side view of the spherical head of the preferred embodiments of the Hand Held Exercise Device.
FIG. 6 depicts a cross section of the spherical head with a partial granular filling.
FIG. 7 depicts a cross section of the spherical head constructed of self-skinning urethane foam.
FIG. 8 depicts a cross section of the spherical head filled with urethane foam.
FIG. 9 depicts a cross section of the spherical head partially filled with a liquid.
FIG. 10 depicts a cross section of the spherical head incorporating a needle valve opening.
FIG. 11 depicts a perspective view of the style of spherical head having a thread on the insert section to engage within a threaded orifice in a one piece handle to be locked in place by the means of a single dowel pin.
FIG. 12A depicts a perspective view of an alternate embodiment of the Hand Held Exercise Device illustrating a three piece handle in the preferred configuration of a spherical head.
FIG. 12B depicts a perspective exploded view of the alternate embodiment of the Hand Held Exercise Device, shown in FIG. 12A , in the preferred configuration of a three piece handle and spherical head.
FIG. 13A depicts a perspective view of another alternate embodiment of the Hand Held Exercise Device in the preferred configuration of a sledge hammer.
FIG. 13B depicts a perspective exploded view of the alternate embodiment of the Hand Held Exercise Device, shown in FIG. 13A , in the preferred configuration of a sledge hammer.
FIG. 14 depicts a top view of the head of the sledge hammer configuration of the Hand Held Exercise Device with the steel retainers.
FIG. 15 depicts a cross section of the head of the sledge hammer configuration of the Hand Held Exercise Device with the steel retainers.
FIG. 16 depicts a cross section of the head of the sledge hammer configuration of the Hand Held Exercise Device having a weighted insert attached to the handle with the molded self-skinning urethane outer covering.
FIG. 17 depicts a cross section of the head of the sledge hammer configuration of the Hand Held Exercise Device with a partial granular filling.
FIG. 18 depicts a cross section of the head of the sledge hammer configuration of the Hand Held Exercise Device with a partial liquid filling.
FIG. 19 depicts a cross section of the head of the sledge hammer configuration of the Hand Held Exercise Device with a needle valve orifice for a pressurized inflation.
FIG. 20 depicts a cross section of the head of the sledge hammer configuration of the Hand Held Exercise Device that is made with the steel retainers on the handle using a self-skinning urethane foam for the outer covering.
For a fuller understanding of the nature and advantages of the Hand Held Exercise and Fitness Device, reference should be had to the following detailed description taken in conjunction with the accompanying drawings which are incorporated in and form a part of this specification, illustrate embodiments of the design and together with the description, serve to explain the principles of this application.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein similar parts of the preferred embodiment of the Hand Held Exercise Device 10 A and 10 B (wherein the detailed description of JOB in is shown beginning with FIG. 12 ) are identified by like reference numerals, there is seen in FIG. 1 a perspective view of a person holding two of the preferred embodiments of the Hand Held Exercise Device 10 A with one in his left hand 12 holding the handle 14 massaging his left shoulder with the spherical head 16 and the other in his right hand 18 holding the handle 14 in an upright position. Lanyards 20 are illustrated going around the wrists and attached through an orifice 22 in the grip end 24 of the handle 14 .
FIG. 2 depicts a perspective view of an exploded view of the preferred embodiments of the Hand Held Exercise Device 10 A illustrating the reinforcing ribs 26 in the handle 14 with the mounting screw orifices 28 where the mounting screws 30 secure the two halves of the handle 14 together. Two additional mounting screw orifices 28 are located in the spherical head retainers 32 that locate within the two depressions 34 on either side of the head insertion section 36 of the spherical head 16 . The handle 14 may be constructed with an over-molded rubberized grip surface, and that rubberized grip surface may be comprised of thermoplastic rubber (also known as TPR). Other rubberized sleeves and grips can alternatively be used in place of over-molded material.
FIG. 3 depicts a cross section through the preferred embodiments of the Hand Held Exercise Device 10 A illustrating the orifice 22 for the lanyard 20 in the grip end 24 of the handle 14 . A polarity of reinforcing ribs 26 extend through the central portion 38 of the handle 14 . Four mounting screw orifices 28 are the locations where the mounting screws 30 hold the two halves of the handle 14 together. The spherical head 16 consists of an outer shell 40 that can be manufactured by, but not limited to a rotational molding process with a flat surface 42 on the spherical end so that the device can stand upright and the head insertion section 36 at the other end. The insertion section 36 is held within the two halves of the handle 14 by the means of the two depressions 34 on the opposing sides being locked in place by the means of the two spherical head retainers 32 on both inside surfaces of the handle 14 . Additionally a circumferential rib 44 at the distal end of the handle 14 locks into the circumferential groove 46 at the edge of the insertion section 36 of the spherical head 16 . The central cavity 48 of the spherical head 16 is partially filled with a granular material 50 . At the upper end of the head insertion section 36 is a tubular orifice 52 for the purpose of installing a variety of materials into the central cavity 48 and will be sealed with a plug 54 . With regard to contemplated dimensions, the proportion of the club head diameter in relation to the widest portion of the handle at the attachment location may be in the ratio of 2:1, as shown here in FIG. 3 . For example, if the club head diameter is approximately 6 inches, then the fluted upper portion of the handle at the attachment location would be approximately 3 inches.
FIG. 4 depicts a front view of the of the spherical head 16 of the preferred embodiments of the Hand Held Exercise Device 10 A further illustrating the locations of the two depressions 34 on the opposing sides of the head insertion section 36 .
FIG. 5 depicts a side view of the spherical head 16 of the preferred embodiments of the Hand Held Exercise Device 10 A additionally illustrating the locations of the two depressions 34 on the opposing sides of the head insertion section 36 .
FIG. 6 depicts a cross section of the spherical head 16 with a partial granular material filling 50 within the central cavity 48 .
FIG. 7 depicts a cross section of the spherical head 16 constructed in one piece of self-skinning urethane foam 56 .
FIG. 8 depicts a cross section of the spherical head 16 manufactured by a rotational molding process with a flat surface 42 on the spherical end and the surface 58 sealed to be filled with urethane foam 57 .
FIG. 9 depicts a cross section of the spherical head 16 with the central cavity 48 partially filled with a liquid 60 .
FIG. 10 depicts a cross section of the spherical head 16 incorporating a needle valve opening 62 into the central cavity 48 for a pressurized inflation.
FIG. 11 depicts a perspective view of the style of spherical head 16 having a thread on the insert section 64 to engage within a threaded orifice 66 in a one piece handle 68 to be locked in place by the means of a single dowel pin 70 going through orifice 72 in the handle 14 .
FIG. 12A depicts a perspective view of an alternate embodiment of the Hand Held Exercise Device illustrating a three-piece handle in the preferred configuration of a spherical head. The three piece handle is comprised of a handle upper portion 73 , a locking annulus side 1 74 and a locking annulus side 2 75 . The locking annulus sides function to secure the spherical head to the handle portion as described in FIG. 12 B below.
FIG. 12B depicts a perspective exploded view of the alternate embodiment of the Hand Held Exercise Device, shown in FIG. 12A , in the preferred configuration of a three piece handle and spherical head. The three piece handle is comprised of a handle upper portion 73 , a locking annulus side 1 74 and a locking annulus side 2 75 . Each of the locking annulus sides 1 and 2, 74 and 75 , respectively, include a threaded locking channel 76 . The interface 77 of the club handle with the locking annulus is constructed with openings 78 which accept both of the locking annulus side 1 74 and locking annulus side 2 75 . These are then secured using fasteners, in this embodiment, screws 79 which are accepted by the threaded locking channels 76 of the locking annulus sides. In this way, the three-piece handle with locking annulus sides functions well to secure the handle to the spherical head.
FIG. 13A depicts a perspective view of the alternate embodiment of the Hand Held Exercise Device 10 B in the preferred configuration of the head 80 made from a soft polymer flexible very durable polymer material in the same manner as the spherical club head 16 and in a variety of shapes with the preferred being of a sledgehammer appearance with a long extended fiber glass handle 82 having a grip stopper section 84 . The upper surface of the head 80 is cavity 86 with an upper metal handle retainer 88 with mounting screws 90 .
FIG. 13B depicts a perspective exploded view of the alternate embodiment of the Hand Held Exercise Device 10 B in the preferred configuration of a sledge hammer illustrating the upper metal handle retainer 88 and the mounting screws 90 pulled away from the cavity 86 . The upper metal handle mount 88 has four counter bored orifices 92 for the mounting screws 90 and a central elongated orifice 94 for the fiber glass handle 82 . Below the head 80 is illustrated the lower metal handle mount 96 with four threaded orifices 98 for mounting along with a central elongated orifice 100 handle locking screw 102 on the side. The upper metal handle retainer 88 and the lower metal handle retainer 96 can vary in size and shape depending upon the desired weight of the device.
FIG. 14 depicts a top view of the head 80 of the sledge hammer configuration of the Hand Held Exercise Device 10 B illustrating the location of the upper metal handle retainer 88 along with the mounting screws 90 and the direction that the lower sections were taken.
FIG. 15 depicts a cross section of the head 80 of the sledge hammer configuration of the Hand Held Exercise Device 10 B with the upper metal handle retainer 88 and the lower metal handle retainer 96 in place within the outer shell 104 . The inner cavity 106 is filled with urethane foam 57 .
FIG. 16 depicts a cross section of the head 80 of the sledge hammer configuration of the Hand Held Exercise Device 10 B having a weighted insert 110 attached to the fiber glass handle 82 with the molded self-skinning urethane foam 56 outer covering. The weighted insert 110 can be a variety of shapes but in this case has been shown as a sphere with a plurality of orifices 112 to help stabilize it within the foam structure.
FIG. 17 depicts a cross section of the head 80 of the sledge hammer configuration of the Hand Held Exercise Device 10 B with a partial granular filling 50 in the inner cavity 106 . Within the cavity 86 and located below the upper metal handle mount 88 there is shown an orifice 87 for adding fill to the head 80 .
FIG. 18 depicts a cross section of the head 80 of the sledge hammer configuration of the Hand Held Exercise Device 10 B with a partial liquid filling 60 in the inner cavity 106 . Within cavity 86 and located below the upper metal handle mount 88 there is shown an orifice 89 for adding fill to the head 80 .
FIG. 19 depicts a cross section of the head 80 of the sledge hammer configuration of the Hand Held Exercise Device 10 B with a needle valve orifice 62 for a pressurized inflation in the inner cavity 106 .
FIG. 20 depicts a cross section of the head 80 of the sledge hammer configuration of the Hand Held Exercise Device 10 B that is made with the metal handle retainers 88 and 96 on the fiber glass handle 82 using the molded self-skinning urethane foam 56 for the outer covering.
The Hand Held Exercise and Fitness Devices 10 A and 10 B shown in the drawings and described in detail herein disclose arrangements of elements of particular construction and configuration for illustrating preferred embodiments of structure and method of operation of the present application. It is to be understood, however, that elements of different construction and configuration and other arrangements thereof, other than those illustrated and described may be employed for providing Hand Held Exercise and Fitness Devices 10 A and 10 B in accordance with the spirit of this disclosure, and such changes, alternations and modifications as would occur to those skilled in the art are considered to be within the scope of this design as broadly defined in the appended claims.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly and readily the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
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The present invention is directed to Hand Held Exercise and Fitness Devices that deals with exercise, fitness and therapeutic massage that may be held in the hand and used for a wide range of wrist, forearm and shoulder manipulation, massage and fitness exercises. The preferred embodiment will be in the shape of an Indian club with a light weight handle and a soft flexible polymer head that can have a variety of materials in the inner cavity. The second embodiment will have the head in the shape of a sledge hammer with a long handle and constructed in a similar fashion as the preferred embodiment.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of application Ser. No. 07/302,098, filed Jan. 24, 1989, now abandoned; which in turn is a continuation of application Ser. No. 07/185,305, filed Apr. 20, 1988, now abandoned; which in turn is a continuation of application Ser. No. 06/858,454, filed May 1, 1986, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a method for the production of proteins.
The presence of a variety of physiologically active proteins such as cytokines and peptide hormones has been ascertained and recent advances in genetic engineering technology are opening ways for large-scale production of these physiologically active proteins and clinical application of the same.
Interleukin-2 [hereinafter referred to as IL-2; also called T cell growth factor (TCGF)] is a lymphokine produced by T cells upon stimulation by a lectin or alloantigen, among others [Science, 193, 1007 1976)].
A large number of clones of killer T cells or helper T cells and, further, natural killer cells have so far been obtained through the utilization of IL-2 [e.g. Nature, 268, 154 (1977)]. In addition to such direct use in cloning T cells or natural killer cells, the use of IL-2 can result in selective in vitro proliferation of antigen-specific killer T cells capable of recognizing and destroying a certain particular antigen, for example a tumor antigen By introducing into animals tumor-specific killer T cells grown in this manner, it is possible to control or inhibit tumor growth [The Journal of Immunology, 125, 1904 (1980)].
These experimental findings suggest the possible utility of IL-2 as an antitumor agent It is further known that IL-2 restores the helper T cell function in nude mice which are deficient in thymus function [European Journal of Immunology, 10, 719 (1980)] and restores the induction of killer T cells against allogenic cells [Nature, 284, 278 (1980)], and therefore IL-2 can be expected to be useful in the treatment of immunocompromised diseases
Interferon-α (hereinafter referred to as IFN-α) and interferon-γ (hereinafter referred to as IFN-γ) are lymphokines produced by virus- or nucleic acid-activated lymphocytes, are biologically active in that they act on cells and bring them into an antiviral state, and thus play an important role in the prophylactic system or oncoimmune system.
Proteins such as these cytokines can be obtained as naturally occurring substances but in very limited amounts. However, recent advances in recombinant DNA technology have opened the way for the recovery of biologically active proteins from cultures of those strains of Escherichia coli and so forth which respectively carry expression vectors with genes for said proteins inserted therein [for IL-2: Nature, 302, 305 (1983) and Nucleic Acids Research, 11, 4307 (1983); for IFN-α: Journal of Interferon Research, 1, 381 (1981); for IFN-γ: Nature, 295, 503 (1982)].
Since, whether it takes place in a eukaryote or in a prokaryote, protein biosynthesis starts with the messenger RNA codon AUG (which corresponds to methionine,) it is possible that the product protein may possibly be either a molecular species having a methionine residue at the N-terminal end or a molecular species having no such residue or a mixture of the two. In fact, it is known, for instance, that in Escherichia coli, the N-terminal end of many cell proteins is methionine [Conn & Stumpf: Outlines of Biochemistry, 4th edition, John Wiley & Sons (1976)] and that the initiation factor IF-3 of Escherichia coli comprises both the molecular species having a methionine residue at the N-terminal end and the species free of such residue [Hoppe-Seyler's Zeitschrift fur Physiologische Chemie, 354, 1415 (1973)]. With regards to proteins produced in Escherichia coli by using recombinant DNA techniques, it is known that the percentage of a addition of methionine residue to the N-terminal end is about 50% for IFN-α [Journal of Interferon Research, 1, 381 (1981)] and as high as 100% for human growth hormone [Nature, 293, 408 (1981)]. However, no instances have so far been reported to the control of the percentages of methionine residue addition percentage in such proteins
In the course of their investigations concerning the process for producing the IL-2 protein using strains of Escherichia coli with the IL-2 gene introduced therein, the present inventors found that the IL-2 protein produced in Escherichia coli is comprised of two molecular species, namely an N-terminal methionine residue-free IL-2, that is a molecular species beginning with an alanine residue as the N-terminal amino acid [Ala-IL-2], and a molecular species having a methionine residue added to the N terminal end and thus beginning with a methionyl-alanine residue [Met-Ala-IL-2], the content of the latter being much higher than that of the former.
Similarly, it was found that when IFN-α and IFN-γ are produced in Escherichia coli each is a mixture of a molecular species the N-terminal end of which begins with a cysteine residue [Cys-IFN-α and Cys-IFN-γ, respectively] and a molecular species having a methionine residue added to the N terminal and thus beginning with a methionyl-cysteine residue [Met-Cys-IFN-α and Met-Cys-IFN-γ, respectively], the latter accounting for from 5-50%.
Those proteins which have a methionine residue at the N-terminal end are supposed to be similar in biological activity to the corresponding proteins of the naturally occurring type but, in any event, are different substances from the latter. Therefore, the known methods are not fully satisfactory for producing proteins having the respective amino acid sequences of the naturally occurring type protein.
SUMMARY OF THE INVENTION
The present invention provides an improvement in the method for producing proteins by cultivating Escherichia coli having an expression vector which contains a structural gene for the protein at the downstream end of translational starting codon, which comprises cultivating the Escherichia coli in a medium containing (1) an iron ion source, a manganese ion source or a mixture thereof and (2) a nitrogen source from natural origin to increase the yield of the protein free of methionine corresponding to translational starting codon ATG at the N-terminus.
As the above-mentioned protein, there may be mentioned a variety of physiologically active proteins, for example cytokines such as interferons (e.g. IFN-α, IFN-β, IFN-γ), interleukins (e.g. interleukin-1, IL-2), B cell growth factor (BGF), B cell differentiation factor (BDF), macrophage activating factor (MAF), lymphotoxin (LT) and tumor necrosis factor (TNF); transforming growth factor (TGF-α); peptide protein hormones such as erythropoietin, epidermal growth factor, insulin and human growth hormone; pathogenic microbial antigen proteins such as hepatitis B virus antigen, influenza virus antigen, foot and mouth disease virus antigen and malarial parasite antigen; enzymes such as peptidases (e.g. tissue plasminogen activator, urokinase, serratiopeptidase) and lysozyme; and serum proteins such as human serum albumin (HSA)
The method of the present invention may be applied with particular advantage to those instances in which IL-2, IFN-α and IFN-γ, among others, are produced by cultivating certain strains of Escherichia coli.
The term "IL-2" as used herein refers to any species having the same biological or immunological activities that natural human IL-2 has, for example the IL-2 receptor-binding or anti-IL-2 antibody-binding abilities. Thus, for example, such species may be a polypeptide having the amino acid sequence shown in FIG. 1 [polypeptide (I)] or a fragment thereof comprising some or other part of the amino acid sequence as required for the biological or immunological activities of polypeptide (I), such as a fragment of polypeptide (I) which is lacking one amino acid [EPC (laid open) No. 91539] or 4 amino acids (Japanese Patent Application No. 58-235638, filed on Dec. 13, 1983 and laid open under Japanese Patent Publication No. 126088/1985) from the N-terminal end thereof or a fragment of polypeptide (I) which is lacking in several amino acids of the C terminal portion thereof. Furthermore, such species may be a polypeptide which is otherwise the same as the above polypeptide (I) but is lacking in part of the constituent amino acids of polypeptide (I) or containing one or more amino acids other than the amino acid or acids originally occurring in polypeptide (I), such as a polypeptide (I) analog which contains a serine residue in lieu of the No. 125-cysteine residue [Japanese Patent Publication (laid open) No. 93093/1984]. The polypeptides mentioned above are preferably in the unglycosylated form.
The term "IFN-α" as used herein refers to any species having the same biological or immunological activities that natural human IFN-α has, for example the IFN-α receptor-binding or anti-IFN-α antibody-binding abilities. An example is a polypeptide having the amino acid sequence shown in FIG. 3 [polypeptide (II)]. Furthermore, said species may be a fragment having a partial amino acid sequence exhibiting the biological or immunological activities of IFN-α, such as a fragment of polypeptide (II) which is lacking in several amino acids of the N-terminal portion thereof or in several amino acids of the C-terminal portion thereof. It may further be a polypeptide which is otherwise the same as the above polypeptide (II) but is lacking part of the constituent amino acids of polypeptide (II) or containing one or more amino acids other than the amino acid or acids originally occurring in polypeptide (II). Particularly preferred among them is IFN-αA.
The term "IFN-γ" as used herein refers to any species having the same biological or immunological activities that natural human IFN-γ has, for example the IFN-γ receptor-binding or anti-IFN-γ antibody-binding abilities. Examples are the polypeptide (III) shown in FIG. 4 which comprises 146 amino acids and various fragments of polypeptide (III). Specific examples of such fragments are an N terminal-lacking molecular species which is lacking up to 4 amino acids of the N-terminal portion of polypeptide (III) and a C terminal-lacking molecular species resulting from cleavage of polypeptide (III) or a corresponding N terminal-lacking molecular species at a site not preceding the 131st amino acid residue. Furthermore, the above-mentioned IFN-γ may be an analog thereof which contains a serine or threonine residue in place of the cysteine residue in the above polypeptide. Among others, polypeptide (III) is preferred.
The protein-encoding structural gene may be any DNA, either naturally-derived or synthetic, which codes for the amino acid sequence of the above protein.
Thus, for instance, there may be mentioned, for IL-2, a DNA having the base sequence shown in FIG. 2 [DNA (IV) which codes for the amino acid sequence shown in FIG. 1]; for IFN-α, a DNA [DNA (V); e.g. Japanese Patent Publication (laid open) No. 79897/1982] coding for the amino acid sequence (IFN-αA) shown in FIG. 3; and, for IFN-γ, a DNA [DNA (VI); e.g. Japanese Patent Publication (laid open) No. 189197] coding for the amino acid sequence shown in FIG. 4.
The above-mentioned structural gene (DNA) exists downstream from the translation start codon ATG. Said gene may be present downstream from ATG either in direct connection therewith or via a spacer incapable of being expressed or some other structural gene occurring between ATG and said gene. It is particularly preferable that ATG and the structural gene are directly connected with each other.
It is preferable that the above-mentioned gene (DNA) has a promoter upstream therefrom. Said promoter may be any of the λPL or λPR promoter which takes part in the growth of λ phage, the tryptophan (trp) promoter, the lactose (lac) promoter, the protein chain elongation factor Tu (tuf B) promoter and the rec A promoter, among others. In particular, the λPL and trp promoters may be used in the practice of the present invention with particular advantage.
The above gene and promoter are generally inserted into a vector to yield an expression vector. As the plasmid for producing said a vector, there is used most frequently ColEl-derived pBR322 [Gene, 2, 95 (1977)], for instance, but any other plasmids capable of being maintained by replication in Escherichia coli may also be used. Examples are pBR313 [Gene, 2, 75 (1977)], pBR324 and pBR 325 [Gene, 4, 121 (1978)], pBR327 and pBR328 [Gene, 9, 287 (1980)], pKY2289 [Gene, 3, 1(1978)], pKY2700 [Seikagaku (Biochemistry), 52, 770 (1980)], pACYC177 and pACYC184 [Journal of Bacteriology, 134, 1141 (1978)], and pRK248, pRK646 and pDF41 [Methods in Enzymology, 68, 268 (1979)].
Bacteriophage-derived vectors, for example λ phage-derived λgt series vectors such as λgt·λC [Proceedings of the National Academy of Sciences USA, 71, 4579 (1974)], λgt·λB [ibid., 72, 3416 (1975)] and λDam Gene, 1, 255 (1977)], Charon vectors [Science, 196, 161 (1977); Journal of Virology, 29, 555 (1979)], and filamentous phage-derived vectors may also be used as expression vectors.
The above-mentioned expression vector may be constructed by an appropriate known method [e.g. Nature, 302, 305 (1983); Nucleic Acids Research, 11, 4307 (1983); Japanese Patent Publication (laid open) No. 79897/1982; Japanese Patent Publication (laid open) No. 18197/1983].
As the host into which the expression plasmid with a structural gene for a protein inserted therein is to be introduced, a strain of Escherichia coli is used and an Escherichia coli K-12-derived strain is particularly preferred from handling and safety viewpoints. Examples of said Escherichia coli K-12-derived strain which are used with advantage are the strains 294, RR-1, DH-1, N4830 and C-4.
The strain 294 is a known strain [Proceedings of the National Academy of Sciences USA, 73, 4174 (1976)] which has been deposited with the Institute for Fermentation, Osaka (IFO) under the deposit No. IFO-14171.
The strain RR-1 is described in Gene, 2, 75 (1977), the strain DH 1 in Nature, 217, 1110 (1968), and the strain N4830 in Cell, 25, 713 (1981). Having the temperature-sensitive cI represser in the host, the strain N4830 is especially useful when λPL is used as the expression promoter, and it is commercially available from Pharmacia P-L Biochemicals.
The strain C-4 is deposited at IFO under IFO-14421 and at FRI under FERM BP-966, respectively.
The Escherichia coli strain to be used in the practice of the present invention may be produced by transforming a host Escherichia coli strain with an expression vector containing the structural gene for a protein and the transformation may be effected by the means described, for example, in Journal of Molecular Biology, 53, 159 (1970), Methods in Enzymology, 68 253 (1979), Gene, 3, 279 (1978), and Proceedings of the National Academy of Sciences USA, 69, 2110 (1972).
In accordance with the present invention, the above Escherichia coli strain is cultivated in a medium supplemented with an iron ion source and/or a manganese ion source.
Referring to the iron ion source and manganese ion source to be added to the medium, the iron ion source means a substance capable of supplying iron ions when it is dissolved or a substance capable of being utilized in the form of iron ions. Iron salts are examples. Preferred are inorganic salts of divalent or trivalent iron (e.g. ferrous chloride, ferric chloride, ferrous sulfate, ferric sulfate, ferric phosphate, ferric nitrate), among which mineral acid salts of trivalent iron (e.g. ferric chloride, ferric sulfate) are most preferred.
The manganese ion source means a substance capable of yielding manganese ions upon dissolution or a substance capable of being utilized in the form of manganese ions. Examples of such substance are manganese salts, preferably inorganic salts of manganese (e.g. manganese sulfate, manganese chloride, manganese carbonate, manganese phosphate), most preferably mineral acid salts of manganese (e.g. manganese sulfate, manganese chloride).
The iron ion source and manganese ion source may be used either alone or in combination. They are preferably added in the form of aqueous solutions.
The iron ion source and manganese ion source are each added at a concentration of 10 -6 to 10 -3 moles, preferably 2×10 -5 to 5×10 -4 moles, per liter. When used in combination, they are added each to a concentration within the above range.
The medium supplemented with nitrogen sources of natural origin which is to be used for cultivating the above Escherichia coli strain is a medium prepared by supplementing a known basal medium with a nitrogen source obtained from a naturally occurring substance, such as casamino acids, peptone, yeast extract or malt extract. The nitrogen source is usually supplemented in a concentration from 1 g/l to 50 g/l. A few examples of such medium which are suited for the practice of the present invention are given, in Table 1.
TABLE 1______________________________________Examples of medium suited for use ModifiedConstituent M-9 medium M-33 medium M-03 medium______________________________________Glucose 10 g/l 10 g/l 10 g/lNa.sub.2 HPO.sub.4 6 g/l 3 g/l --KH.sub.2 PO.sub.4 3 g/l 3 g/l 3 g/lNaCl 0.5 g/l 0.5 g/l 0.5 g/lNH.sub.4 Cl 1 g/l 1 g/l 1 g/lMgSO.sub.4.7H.sub.2 O 0.34 g/l 0.34 g/l 0.34 g/lCasamino acids 10 g/l 10 g/l 10 g/l______________________________________
The method of the present invention may be conducted under an acidic condition, especially in Escherichia coli harboring an expression plasmid and having trp promoter, such that Escherichia coli is inoculated into a medium of pH 4.8 to 6.0 and cultured while maintaining the range. A pH range of 5.0 to 5.8 is more recommended; a pH value of approx. 5.5 is particularly conductive to culturing.
After sufficient growth, however, culture conditions may be shifted out of this pH range, e.g. to more acidic conditions.
pH is adjusted using an inorganic base or a mineral acid before or after the medium is prepared and sterilized. pH adjustment may be required during E. coli cultivation to maintain the pH within the specified range. Since pH usually decreases during cultivation, pH is adjusted by adding an inorganic base, e.g. ammonia, sodium hydroxide, and sodium carbonate; however, mineral acids such as sulfuric acid may be added, if desired. Of these substances, ammonia water is especially preferable as it constitutes a nitrogen source for the media.
For transformants harboring an expression plasmid and having a trp promoter, for instance, an agent for causing the promoter to function efficiently, for example 3-β-indolylacrylic acid, may be added.
In case the host is an auxotroph, the amino acid or amino acids required (e.g. L-lysine, L-arginine, L-methionine, L-leucine, L-proline, L-isoleucine, L-valine, L-tryptophan) are preferably each added to a concentration of about 10 to 1,000 mg/liter. It is also possible to additionally supplement glucose, casamino acids and other components during cultivation as necessary. Furthermore, for selective growth of the recombinant Escherichia coli strain, an agent to which the strain is resistant, for example tetracycline, may be added, depending on the gene for drug resistance or the like retained in the plasmid.
The medium used for large scale cultivation is prepared in advance (namely, before starting fermentation) by adding the iron ion source and/or manganese ion source (mentioned above) at an appropriate concentration. seed culture medium.
The cultivation is generally carried out at 15°-45° C. In strains carrying the λPR or λPL promoter and the temperature sensitive repressor, for instance, proliferation at 25°-35° C. followed by shifting up to about 42° C. is advantageous for gene expression. In strains carrying other promoters, high productivity may be attained by maintaining a temperature of about 37° C. from the beginning of growth to about the middle thereof and then decreasing the temperature with proliferation, followed by maintenance at 20°-30° C.
The cultivation is generally performed with aeration and stirring. Cultivation while maintaining the oxygen concentration in medium at a level of not lower than about 5% (v/v) of the saturation oxygen concentration is advantageous since, in that case, an increased yield of the desired protein may be obtained.
The protein thus produced may be assayed by a known method.
For assaying IL-2, for instance, an IL-2-dependent cell line may be used. Since human IL-2 is known to promote the growth of rat, mouse and some other IL-2-dependent cell lines as well as human cell lines [Immunological Reviews, 51, 257 (1980)], not only human IL-2-dependent cell lines but also rat or mouse IL-2-dependent cell lines may be used [Journal of Immunology, 130, 981 and 988 (1983)].
In particular, IL-2-dependent murine cell lines may be stably maintained by passage for a long period of time and give assay results with high reproducibility.
The total IL-2 yield data given in this specification are data as measured by the method which uses IL-2-dependent cells and takes the uptake of radioactive thymidine as an index [Biochemical and Biophysical Research Communications, 109, 363 (1982)].
The yield of Ala-IL-2 was determined by extracting IL-2 from cells with 7M guanidine hydrochloride, dialyzing the extract, subjecting the dialyzate to FPLC (fast protein liquid chromatography) to be mentioned later herein for separation of an Ala-IL-2 fraction and a Met-Ala-IL-2 fraction, determining IL-2 activities of both fractions by the method mentioned above, calculating the proportion of Ala-IL-2 and multiplying the total yield of IL-2 by this proportion.
Purified samples (i.e., an Ala-Il-2 fraction and a Met-Ala-Il-2 fraction), which were obtained by FPLC, were quantified by measuring the absorbance values at 280 nm, respectively and the proportion of Ala-Il-2 was calculated from the measured values.
IFNs are assayed either by the antiviral assay method [Journal of Virology, 37, 755 (1981)] or by the enzyme immunoassay method [Journal of Immunology, 80, 55 (1985)]. The proportion of the IFN species having N-terminal methionine relative to the whole IFN produced is determined by subjecting the IFN protein extracted from cells and purified by appropriate methods, for examples a purified sample of IFN-αA, to FPLC to thereby separate the molecular species having N-terminal methionine and the molecular species without N-terminal methionine, which are quantified by measuring an absorbance value at 280 nm, respectively and the proportion of the species having N-terminal methionine relative to the whole IFN produced is then calculated based on the measured values. In the case of IFN-γ, both species are quantified by determining the N-terminal methionine content by the dansylation method or by using a peptide sequenser.
In extracting the protein produced in accordance with the present invention from cultured cells, the cells are harvested after cultivation and suspended in a buffer containing a protein-denaturing agent such as guanidine hydrochloride and, after stirring in a cool place, a supernatant containing the protein is collected by centrifugation. In accordance with another method, cells are suspended in a buffer and disrupted by sonication, lysozyme treatment and/or freezing and thawing, and then a supernatant containing the protein is collected by centrifugation. Any other appropriate methods may also be used.
The protein may be isolated from the above-mentioned supernatant and purified by an appropriate combination of per se known methods of separation and purification. Examples of such known separation and purification methods are methods making good use of solubility differences, such as salting out and solvent precipitation; methods mainly utilizing molecular weight differences, such as dialysis, ultrafiltration, gel filtration and SDS-polyacrylamide gel electrophoresis; methods making use of electric charge differences, such as ion exchange chromatography; methods based on specific affinity, such as affinity chromatography; methods based on hydrophobicity differences, such as reversed-phase high-performance liquid chromatography; and methods utilizing isoelectric point differences, such as isoelectric focusing In particular, the human IL-2 protein, which has high hydrophobicity, may be purified very effectively by hydrophobic column chromatography, in particular by high-performance liquid chromatography using a reversed-phase type column. For IFN-α and IFN-γ, the method of purification which uses monoclonal antibodies capable of specifically binding to the respective IFN species is very effective.
When the above IL-2 protein is a mixture of Ala-IL-2 and Met-Ala-IL-2, Ala-IL-2 may be isolated, as desired, by the separation means based on isoelectric point differences as disclosed by the same applicant as in the instant application of PCT/JP84/00460 (date of international application: Sep. 26, 1984), for instance.
As the separation means based on isoelectric point differences, there may be used any method of separating proteins differing in isoelectric point by about 0.01-0.2 from one another, for example density gradient isoelectric focusing using Ampholines, gel isoelectric focusing, constant-rate electrophoresis or the like method of electrophoresing proteins in an electric field, chromatofocusing, FPLC (fast protein liquid chromatography), pH gradient DEAE (diethylaminoethyl)- and CM (carboxymethyl) ion exchange column chromatography or the like method of eluting proteins one by one from a column in which a pH gradient is produced, or some other per se known method, or a combination of these. The reagents and apparatus to be used in these methods of separation are all commercially available and may be readily purchased.
A mixture of Cys-INF-α and Met-Cys-IFN-α may also be treated, if desired, in the same manner for mutual separation of the components.
The thus-purified proteins free of the N-terminal methionine residue corresponding to the translation start codon ATG have the same physiological activities as the corresponding known proteins, such as the corresponding naturally occurring proteins, and may be used as pharmaceuticals.
The Ala-IL-2 protein, like known IL-2 species, may cause selective in vitro growth of antigen-specific killer T cells capable of recognizing and destroying tumor antigens, for instance, or of natural killer cells capable of killing tumors. In other words, these cells are lymphocytes which destroy tumor cells and virus infected cells unspecifically, without depending on an immune response which starts with antigen sensitization. Since simultaneous inoculation with said IL-2 with introduction of the above killer cells into a living organism results in an increased antitumor activity of the killer cells, said protein may be used in the prevention and treatment of tumors or in the treatment of immunocompromised diseases in warm-blooded animals (e.g. mouse, rat, rabbit, dog, cat, pig, horse, sheep, cattle, human).
For using the above Ala-IL-2 protein as a prophylactic or therapeutic agent against tumors, said protein may be administered either parenterally or orally in the form of injections or capsules, for instance, as prepared by dilution with a per se known carrier. Furthermore, it may be used either alone or in combination with killer T cells or natural killer cells grown in vitro as mentioned above.
The above-mentioned Ala-IL-2 protein has substantially the same biological activities as known human IL-2 isolated from nature and therefore may be used in the same manner as the latter. Since the constant for its dissociation from cellular IL-2 receptors is very small, administration of said protein in very small doses is sufficient.
IFN, which has antiviral, antitumor, cell proliferation inhibiting, immunopotentiating and other activities, may be used in the treatment of viral infections and tumors, among others, in mammals (e.g. human, cattle, horse, pig, mouse, rat). In using said IFN as an antiviral, antitumor, cell proliferation inhibiting or immunopotentiating agent, for instance, said IFN is mixed with a pharmacologically acceptable carrier, excipient or diluent, which is known per se, and is administered in a form suitable for injections (parenterally intravenously, or intramuscularly, injection, for instance. In normal humans, the daily dose ranges from about 100 thousand to 100 million units, preferably from about 1 million to 50 million units. In mammals other than human, the dose ranges 2,000 to 2 million units/kg/day, preferably from about 20 thousand to 1 million units/kg/day.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the amino acid sequence of human IL-2.
FIG. 2 shows an example of the DNA base sequence coding for human IL-2.
FIG. 3 shows the amino acid sequence of human IFN-αA.
FIG. 4 shows the amino acid sequence of human IFN-γ.
FIG. 5 and FIG. 6 show the schemes for constructing the plasmids pTF1 and pTB285 described in the Reference Example, respectively.
EXAMPLES
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following examples and reference examples illustrate the present invention in further detail
The transformants disclosed in the examples have been deposited with the Fermentation Research Institute (FRI), Agency of Industrial Science and Technology, Ministry of International Trade and Industry and the Institute for Fermentation, Osaka (IFO) under the deposit numbers specified in Table 2.
TABLE 2______________________________________ Deposited with FRITransformant (Date of deposition) IFO______________________________________Escherichia coli FERM BP-852 IFO-14437N4830/pTB285 (Apr. 30, 1985)Escherichia coli FERM BP-628 IFO-14299DH1/pTF4 (Apr. 6, 1984)Escherichia coli FERM BP-967 IFO-14422C-4/pTF4 (Feb. 16, 1985)______________________________________
EXAMPLE 1
A 50-ml portion of a medium prepared by adding 50 mg/liter of sodium ampicillin and 15 mg/liter of tetracycline hydrochloride to L medium (10 g/liter Bactotryptone, 5 g/liter Bacto-yeast extract, 5 g/liter sodium chloride) was inoculated with Escherichia coli N4830/pTB285 obtained in Reference Example 1 (ii), followed by overnight incubation at 37° C. with rotation and shaking. The culture broth was transferred to a 5-liter jar fermenter containing 2.5 liters of modified M-9 medium supplemented with one or more metal salts as specifically given in Table 3, and cultivation was started at a rate of aeration of 2.5 liters/minute, a rate of stirring of 1,000 rpm and a temperature of 30° C. In the middle of cultivation, when the growth reached 1,000 Klett units, the temperature was shifted up to 42° C. and, after 4 hours of continued incubation, cells were harvested and frozen. For each culture broth, the frozen cells were examined for Ala-IL-2 productivity. The results obtained were as shown in Table 3.
TABLE 3__________________________________________________________________________Effects of addition of various metal ionsMetal ion added*.sup.1 (moles) Ala-IL-2Mn.sup.+ +Fe.sup.+++ Cu.sup.++ Zn.sup.++ Ca.sup.++ Co.sup.++ productivity*.sup.2__________________________________________________________________________0 0 0 0 0 0 1004 × 10.sup.-54 × 10.sup.-4 2 × 10.sup.-5 3 × 10.sup.-5 7 × 10.sup.-5 2 × 10.sup.-5 5004 × 10.sup.-50 0 0 0 0 4700 4 × 10.sup.-4 0 0 0 0 3204 × 10.sup.-54 × 10.sup.-4 0 0 0 0 570__________________________________________________________________________ *.sup.1 The metal ions were added in the form of the following compounds, respectively: MnSO.sub.4.4-6H.sub.2 O, FeCl.sub.3.6H.sub.2 O, CuSO.sub.4.5H.sub.2 O, ZnSO.sub.4.7H.sub.2 O, CaCl.sub.2.2H.sub.2 O, and CoCl.sub.2.6H.sub.2 O. *.sup.2 Given in terms of relative value, the productivity for the no metal ion addition case, was assigned a value 100.
As is evident from Table 3, the addition of Mn ++ and/or Fe +++ resulted in an markedly increased Ala-IL-2 productivity whereas the addition of other ion sources (Cu ++ , Zn ++ , Ca ++ , Co ++ ) did not improve the productivity to any further extent.
EXAMPLE 2
The Escherichia coli N4830/pTB285 strain was grown in the same manner as in Example 1 in M-33 medium supplemented with the Mn ion in different concentrations, and the results as shown in Table 4 were obtained.
TABLE 4______________________________________Effects of addition of manganese ionMnSO.sub.4.4-6H.sub.2 O (moles) Ala-IL-2 productivity*______________________________________0 1002 × 10.sup.-5 3104 × 10.sup.-5 4908 × 10.sup.-5 6002 × 10.sup.-4 360______________________________________ *The productivity for the medium without metal salt addition assigned a value of 100.
EXAMPLE 3
The Escherichia coli N4830/pTB285 strain was cultivated in the same manner as in Example 1 in M-33 medium supplemented with the Fe ion in different concentrations, and the results shown in Table 5 were obtained.
TABLE 5______________________________________Effects of addition of iron ionFeCl.sub.3.6H.sub.2 O (moles) Ala-IL-2 productivity*______________________________________0 1007 × 10.sup.-5 3704 × 10.sup.-4 410______________________________________ *The productivity for the medium without metal salt addition was assigned a value of 100.
EXAMPLE 4
A 50 ml-portion of a liquid medium (pH 7.0) prepared by adding 7 mg/liter of tetracycline hydrochloride to L medium was inoculated with the transformant Escherichia coli DH1/pTF4 [Japanese Patent Application No. 225079/1983 filed on Nov. 28, 1983 and laid open under Japanese Patent Publication No. 115528/1985; Example 3], followed by overnight cultivation at 37° C. with rotation and shaking. The culture broth was inoculated into a 5-liter jar fermenter containing 2.5 liters of modified M-9 medium or of the same medium supplemented with 4×10 -4 moles of FeCl 3 ·6H 2 O and 4×10 -5 moles of MnSO 4 ·4-6H 2 O, and cultivation was started at an aeration rate of 2.5 liters/minute, a stirring rate of 1,000 rpm and a temperature of 37° C. During the cultivation, when the growth reached about 500 Klett units, the temperature was reduced to 30° C. and, when the growth reached about 1,000 Klett units, to 25° C. After 24 hours of cultivation, cells were harvested and frozen, and examined for Ala-IL-2 productivity by extracting IL-2 from the cells The results obtained were as shown in Table 6.
TABLE 6______________________________________Metal ion (moles)Mn.sup.+ .sup.+ Fe.sup.+++ Ala-IL-2 productivity*______________________________________0 0 1004 × 10.sup.-5 4 × 10.sup.-4 230______________________________________ *The productivity for the medium without metal salt addition was assigned a value of 100.
EXAMPLE 5
Six 50-ml portions of a liquid medium (pH 6.0), which was L medium containing 50 mg/liter of sodium ampicillin, each in a 250-ml erlenmeyer flask was inoculated with Escherichia coli N4830/pTB285, followed by overnight cultivation at 30° C. with rotation and shaking. The culture broth was inoculated, in 125-ml portions, into a 2.5-liter portion of M-33 medium containing 50 mg/liter of sodium ampicillin [medium (A)] and a 2.5-liter portion of M-33 medium containing 50 mg/liter of sodium ampicillin, 8×10 -5 moles of MnSO 4 ·4-6H 2 O and 4×10 -4 moles of FeCl 3 ·6H 2 O medium (B)], and cultivation was started at an aeration rate of 2.5 liters/minute, a stirring rate of 1,000 rpm and a temperature of 30° C., the pH being maintained at 6.5 throughout cultivation with aqueous ammonia. Each time when the glucose concentration decreased to 0.5% (w/v) or below, glucose and casamino acids were added each in an amount corresponding to 1%. Furthermore, when the growth reached 1,000 Klett units, the temperature was raised to 42° C. Four (4) hours after the change in the temperature to 42° C., the cultivation was complete. The culture broth was centrifuged, the cells were harvested, then frozen at -80° C., and stored.
A 12-g portion of the frozen cells from either culture broth was suspended homogeneously in 100 ml of an extractant (pH 7.0) containing 7M guanidine hydrochloride and 0.1M Tris-HCl buffer. After stirring at 4° C. for 1 hour, the suspension was centrifuged at 28,000×g for 20 minutes to give a supernatant.
Each supernatant obtained was dialyzed against 0.01M Tris-HCl buffer (pH 8.5) and centrifuged at 19,000×g for 10 minutes. The supernatant obtained was passed through a DE52 (DEAE-cellulose, Whatman, Great Britain) column (50 ml in volume) equilibrated with 0.01M Tris-HCl buffer (pH 8.5) for effecting protein adsorption. By constructing a linear NaCl concentration gradient (0 to 0.15M NaCl, 1 liter), IL-2 was eluted to give active fractions.
Each active fraction obtained in the above was concentrated to about 5 ml using a YM-5 membrane (Amicon, USA) and the concentrate was subjected to gel filtration using a Sephacryl S-200 (Pharmacia, Sweden) column (500 ml in volume) equilibrated with 0.1M Tris-HCl (pH 8.0)-1M NaCl buffer. Each active fraction measuring about 30 ml was concentrated to about 2.5 ml using a YM-5 membrane. The concentrate was applied to an Ultrapore RPSC (Altex, USA) column for adsorption, followed by high-performance liquid chromatography using a trifluoroacetic acid-acetonitrile system as the eluent. Column, Ultrapore RPSC (4.6×75 mm); column temperature, 30° C.; eluent A, 0.1% trifluoroacetic acid-99.9% water; eluent B, 0.1% trifluoroacetic acid-99.9% acetonitrile; elution program, minute 0 (68% A+32% B)-minute 25 (55% A+45% B)-minute 35 (45% A+55% B)-minute 45 (30% A+70% B)-minute 48 (100% B); elution rate, 0.8 ml/minute; detection wavelength, 230 nm.
For each culture, about 10 ml of an active fraction eluting after about 39 minutes of retention under the above conditions was collected.
Each of the thus-obtained liquids containing a mixture of Ala-IL-2 and Met-Ala-IL-2 was lyophilized and the lyophilizate was dissolved in 5 ml of 0.005M ammonium acetate buffer (pH 5.0) and applied to a Mono P column for FPLC (0.5×20 cm, Pharmacia) equilibrated with 0.025M diethanolamine hydrochloride buffer (pH 9.4) and then the protein adsorbed on the Mono P column was eluted with 1% (v/v) Pharmalite (8-10.5)-5.2% (v/v) Polybuffer 96 hydrochloride buffer (pH 8.0). FPLC was conducted at room temperature and at a flow rate of 30 ml/hour. For each culture, an active eluate fraction of from 17 ml to 19 ml was collected and subjected to high-performance liquid chromatography using a trifluoroacetic acid-acetonitrile system as the eluent for removing Polybuffer. Column, Ultrapore RPSC (1.0×25 cm, Altex); column temperature, eluent A and eluent B, the same as above; elution program, minute 0 (55% A+45% B)-minute 4 (55% A+45% B)-minute 28 (42% A+58% B)-minute 38 (34% A+66% B)-minute 43 (20% A+80% B)-minute 44 (55% A+45% B); elution rate, 3.0 ml/minute.
Each Ala-IL-2 fraction thus obtained was lyophilized to give a white powder.
The powder mentioned above as obtained from medium (A) without addition of any metal salts weighed 1.53 mg, whereas medium (B) with metal salt addition gave 6.31 mg of a powder.
With these two samples, the N-terminal amino acid was identified by the automatic Edman degradation method using a vapor phase protein sequencer (Applied Biosystems model 470A) and it was confirmed that Ala accounted for 98% or more. It was simultaneously confirmed that other protein chemistry characteristics (C-terminal amino acid, amino acid composition analysis, peptide mapping) of the two samples were quite identical.
EXAMPLE 6
The Escherichia coli 294 (ATCC 31446)/pLeIF-A-trp25 strain [cf. Example 1 of EPC (laid open) No. 43980] carrying an expression plasmid with a human IFN-αA gene coding for the amino acid sequence shown in FIG. 3 inserted therein was inoculated into 50 ml of a medium prepared by adding 5 mg/liter of tetracycline hydrochloride to L medium, followed by overnight incubation at 37° C. with rotation and shaking. The culture broth was transferred to a 5-liter jar fermenter containing 2.5 liters of modified M-9 medium supplemented with one or two metal salts specified in Table 7. Cultivation was started at an aeration rate of 2.5 liters/minute, a stirring rate of 1,000 rpm and a temperature of 37° C. The temperature was lowered to 30° C. at an extent of growth of 500 Klett units and further to 25° C. at 1,000 Klett units. Cultivation was performed for 24 hours in that manner. During cultivation, each time the glucose concentration fell to 0.2% (w/v) or below, glucose was added, to give a final concentration of 1% (w/v). each culture broth was centrifuged, whereby cells were harvested, which were suspended in 100 ml 50 mM Tris-HCl (pH 7.6) containing 10% (w/v) sucrose, 0.2M NaCl, 10 mM ethylenediaminetetraacetate (EDTA), 10 mM spermidine, 2 mM phenylmethylsulfonyl fluoride (PMSF) and 0.2 mg/ml lysozyme. After stirring at 4° C. for 1 hour, the suspension was warmed at 37° C. for 5 minutes and, then, further treated in a sonicator (Altex, USA) at 0° C. for 40 seconds. The resulting lysate was centrifuged at 11,300×g for 1 hour to give 95 ml of a supernatant.
This supernatant (95 ml) was diluted with 300 ml of 20 mM Tris-HCl (pH 7.6) containing 1 mM EDTA and 0.15M NaCl (TEN) and the dilution was applied to an anti-IFN-αA antibody column (20 ml).
After washing the column sufficiently with TEN, IFN-αA was eluted with 0.2M acetic acid containing 0.1% Tween 20 (Wako Pure Chemical Industries), the active fraction collected was adjusted to pH 4.5 and applied to a CM cellulose column for adsorption. After sufficient washing of the column, elution was effected with 0.025M ammonium acetate buffer (pH 5.0) containing 0.15M NaCl. The active fraction thus collected again was lyophilized to give a human leucocyte IFN-αA powder in an amount given in the table below.
Each sample thus obtained gave a single band in SDS-polyacrylamide gel electrophoresis and had a molecular weight of 19,000±1,000 and an antiviral activity of 2 to 3×10 8 U/mg. The sample obtained was subjected to FPLC using a Mono P column for chromatofocusing with Polybuffer from pH 6.7 to pH 5.5, whereby the proportions of the molecular species having an N-terminal methionine and the molecular species free of such methionine were determined. The results were as shown in Table 7. Thus, the addition of manganese and/or iron ions resulted in production of IFN-αA substantially free of the N-terminal methionine-containing molecular species.
TABLE 7______________________________________Metal ion added IFN-αA powder Proportion of N-(moles) yield terminal methionine-Mn.sup.++ Fe.sup.+++ (mg) containing species______________________________________0 0 28 14.6%4 × 10.sup.-5 0 29 0.8%0 7 × 10.sup.-5 30 1.0%4 × 10.sup.-5 7 × 10.sup.-5 32 less than 0.5%______________________________________
EXAMPLE 7
Escherichia coli RR-1 (pRK248cIts, pRC231/IFN-900) bearing an expression plasmid with a human IFN-γ gene coding for the amino acid sequence shown in FIG. 4 inserted therein as described in Example 8 of Japanese Patent Publication (laid open) No. 189197/1983 was inoculated into 50 ml of a medium prepared by adding 50 mg/liter of sodium ampicillin and 10 mg/liter of tetracycline hydrochloride, followed by overnight incubation at 30° C. with rotation. The culture broth was transferred to a 5-liter jar fermenter containing 2.5 liters of M-33 medium supplemented with one or two metal salts specified in Table 8. Cultivation was started at an aeration rate of 2.5 liters/minute, a starting rate of 1,000 rpm and a temperature of 30° C. At the logarithmic stage, when the growth was at about 700 Klett units, glucose and casamino acids were added each in an amount corresponding to a concentration of 1% (w/v) and at the same time the incubation temperature was raised from 30° C. to 42° C., followed by 4 hours of continued cultivation. Each time when the glucose concentration had become 0.2% or below, glucose and casamino acids were added, each in an amount corresponding to a concentration of 1% (w/v).
After completion of cultivation, the culture broth was centrifuged, whereby cells were collected, which were then frozen and stored.
Extraction of a 100-g portion of frozen cells from each culture with 300 ml of 100 mM Tris-hydrochloride buffer (pH 7.0) containing 7M guanidine hydrochloride was followed by centrifugation, giving a supernatant. This supernatant was diluted 70-fold with a buffer (hereinafter referred to as P.B.S.) comprising 137 mM sodium chloride, 27 mM potassium chloride, 8 mM disodium phosphate and 147 mM monopotassium phosphate and the dilution was again centrifuged to give a clear and transparent supernatant. This supernatant was applied to a monoclonal antibody (γ2-11.1 MoAb; Japanese Patent Publication (laid open) No. 80646/1984) column (50 ml) and, after sufficient washing, elution was carried out with 20 mM phosphate buffer (pH 7.0) containing 2M guanidine hydrochloride. An active fraction was collected and further applied to a Sephacryl S-200 (Pharmacia) column and then to a Sephadex G-25 column, the active fraction was collected in each case, whereby a purified IFN-γ sample was obtained. The yields from the respective media are shown in Table 8.
Each sample obtained showed an IFN-γ purity of not less than 95% and an antiviral activity of 3 to 4×10 6 IU/mg. The sample was dansylated and dansyl methionine was isolated and quantified by HPLC. The proportion of the molecular species containing N-terminal methionine relative to the total molecular species was thus determined and the data obtained are shown in Table 8.
TABLE 8______________________________________Metal ion added IFN- Proportion of N-terminal(moles) yield methionine-containingMn.sup.+ .sup.+ Fe.sup.+++ (mg) molecular species______________________________________0 0 15 12.0%4 × 10.sup.-5 0 16 1.0%0 7 × 10.sup.-5 16 1.2%4 × 10.sup.-5 7 × 10.sup.-5 17 less than 1%______________________________________
Thus, the addition of iron and manganese ions resulted in successful production of IFN-γ substantially free of the accompanying, N-terminal methionine-containing molecular species.
EXAMPLE 8
A medium prepared by adding 5 mg/l of tetracycline hydrochloride to L medium was inoculated with Escherichia coli C-4/pTF4 obtained in Reference Example 2, followed by cultivation at 37° C. with rotation and shaking (200 rpm) for 16.5 hours. The following media were prepared; (1) an M-03 medium adjusted to pH 5.5 and (2) an M-03 medium supplemented with 20 mg/l of FeCl 2 ·6H 2 O and 10 mg/l of MnSO 4 ·6H 2 O. A 2.5 liter portion each of medium (1) and medium (2) were respectively transferred to two 5-liter jar fermenters, and then a 125 ml-portion of the culture broth was inoculated into each of the respective 2.5 liter broths. These media were cultivated at 34.5° C. with 2.5 l/min. aeration stirring with maintaining the pH at 5.5 by the use of 14% aqueous ammonia and 5N sulfuric acid. During the cultivations, when the growth reached about 500 Klett units, the temperature was reduced to 27.5° C., and when the growth reached about 1,000 Klett units, the temperature was lowered to 22.5° C. Six (6) hours after the cultivation was started, 2 g/l of glucose and 2 g/l of casamino acid were added. After 24 hours of cultivation, the culture broths were examined for the production of Ala-IL-2, providing the data shown in Table 9.
Cells were harvested from the culture broth and IL-2 was extracted from the respective 12 g of frozen cells and purified to Ala-IL-2 by the same manner described in Example 5. 2.1 mg and 10.0 mg of Ala-IL-2were obtained from the cells grown in medium (1) and in medium (2), respectively.
TABLE 9______________________________________Metal salts Ala-IL-2 productivity______________________________________ -- 100FeCl.sub.3.6H.sub.2 O 20 mg/lMnSO.sub.4.4-6H.sub.2 O 10 mg/l 509______________________________________
REFERENCE EXAMPLE 1
Production of human IL-2-producing transformant (I)
(i) The human IL-2 gene-containing plasmid pILOT135-8 [Japanese Patent Application No. 225079/1983, filed on Nov. 28, 1983 and laid open under Japanese Patent Publication No. 115528/1985; see Example I (vii) thereof] was cleaved with the restriction enzyme HgiAI The 1294 bp DNA fragment obtained was rendered blunt-ended with T4 DNA polymerase and ligated with the EcoRI linker dTGCCATGAATTCATGGCA using T4 DNA ligase. The DNA obtained was digested with EcoRI to give a DNA fragment having the translation start codon ATG and the human IL-2 gene.
This DNA fragment was inserted into the plasmid ptrp781 [Nucleic Acids Research, 11, 3077 (1983)] digested in advance at the EcoRI-PstI sites, using T4 DNA ligase. The thus-obtained expression plasmid pTF1 has the translation start codon and human IL-2 gene downstream from the trp promoter (FIG. 5).
The plasmid pTF1 was cleaved with the restriction enzyme StuI, followed by ligation with the BamHI linker. The resulting plasmid DNA was treated with the restriction enzymes BamHI and EcoRI and the EcoRI-BamHI fragment was inserted into the λPL promoter-containing plasmid pTB281. The thus-obtained expression plasmid was named pTB285 (FIG. 6).
(ii) Escherichia coli N4830 was transformed with the plasmid pTB285 obtained in the above by the method of Cohen et al. [Proceedings of the National Academy of Sciences USA, 69, 2110 (1972)], whereby a transformant, Escherichia coli N4830/pTB285, was obtained.
REFERENCE EXAMPLE 2
Production of human IL-2-producing transformant (II)
Expression plasmid pTF4, which contains a human IL-2 structural gene, was isolated from E. coli DHl/pTF4 [European Patent Publication (laid open) No. 145390] in accordance with the method of Birnboim, H. C. et al. [Nucleic Acids Research, 7, 1513 (1979)]. Using said plasmid, E. coli PR 13 [J. Bacteorogy, 97, 1522 (1969)] was transformed in accordance with the method of Cohen, S. N. et al. [Proceedings of the National Academy of Science, USA, 69, 2110 (1972)]. The resulting transformant cells were inoculated into media (50 ml, pH 7.0) containing 1% Bacto-trypton (Difco Laboratories, USA), 0.5% Bacto-yeast Extract (same as above), 0.5% sodium chloride and 5 mg/l tetracycline hydrochloride in a conical flask of 200 ml capacity, and then cultured at 37° C. for one night. Each resulting culture liquid was then inoculated into a 200 ml conical flask which has a hollow containing a medium (30 ml) prepared by adding 1 mg/l vitamin B 1 hydrochloride to an modified M-9 medium, after which it was continuously cultured at 37° C. for 4 hours, at 30° C. for 4 hours and at 25° C. for 10 hours; a strain possessing an eminently high IL-2 producibility, i.e. E. coli C-4/pTF4, was selected.
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The present invention provides an improvement in a method for producing physiologically active proteins by cultivating Escherichia coli having an expression vector which contains a structural gene for such proteins at the downstream end of the translational starting codon. The method comprises cultivating the Escherichia coli in a medium containing (1) an iron ion source, a manganese ion source or a mixture thereof and (2) a nitrogen source derived from natural origin. The advantage of this method is an increase in the yield of physiologically active proteins substantially free of methionine (corresponding to translational starting codon ATG) at the N-terminus.
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FIELD OF THE INVENTION
[0001] The present invention is directed to a combine having a separator from which straw is expelled to a discharge assembly, an adjustable straw guide is associated with the discharge assembly. A motor adjusts the straw guide in response to signals from a controller.
BACKGROUND OF THE INVENTION
[0002] When one uses add-on straw choppers attached to combines, the chopped straw should be delivered along a cutting width in as uniform a weight distribution as possible over that width. A conventional straw chopper works with several knives attached to the chopper rotor. This chopper rotor rotates at high rpm and cuts the straw that is fed to it. The rotating knives pass through a stationary knife bar. At the same time, the chopper rotor must generate an air stream capable of blowing out the chopped straw. To achieve an even distribution by the chopper of the chopped straw from the machine channel width to the harvesting platform, feeding of the straw chopper must be done very evenly. Even feeding is also required with combines that operate with two independent discharge means.
[0003] In conventional straw walker combines, even feeding of the chopper generally does not present a problem because the loading of the straw walker is very even. In combines with rotating discharge systems, however, even feeding of the straw chopper is not always guaranteed. With these combines, the straw is conveyed by one or two helical threshing and/or separation rotors through a cylindrical and partially eccentric casing.
[0004] As a function of various material parameters, especially the material humidity, the number of revolutions about the threshing and/or separation rotor varies in rotor separation systems. As a result, the exit point from the threshing and/or separation rotor, and thus feeding of the straw, also changes. It is thus conceivable, in the case of a combine equipped with two separation rotors, that dry materials will be cast off more toward the middle, and humid materials more toward the outside. For a combine equipped with only one threshing and/or separation rotor, the material is accordingly cast further to the left or to the right.
[0005] In DE 43 13 841 A, an axial flow combine is described in which the crop material other than grain (straw) are fed to a straw chopper with a horizontal rotating shaft that is oriented transversely to the direction of movement. A straw guide means is provided between the outlet of the rotor and the inlet of the straw chopper. The straw guide can be rotated about a shaft located in its front area, to allow adaptation to the respective requirements. A motor is provided for remote adjustment of the straw guide device from the cab of the combine.
[0006] EP 0 685 151 A proposed a distribution means for a straw chopper of a combine that comprises a number of laterally contiguous guide plates. The guide plates are moved by servomotors that are coupled to sensors which detect the flight path of the exiting chopped material. The sensors work with light, ultrasound, or microwaves. As a result, compensation for crosswind effects is achieved.
[0007] The remotely adjustable straw guide of DE 43 13 841 A, can be considered to have the drawback that the combine operator is distracted from more important tasks during adjustment of the straw guide. The operator can inspect the results of adjustment only indirectly and very incompletely based on the ejected straw. This inspection requires observing via the rearview mirror.
[0008] The distribution assembly according to EP 0 685 151 A has the drawback that the sensors proposed therein are complicated and expensive. In addition, there is no possibility here to compensate for uneven feeding of the straw chopper at its inlet.
SUMMARY OF THE INVENTION
[0009] It is an object of the present invention to provide a simple system for transversely distributing chopped straw from the straw chopper.
[0010] According to a first aspect of the invention, a sensor determines the transverse distribution of the straw. The sensor is connected to a controller that controls a motor. The motor adjusts a straw guide arranged between the separator and the discharge assembly. The discharge assembly can be a straw chopper or another driven device for discharging straw, for example a rotating straw distribution disc.
[0011] In this manner, by means of appropriate control of the motor of the straw guide, one can automatically achieve as even as possible a feeding of the discharge assembly on its inlet side. By using sensor signals, the controller can regulate the motor to correctly position the straw guide and react to disturbances in the flow of straw. If two discharge assemblies are arranged laterally adjacent, approximately identical quantities of straw are fed to them through the straw guide. The type and attachment of the sensor is optional; for example, one can use the sensors known from EP 0 685 151 A.
[0012] The sensor for determining the transverse distribution of straw should be located upstream from the outlet of the discharge assembly. Consequently, cost advantageous sensors with a relatively small range can be used. They can be arranged at a relatively protected place inside the housing of the discharge assembly, in this specific case, the straw chopper.
[0013] The measurement values of the sensors are fed to the controller, which by means of a motor adjusts the straw guide to influence the transverse distribution of straw. The straw guide can be arranged upstream of the inlet of the discharge assembly; or alternatively, or in addition, it can be arranged downstream from the outlet of the discharge assembly. For this purpose, one can consider using, in particular, straw guide plates that are arranged under the distribution hoods. In this case the motor can move the straw guide means at the side adjacent to the discharge assembly. The straw guide plates are thus moved at the end facing the discharge assembly. As a result, it becomes possible to bring the straw guide plates into positions in which they are fed with chopped straw such that the chopped straw is distributed homogeneously over the cutting width of the combine.
[0014] The sensors are used to determine the transverse distribution of the straw. In order to avoid using expensive sensors with a relatively high range, it is possible to distribute several sensors over the width of the flow of straw that are each arranged so as to determine proximate straw flow intensity. Such sensors can operate on the basis of capacitance, or they can sense the sounds caused by impact of the harvest material on surfaces adjacent to the sensor. The last sensor type mentioned is already used to determine grain losses in combines. Another sensor type comprises an element that can be moved by the straw against a force generated, for example, by a spring or by gravity. The position of the element depends on the quantity of straw that flows by, and it is preferably determined by a potentiometer.
[0015] The sensor signals can be used by the controller not only to control the motor of the straw guide means, but also to control the combine separator. The separator can thus be operated at a speed at which the straw exits from the separator with as even as possible a width distribution. Alternatively, or additionally, it is also conceivable to adjust the guide plates of a separator casing, which influence the number of rotations of the harvested material within the separator, on the basis of the sensor signals to achieve a uniform width distribution of the straw at the outlet of the separator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1 is a semi-schematic side view of a combine.
[0017] [0017]FIG. 2 is a schematic top view of the straw chopper and the end region of the axial separators.
[0018] [0018]FIG. 3 is a schematic cross sectional view through the housing of a second embodiment of a straw chopper.
[0019] [0019]FIG. 4 is a schematic cross section through the housing of a third embodiment of a straw chopper with a straw guide means.
DETAILED DESCRIPTION
[0020] [0020]FIG. 1 shows a self-propelled combine 10 having a frame 12 , which is supported on the ground by wheels 14 . The combine 10 is propelled across a field by wheels 14 . A harvesting assembly 16 is coupled to the feeder house 18 that extends forwardly from the frame 12 . Crop material harvested by the harvesting assembly 16 is directed into the feeder house 18 which conveys the harvested crop material upwardly and rearwardly between the side sheets of the frame 12 into the combine 10 . The harvested crop material is processed inside the combine 10 by threshing and separating assemblies. The threshing and separation assemblies comprise a transversely arranged threshing cylinder 20 and a threshing concave 21 , to which the harvested crop material is first directed. The threshed crop material is then led to a stripping roll 23 and a transverse beater 22 . The beater 22 directs the threshed crop material to two axially arranged separators 24 . However, it is also conceivable to omit the transverse threshing cylinder 20 and to use an axially arranged rotary threshing assembly that is integral with an axially arranged separator. It is possible to use a single axial separator or two (or more) axial separators that are arranged next to each other.
[0021] The grain and the chaff, which are separated during the threshing process, fall onto at least one auger 30 , which leads the grain and chaff to a grain pan 33 . Grain and chaff falling from the axial separators 24 fall onto a shaking pan 32 , which conveys the grain and chaff to the grain pan 33 . The grain pan 33 conveys the grain and the chaff to cleaning shoe 34 , which is associated with a blower 36 , to facilitate separation of the chaff from the grain. Cleaned grain is led by an auger conveyor 38 to an elevator, not shown, that carries the grain to a grain tank 40 . A tailings screw 42 returns unthreshed head portions back to threshing processing via an additional elevator, not shown. Finally, the cleaned grain is unloaded from the grain tank 40 by means of a discharge system with transverse augers 44 feeding a discharge auger 46 .
[0022] All the above described systems are driven by an internal combustion engine 48 that is operated by an operator from a driver's cab 50 . The various means for threshing, conveying, cleaning and separation are located within the support frame 12 .
[0023] The stripping roll 23 and the beater 22 , together with a feed housing 52 , lead the threshed crop material from the threshing drum and concave 20 and 21 to the axial separators 24 . From the axial separators 24 , the harvested crop material other than grain (straw) are thrown out the back through outlet 64 . The straw falls by gravity onto the straw guide plate 62 and reach the inlet of a straw chopper 66 . The straw chopper 66 comprises a rotor 68 with flails 70 that are distributed over its circumference and along its length. The flails 70 are pivotally suspended on the rotor 68 . The rotor 68 rotates in housing 72 , about an approximately horizontally shaft transverse to the direction of movement. In cooperation with stationary knives 74 , the large straw parts are cut to smaller star parts. At the rear of the straw chopper 66 is arranged the straw spreader 76 , which comprises a number of straw guide plates 78 that are arranged laterally adjacent underneath a straw distribution hood 80 .
[0024] Two straw guides 82 are located next to each other between the outlet 64 of the axial separators 24 and the inlet of the straw chopper 66 . The guide plates 82 are approximately vertical and extend in the direction of movement. The relationship of the straw guides 82 , to the axial separators 24 and the straw chopper 66 is best illustrated in FIG. 2. Each of the straw guides 82 is located approximately in the middle of the outlet 64 of the respective axial separator 24 . They are mounted at the front end on an approximately vertical shaft 84 so they are pivotable on the support frame 12 of the combine 10 . Each is mechanically connected by means of coupling rod 86 to a respective motor 88 that can be operated to pivot associated the straw guides 82 about the shaft 84 . The farther the straw guides 82 are pivoted to the left by the motor 88 , the more crop material is led to the left area of the straw chopper 66 , and vice versa.
[0025] The motors 88 are electric motors that are connected to a controller 90 . The controller 90 is connected to three sensors 92 arranged at the bottom side of housing 72 of the straw chopper 66 . The sensors 92 , in the embodiment according to FIG. 2, are capacitive sensors that deliver signals which are a function of the quantity of conveyed crop material in close proximity in the housing 72 of the straw chopper 66 . Based on the output signals of the three sensors 92 , the controller 90 determines whether the left, the middle and the right side of the straw chopper 66 are fed with approximately the same quantities of straw. If not, the motors 88 are actuated until all the sensors 92 delivery approximately the same output signal. For example, if the outer sensors 92 present a lower signal strength than the middle sensor 92 , this means that too much straw has been directed to the middle of the straw chopper 66 . The controller 90 then intervenes and adjusts the straw guide means 82 in such a manner that more crop material is directed into the outer areas of the straw chopper 66 . As a result, the straw becomes distributed more uniformly over the width of the straw chopper 66 and also over the cutting width of the combine 10 .
[0026] If only a single axial separator 24 is present, a single straw guide 82 , or several smaller straw guides may be used. The several small straw guides would be distributed over the width of the outlet of the axial separator 24 , as represented, for example, in DE 43 13 841 A. It would also be conceivable to provide only one straw guide 82 that is installed so that depending on its position, the flow of straw is distributed farther to the left or right, or farther toward the inside or outside. For the last mentioned purpose, it is possible to consider using a guide element that divides the flow of material, and that has the shape of a so-called splitter which is moved in the direction of movement of the combine 10 .
[0027] [0027]FIG. 3 shows a vertical cross section through a straw chopper 66 that is equipped with another embodiment of the sensors 92 for determining the transverse distribution of the straw. The sensors 92 ′ according to FIG. 3 comprise a plate 94 which, at the upstream end relative to the flow of the material, is articulated to the housing 72 so it can be pivoted about a horizontal axis. The plate 94 is supported on the housing 72 by a spring 96 , and is mechanically coupled to a potentiometer 98 . The straw presses the plate 94 toward the housing 72 against the force of the spring 96 , so that the position—and thus the output voltage—of the potentiometer depends in each case on the quantity of straw that flows past the plate. The potentiometer 98 is electrically connected to the control device 90 . In the illustrated embodiment, three such sensors 92 ′ are distributed over the width of the flow of the straw.
[0028] [0028]FIG. 4 shows yet another embodiment of a sensor and of a straw guide. Here the sensor 92 ″ is a known knocking sensor like those used to measure grain loss in combines. Cut material that flows by generates, at the housing 72 and/or directly on the sensor 92 ″, acoustical oscillations that are detected by the sensor 92 ″. In this embodiment, the straw guide is not arranged upstream, as described above, but rather downstream of the straw chopper 66 . The straw guide is a straw guide plate 78 that is arranged under straw distribution hood 80 . The guide plate 78 is pivotally coupled to the distribution hood 80 by an approximately vertical shaft 100 . The straw guide plate 78 is connected at its front side with a motor 88 that can be driven to pivot the straw guide plate 78 about the shaft 100 . Naturally, several such straw guide plates 78 are distributed over the width of the straw chopper 66 . Either a common motor 88 is assigned to them, or the various straw guide plates or groups of straw guide plates are adjusted by several motors 88 .
[0029] The controller 90 receives output signals from the sensors 92 ″ that provide information regarding the quantities of straw flowing by the sensors 92 ″. The controller 90 controls the motor 88 , or the motors 88 , as a function of the output signals of the sensors 92 ″ such that at least an approximately uniform distribution of chopped straw is achieved over the cutting width of the combine 10 . For example, the position of the straw guide plates 78 would be adjusted to direct more chopped straw outwardly if the sensors 92 ″ indicate a greater flow of straw in the middle of the straw chopper 66 . It is also conceivable to move the straw guide plates 78 at their back sides as well. Furthermore, it is conceivable to use sensors of slope, and/or wind direction and strength, to control the motors of the adjustable straw guide plates. The straw guide according to the invention can be used not only in the described axial combines, but also in conventional combines having straw walkers.
[0030] Having described the illustrated embodiment, it will become apparent that various modifications can be made without departing from the scope of the invention as defined in the accompanying claims.
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A combine comprising a separator feeds straw to a discharge assembly. An adjustable straw guide is adjusted by a motor that is controlled by a controller. The controller receives signals from a sensor that senses the transverse distribution of the straw. The adjustable straw guide is positioned between the separator and the discharge assembly. The sensor is arranged to detect the straw upstream of the outlet of the discharge assembly.
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FIELD OF THE INVENTION
The present invention relates to a method and apparatus for the recovery of valuable conductive metal from transformers containing hazardous chemicals, especially polychlorinated biphenyls (PCBs), including a method of separating insulation paper from the conductive metal.
BACKGROUND OF THE INVENTION
The continual retirement of existing electrical power transformers poses a substantial disposal problem because of toxic materials contained therein, especially PCBs. Because of the presence of the toxic materials, the recycling of otherwise useful materials (especially copper and other conductive metal) contained therein is discouraged due to health, environmental and safety reasons.
Conventional methods of salvaging conductive material from electrical power transformers are generally very labor-intensive, expensive, and relatively unsafe. Presently, most reclaiming operations use either wire stripping or thermal-wire reclaimers to salvage the valuable conductive materials from the cores of discarded transformers. A wire stripping process, besides being labor-intensive, is very slow and is generally conducted in an environment with an elevated temperature and hazardous environmental atmosphere, which requires a worker to wear a tyvek suit, a respirator and other protective gear. In addition, reclamation by stripping usually results in low recovery efficiency. Also, as the process is boring, workers frequently lose concentration leading to accidents and injury.
A thermal-wire reclamation process utilizes temperatures which are sufficient to pyrolyse or "vaporize" the paper insulation from the surfaces of the conducting material. Unfortunately, the temperatures used for thermal reclamation are generally sufficient to cause deterioration in the quality of the metallic material. More importantly, the residual ash which remains after such paper pyrolysis can contain measurable quantities of hazardous chemicals, including PCDDs and PCDFs. When such ash is subsequently dislodged, a worker is potentially exposed to dioxins and dibenzo furans. In addition, stack effluent from furnaces associated with the thermal reclamation contains such undesirable compounds that are consequently spread throughout the surrounding environment. In addition, thermal reclamation processes generally produce a substantial environmental odor that can create a public nuisance.
SUMMARY OF THE INVENTION
The present invention is directed to a simple method and apparatus to chemically remove insulating paper from conductive materials found in the windings of electrical power transformers. The windings, after removal from the transformers, are separated from laminations and are shredded into relatively short length and then conveyed into a separation tank.
An aqueous solution in the separation tank that is relatively non-hazardous and non-flammable, strips the insulating paper away from the shredded conductive material. The solution preferably expands the paper causing the paper to peel or separate from the wiring. When the wiring is copper, the solution preferably includes approximately 2% to 4% metallic hydroxide (especially sodium or calcium hydroxide) and a surfactant. The surfactant reduces the time required to "wet" the paper and separate the paper from the wire. Normally, the paper separates in about five minutes.
After the paper separates, the lesser specific gravity of the stripped paper causes it to float to the surface of the separation tank where it is removed for disposal in an incinerator. Sparged air may be bubbled into the separation tank below the paper to aid in the separation process. Because of the inherently greater specific gravity of conductive metallic material relative to the specific gravity of the aquaeous solution, the former settles to the bottom of the aqueous solution in the separation tank where it can be augered away.
The separation tank solution is heated in the range from 120° F. to 212° F. (preferably greater than 170° F.) so as to accelerate the separation of the insulating paper from the conductive material with the result of reducing processing time and labor costs. The heating also aids in dissolving plasticizers in lacquers on the surfaces of the conductive material.
Air compression equipment is provided to produce compressed air for sparging into the separation tank to create turbulence in the aqueous solution such that large pieces of the paper insulating material and most of the lacquer residue associated therewith is buoyed to the surface of the aqueous solution as a froth where it is skimmed from the tank by automatic or manual operation.
The processes of loading of winding segments into the separation tank and the removal of skimmed paper and conductive metal are preformed on a generally continuous basis. A certain amount of small cellulose fibers separate from the insulating paper and become entrained in the solution. Such cellulose would quickly overburden the solution and eventually make the solution unusable. Consequently, a portion of the aqueous solution is continuously diverted to a separate flocculation tank. In the flocculation tank, a polyelectrolyte (such as gum arabic, polyethyleneimine, or the like) is added to the solution. The cellulose fibers are coagulated by the polyelectrolyte into a quickly settling flocculant. After the cellulose flocculant settles out of the solution in a subsequent settling tank, the remaining aqueous solution is returned with makeup water and caustic, as required to maintain a desired level, to the separation tank for further processing.
OBJECTS OF THE INVENTION
Therefore, the objects of the present invention are: to provide an improved method for salvaging conductive material from insulated wires and cables obtained from discarded electrical power transformers; to provide a method for chemically separating the conductive material from the insulation paper of the said wires and cables; to provide such a method whereby lacquer and other contaminants can be simultaneously removed from the surfaces of the said conductive material; to provide such a method and apparatus that are relatively low in cost, not labor-intensive, simple and economical to operate, conducive to continuous operation, relatively safe to operate in a work environment, provide efficient salvaging of the conductive material, are not prone to atmospheric contamination and are particularly well adapted for the intended use thereof.
Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention.
The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective exploded view of an electrical power transformer revealing an inner core with windings.
FIG. 2 is an enlarged perspective exploded view of the transformer inner core with windings that have been sectioned.
FIG. 3 is an enlarged and fragmentary cross-sectional view of the core windings, taken along line 3--3 of FIG. 2.
FIG. 4 is a perspective and partially schematic view of an apparatus utilized to separate core metal from insulative paper in accordance with the process steps of the present invention.
FIG. 5 is a schematic block diagram of the process for separating transformer core metal from insulating paper.
DETAILED DESCRIPTION OF THE INVENTION
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, 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 present invention in virtually any appropriately detailed structure.
The present invention is directed to a process for salvaging metal from an electrical power transformer, generally designated by the reference numeral 1, that is contaminated by PCBs or the like. As seen in FIG. 1, a lid 2 is removed from a tank 3 of the transformer 1 from which oil has been previously drained and a core 4 of the transformer 1 is removed from the transformer tank 3. The core 4 is initially cleaned using conventional methods (not shown) of draining, flushing and vapor-degreasing to remove surface oils, PCBs and the like. The core 4 includes central metal (normally iron) laminations 5 and conductor windings 6 that are wound about central openings of the laminations 5. The windings 6 are cut away in sections 7 from the laminations 5 using a band saw or other cutting instrument, as is illustrated in FIG. 2.
The windings 5 include conductive material in the form of long continuous wire or wire-like metal conductors 8 (normally copper but also sometimes aluminum or other conductors) which are coated with a paper material 9 for electrical insulating purposes, as is shown in cross-section in FIG. 3. The insulating paper 9 is normally coated with a layer of lacquer 10. In order to salvage and recycle the conductive material, it is necessary to effectively and efficiently remove the lacquer 10 and the insulating paper 9 from the conductive material 8 along with any contaminants that have soaked into insulating paper 9 and lacquer 10, especially PCBs.
After separation of the sections of windings 7 from the laminations 5, the windings are placed in a shredder 11 or other readily available equipment which is capable of shredding, commutating or the like, the windings 7 into smaller segments on the order of one-fourth to three inches in length including the conductor 8, paper 9 and lacquer 10. The purpose for such shredding is to expose more surface area such that the insulating paper 9 and the lacquer coatings 10 are more susceptible to subsequent processing as hereafter described and so that the winding material is less cumbersome.
Subsequently, the insulating paper 9 is physically separated from the conductive core material 8 of the windings 7. Following the shredding procedure, a large cleaning tank or hopper 12, containing an aqueous solution 13 therein, is utilized for preliminary cleaning and removal of the insulating paper 9 from the conductive material 8.
Interconnecting the lower end of the hopper 12 with a separation tank 16 is a cylindrical duct 17. An auger 18, having an outside diameter dimensioned slightly less than the inside diameter of duct 17, extends into the bottom of the hopper 12, as well as completely through and co-axial with respect to the duct 17, and terminates inside the separation tank 16. The auger 18 is power driven by its own motor such that the insulating paper 9, conductive material 8 and aqueous solution 13 can be turbulently transported as a slurry 19 from the hopper 12 to the separation tank 16 such that the aqueous solution 13 permeates between the insulating paper 9 and the conductive material 8, thereby contributing to some coarse separation of the insulating paper 9 from the conductive material 8 in the duct 17.
Across the bottom of the separation tank 16, a plurality of perforations 20 are provided whereby compressed air 21 sparged into the aqueous solution 13 in the tank 16. During the sparging process, the paper insulation 9 and the other light solids are swept to the surface of the aqueous solution 13 in the separation tank 16 as a froth 22 and the conductive material 8 settles to the bottom of the separation tank 16. A sloped surface 23 in the bottom of the separation tank 16 urges the conductive material 8 toward an auger 24 that, in turn, urges the separated conductive material 25 from the separation tank 16 where it is ready for further processing or baling for shipment to a smelter.
A pipe 26 flow communicates through one side of the separation tank 16 with the solution 13 therein. A portion of the aqueous solution 13 is pumped by a pump 27 through a flocculation tank 28, a settling tank 30, and then returned to a remainder of the solution 13 in the separation tank 16. A flocculation agent 35 from a reservoir 36 is selectively metered into the flocculation tank 28. A stirrer 32 is provided within the flocculation tank 28 to mix the flocculation agent 35 with the aqueous solution 13 extracted from the separation tank 16 and to retain any coagulants in suspension until routed to the settling tank 30. A drain 29 is provided whereby precipitant 34 collected in the bottom tank 30 can be removed from the bottom of the settling tank 30 for disposal or further processing.
Piping means such as the illustrated pipe 37 is provided such that the froth 22 containing paper 9 and the like can be skimmed, dipped or otherwise removed from the surface of the aqueous solution 13 in the separation tank 16 and directed into a solids separator 38, such that the insulating paper 9 and other light solids contained in the froth 22 are separated from a liquid portion thereof. The insulating paper 9 and other light solids separated from the froth 22 are then further dried by auger or filter presses or the like at the separator 38, and thereafter directed into an incinerator 39 for disposal. It is foreseen that the paper 9 may also be disposed of in a landfill approved for such material or, especially where PCB content of the oil in the transformer 1 is above 500 parts per million in a PCB approved incinerator. The liquid portion exiting the separator 38 is then routed by conduit 40 through an aqueous phase - oil phase separator 42 to substantially remove any residual PCBs and other oil-like contaminants contained therein by settling. An incinerator 43 suitable for burning PCBs or other acceptable disposal apparatus is used to appropriately dispose of PCBs and other undesirable contaminants separated from the aqueous solution 13 and the remaining solution 13 is directed back into the hopper 12 for further processing through a pipe 44.
In operation of the present invention, after transporting the slurry 19 including the aqueous solution 13 and the ground up windings 7 into the separation tank 16, the insulating paper 9, not already separated from the conductive material 8, is separated from the conductive material 8 through an oxidative hydrolysis reaction process. In the separation tank 16, mild caustic, such as 2% to 4% by weight sodium hydroxide or the like, and a wetting agent 48, such as 0.1% by weight trisodium phosphate, a sulfate or the like, combine to attack the fibers of the insulating paper 9.
For example, where the conductive material 7 is copper, the preferred aqueous solution 13 includes about 4% by weight sodium hydroxide with sodium hydroxide being continuously added from caustic storage 46 to the solution 13 as necessary to maintain the desired concentration. For other metals such as aluminum, a weaker caustic solution with longer residence time may be utilized to limit etching or dissolving of the metal by the caustic.
The introduction of the wetting agent 48 promotes the reaction since the wetting agent 48 allows more rapid penetration of the oil-soaked paper 9 by the caustic solution. Recycling efficiency is enhanced by using a wetting agent 48 which is not an organic molecule, which helps reduce the organic loading of the aqueous solution 13.
Normal residence time of the conductive material 7 in the aqueous solution 13 is about two to five minutes where the windings are copper and where the solution 13 includes about 4% sodium hydroxide and is preferably heated to approximately between 170° F. and 212° F.
It is theorized that the cellulose fibers in the insulating paper 9 swell due to the absorption of the aqueous solution 13 in the separation tank 16. As the swelling progresses, interfiber bonds in the insulating paper 9 are stretched. The caustic 46 initiates cleavage of these bonds and the paper 9 begins to float loose into the aqueous solution 13 of the separation tank 16. The freed bonds may contain acidic sulfur, which binds with oxygen atoms in the water or in entrained air bubbles to satisfy its requirement for charge stabilization and electrons. As a result, sulfuric acid is produced. The caustic 46 provides sodium ions which neutralize the sulfuric acid thereby providing additional oxygen atoms for the oxidation process.
Additional swelling occurs as the bonds continue breaking and more fibers swell. As the paper 9 literally expands along its width and length, the dimensions of the conductive material 8 remain relatively constant, and the paper insulation 9 simply peels away from the conductor 8. As the reaction progresses, caustic 46 is consumed. The concentration of the caustic 46 in the separation tank 16 is automatically maintained by conventional pH control systems or the like and controlled within an allowable pH range with a controller 49. A unique characteristic of the present invention is that the aqueous solution utilized contains no highly toxic, hazardous or flammable chemical solvents.
In addition to the oxidative hydrolysis of cellulose fibers in the insulating paper 9, another reaction taking place in the separation tank 16 is the destabilization of the lacquer coatings 10 by destruction of the coating plasticizers or phenolics where used therein due to the interactions thereof with the caustic 46 and oxygen.
To increase the paper separation rate, heat is applied to the aqueous solution 13 in the separation tank 16. In the environment of the aqueous solution 13 of the separation tank 16, the lacquer coatings 10 become very brittle. The additional heat facilitates the dissolving of the lacquer coating 10 into the solution 13. When the separation tank 16 is sparged with compressed air 21, the insulating paper 9 which has separated from the conductive material 8 and most of the lacquer coating 10 float to the surface of the aqueous solution 13 in the separation tank 16 where it can be easily skimmed away.
After separating out the paper 9 and other floating solids, which are substantially dried in the separator 38 and disposed of in the incinerator 39 which may be a PCB approved incinerator for use in conjunction with transformers having relatively higher PCB concentrations in the oil thereof, the liquid residue is then diverted through the liquid interface separator 42 to remove PCBs which are disposed of in an incinerator 43 constricted to safely burn PCBs. After removing residual PCBs, the remaining liquid is then directed back into the separation tank 16.
The conductive material 8, which has settled to the bottom of the separation tank 16 because of its greater specific gravity, is then augered along the bottom of the separation tank 16 and disposed of through the discharge 23.
During continuous processing, the aqueous solution 13 in the separation tank 16 eventually becomes overburdened with cellulose fibers such that further processing is inhibited. To prevent this overburdening, the excess cellulose fibers must be removed from the aqueous solution 13 in the separation tank 16. The cellulose fibers contained in the separation tank 16 are ideally suited to coagulation with a polyelectrolyte since the long filamentous, cellulose fibers provide large surfaces for bonding with the charged polymer of a polyelectrolyte. As a result, the cellulose fibers can be coagulated as a quickly settling flocculant.
To accomplish removal of cellulose fibers from the aqueous solution 13 in the separation tank 16 and thereby control the concentration thereof, aqueous solution 13 laden with cellulose is pumped out of the separation tank 16 and into the flocculation tank 28. A flocculation agent or polyelectrolyte 31 is added to the solution in the flocculation tank 28 and gently mixed with the stirrer 32. The mixed solution is then directed into the settling tank 30 where the cellulose flocculant settles out of the solution as the sludge 34. After settling, the aqueous solution 13 is then returned to the separation tank 16. The cellulose flocculant sludge 34 that settles to the bottom of the settling tank 30 is removed through drain 29 and appropriately later processed or disposed of as waste. With the return of the aqueous solution to the separation tank 16, additional water 57 and caustic 46 must be added to the separation tank 16 to readjust for solution and ingredients thereof which were lost due to paper absorption, sludge removal and evaporation.
As a specific example of an application of the present invention that is not intended to limit the scope of the invention, a solution of 4% (by weight) sodium hydroxide, 0.1% (by weight) trisodium phosphate and water was used to successfully separate insulating paper from copper. The solution was heated to a temperature of approximately 200° F. and the separation of the copper conductor from the paper took in less than five minutes. Substantially all paper, lacquer and other contaminants such as PCBs were removed from the resulting cleansed core metal by the process.
It is foreseen that mechanical agitation may also be utilized to help separate the paper 9 from the windings 7.
It is to be understood that while certain forms of the present invention have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of parts described and shown.
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A method and apparatus for salvaging conductive material from electrical power transformers. In the method, the transformer core is removed from the transformer casing and cut so as to separate laminations from windings. The windings with conductive materials and insulative paper are cut into relatively short segments. These segments are then subjected to an aqueous caustic solution with sparging for separating the conductive material from paper insulation and lacquer coatings thereon. The solution is treated with a coagulating or flocculating agent in a separate vessel to remove dissolved cellulose, processed to separate oil and PCBs therefrom and then returned to treat additional windings. The method is adapted to continuous processing.
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This application is a division of application Ser. No. 07/945,722, filed Sep. 21, 1992, now issued as U.S. Pat. No. 5,290,334.
BACKGROUND OF THE INVENTION
Glass manufacture involves the mixing of various batch ingredients, generally including silica sand, dry powders, granular oxides, carbonates, cullet (i.e., broken and/or recycled glass), and other raw materials (depending on the desired type of glass) and heating them to a temperature of about 1500° C., wherein they become molten and acquire a homogeneous nature. In general, substantial quantities of heat are required for the melting process, this heat generally supplied by combustion of fossil fuels. Because of the relatively poor heat transfer from the hot flue gases to the pool of molten glass, exhaust gas temperatures from the process are usually quite high, in spite of various types of heat recovery equipment employed. Also, pollutants of various types are emitted from the melting process along with the exhausted flue gases.
Two areas of improvement to the basic glass manufacturing process are desirable, namely (1) better energy efficiency, which can be achieved by preheating batch materials using exhaust gas heat with corresponding reductions in fuel requirements, or alternatively, more glass can be made with the same energy input to the melting process; and (2) reduced pollution emissions, wherein various types of gas absorption and/or dust filtration systems can be implemented to satisfy government regulations. The prior art has long investigated improvements in these two areas, and as a result, improvements have been implemented in glass manufacturing facilities in various ways in both production and pilot plants.
The present invention relates to a novel means of achieving both of the above improvements in one system and to the novel arrangement which achieves a functioning system incorporating the improvements.
With respect to better energy efficiency, the glass industry has always been concerned with the energy efficiency of the glass melting process, and has routinely implemented equipment for preheating of combustion air with waste heat from exhaust gases. For over 35 years, interest has also existed for preheating of batch materials. Initial interest was directed more towards presintering the glass batch to promote certain chemical reactions between the glass making materials, as opposed to utilizing waste heat per se. The prior art includes a large variety of methods for heating glass batches, utilizing both direct and indirect flue gas contact and batches in raw powder or agglomerated form.
Preheating of glass batch is desirable for three major reasons:
(1) Improved overall thermal efficiency of the glass melting process utilizing waste heat from exhaust gases. About half of the theoretical energy needed to produce container glass from conventional glass-making raw materials is required to heat the raw materials up to 750° C.
(2) Reduced volatilization and resulting pollutants as a consequence of lowering melting temperatures and prereaction of batch materials.
(3) Faster and more uniform melting, especially where agglomerated batch is utilized.
With respect to pollution capture, the nature and amounts of pollution emissions from glass melting furnaces vary considerably within the glass industry, depending upon the type of glass and production method used. Generally, pollutants fall into two general categories, particulate and gaseous. Particulate pollutants can be ash components in the fuel, carryover of batch material, or products of condensation of material volatilized from the glass melt. The latter is the most prevalent and the primary particulate from soda-lime glass furnaces is Na 2 SO 4 resulting from Na and SO 2 volatilized from the glass melt. Particulate emissions from glass furnaces can be reduced somewhat by reducing temperature and as a result volatilization from the surface of the molten glass. The use of preheated glass batch permits a lowering of the furnace temperature and in itself decreases particulate emissions.
Particulate material from glass melting furnaces is extremely difficult to capture owing to its small size, typically 0.2-0.7 μm. Generally, electrostatic forces are required to capture particles of such small size. In fact, electrostatic precipitators have become the glass industry standard for capture of particulate matter.
Gaseous emissions from soda-lime furnaces include sulfur and nitrogen oxides, with sulfur oxides resulting primarily from sulfur components in the batch material and nitrogen oxides resulting from oxidation of N 2 contained in combustion air. Conventional technology for reduction of SO 2 emissions are lime based wet scrubbers. Both these and electrostatic precipitators are add-on devices to the glass manufacturing process which carry significant penalties to the production economics.
Conventional equipment for nitrogen oxide emission reduction has not yet found widespread use. A lowering of furnace temperature should result in reduced nitrogen oxide emissions, so batch preheating would have a beneficial effect here also.
Batch preheating combined with pollution reduction is disclosed in U.S. Pat. No. 4,338,113, relating to a direct/indirect heat exchanger, wherein hot flue gases are directly contacted with durable granular material (such as gravel) in a filter bed. Heated granules are transported to a mixing drum where they are contacted with batch materials, thereby heating the batch materials and cooling the granules. Cooled granules are returned to the filter bed.
The prior art has recognized the potential for simultaneous pollution reduction with batch preheating, but not only from source reduction, as mentioned above. Generally, it has been suggested to use batch preheating in schemes where exhaust flue gases are brought into direct contact with batch materials. Then the batch, whether in raw, loose form or agglomerated form, is expected to function as a mechanical collection site for particulate pollutants. Also, certain components of the glass batch (typically soda ash for soda-lime glass) are chemically reactive with gaseous phase pollutants (notably SO 2 for soda-lime glass) and the gas solid reaction can effectively remove the pollution. While SO 2 reductions have been easily achieved, actual attempts at simultaneously preheating a glass batch and reducing particulate pollution have typically failed.
Hence, there remains a need in the art for a workable arrangement for both preheating a glass batch and simultaneously reducing particulate pollution.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a method and apparatus for glass manufacture which provides simultaneous pelletized glass batch preheating and pollution reduction of exhaust gases from the glass manufacturing process.
It is another object of the invention to provide a method and apparatus for glass manufacture, as above, which enables the use of pelletized glass batch for filtration of particulate material from exhaust gases.
It is yet another object of the invention to provide a method and apparatus for glass manufacture, as above, which enables easy conversion of a glass batch preheater to use in filtration, and vice versa, thereby enabling shutdown and maintenance of either without substantially affecting glass production.
These objects are achieved by a method for glass manufacture having improved energy efficiency and reduced pollution emissions, wherein first and second beds of pelletized glass batch are provided. Exhaust gases from the melting furnace are conveyed to a preheater which contains the first bed. The exhaust gases pass over the first bed, thereby heating the pelletized glass batch which is thereafter fed to the furnace. The exhaust gases exiting the preheater are then electrostatically ionized and conveyed to a filter which includes the second bed of pelletized glass batch. The ionized exhaust gases are filtered by passing over the second bed, which is electrically polarized to aid in removal of particulate matter from the exhaust gases.
The first bed must move either continuously or intermittently to provide raw material feed to the melting furnace. This movement in turn causes abrasion of the glass batch pellets against each other and causes the formation of particles which are entrained in the exhaust gases as they pass over the first bed. To remove these entrained particles, a separator, such as a cyclone dust collector or equivalent device, may be used to collect these particles prior to ionization of the exhaust gases. The particles resulting from abrasion can be removed by the cyclone because they are much larger than the particulate matter from the melting furnace. Cyclones are unable to remove a significant portion of the latter.
Another feature of the invention is the ability to switch the function of the preheater and the filter. They can be of identical modular construction using identical equipment, such that the movable first bed can be made static, and the static second bed can be made movable. This permits periodic maintenance of either module without interrupting glass production, by temporarily shutting down one module and maintaining use of the other. For environmental purposes, it is preferable to shut down the preheater module and maintain filtration of the exhaust gases. However, preheating can be maintained and filtration temporarily halted where process conditions and local environmental regulations permit.
It is another object of the invention to provide an apparatus for carrying out the method of the invention.
It is yet another object of the invention to provide a module for preheating pelletized glass batch and for filtering exhaust gases from a glass melting furnace. The module can thus function as either a preheater or as a filter. The module includes an electrically conductive modular shell which is grounded. An electrode is positioned in the modular shell and is spaced from the inner wall of the modular shell. When the electrode is connected to a high voltage power source, an electric field is maintained between the electrode and the grounded module shell. The module also includes discharge means for discharging the pelletized glass batch and means for controlling the flow rate of the batch through the module.
BRIEF DESCRIPTION OF THE DRAWINGS
For a full understanding of the invention, the following detailed description should be read with reference to the drawings, wherein:
FIG. 1 is an overall process flow diagram of the glass manufacturing process of the invention;
FIG. 2 is a flow diagram for one embodiment of the preheater/filter system of the invention;
FIG. 3 is a cut away side elevation view of a preferred embodiment of a module forming the preheater/filter system of the invention; and
FIG. 4 is a graph of collection efficiency vs. electrostatic collection parameter K.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiment of the invention illustrated in FIGS. 1, 2 and 3 is adapted for soda-lime glass, but the invention also encompasses manufacture of other glass types, such as borosilicate glass, etc.
FIG. 1 is an overall process flow diagram for the invention. The glass manufacturing process, indicated generally by the number 10, includes a pelletizer 11. Glass batch materials are directed into the pelletizer 11, which can be constructed of conventional, commercially available equipment. Water is added and pellets are formed by mechanical action. Certain modifications to normal glass batch specifications may be required for pelletizing, such as the addition of a binder (burnt limestone or caustic soda) and/or a requirement of finer than normal batch material sizes. Wet pellets are then directed to a suitable pellet dryer 12 where at least about 50% by weight, and preferably between about 70 and 80% by weight of pellet moisture is removed. The dryer can be of conventional belt type design. Failure to provide dry pellets to the downstream preheater will result in fusion of pellets into a solid mass. The source of heat for the dryer can be glass furnace exhaust gases or air heated by some other means.
During drying, the pellets can fuse at their contact points and mechanical action is required to break them into individual pellets. This is accomplished in normal material handling between the dryer 12 and the charge hopper 13.
Dried pellets are conveyed by tote bins, bucket elevator, or some other suitable means to the charge hopper 13 at the top of preheater/filter system 14. The charge hopper holds pellets and supplies them to the preheater/filter system as required. Cold, dry pellets are moved through the preheater and filter modules (not shown) of the system 14 where they capture pollution from and are heated to the desired temperature by exhaust flue gases from the regenerator or recuperator 15. Hot gases from the regenerator/recuperator 15 may first be cooled by a water evaporative quencher 16 if the temperature at this point is inconsistent with reliable pellet preheater/filter operation. Quencher 16 may also be used to take over cooling of the exhaust gases if the preheater is shut down. Clean gases are exhausted to the atmosphere. Hot pellets are combined with cullet in the mixer 17 and then introduced to the melter 18 via charger 19.
Generally, cullet is added in amounts of between about 10 and about 20% by weight of the total feed to the furnace. Alternatively, the feed may be up to 100% cullet depending on the type of glass produced. One skilled in the art can determine the amount of cullet necessary for a particular glass product.
FIG. 2 illustrates the flow diagram for a preferred embodiment of the preheater/filter system 14. Hot flue gases from the regenerator/recuperator 15 (or possibly the evaporative quencher 16) are mixed with cooled recycled flue gases and directed to the hot diverter valve 20. In the position shown in FIG. 2, these hot gases are directed to ionizer 21A and then subsequently to module 22A, the preheater module. The ionizer 21A includes a high voltage cathode electrode and grounded anode electrode. The ionizer 21A creates negative ions which attach to passing dust particles in the dust stream. Hot gases and electrically charged dust particles pass through the preheater module 22A where they are contacted with the pellets which fill the module.
Cold, dry pellets from charge hopper 13 are continuously moved by gravity through the module 22A as controlled by wiper bar feeder 23A. The feed rate of pellets through the module is ultimately controlled by the batch feed requirements of the melter. A significant portion (typically 60-80%) of the incoming dust particles are deposited onto the pellets and are accordingly removed from the flue gas. Also, at least about 50% by weight and preferably between about 75 % and 80% by weight of the SO 2 present in the flue gas is removed by contact and chemical reaction with the soda ash in the pellets. Simultaneously, the pellets are heated as they flow through the module 22A with hot pellets being discharged through the wiper bar feeder to the mixer 17A.
Flue gases are cooled while they are in module 22A, but conditions are maintained such that they are not cooled to temperatures below their water or acid dew point, otherwise condensation would occur and interfere with operation of downstream equipment. The temperature of the cooled flue gases is generally from about 100° C. to about 400° C., desirably from about 150° C. to about 300° C., and preferably from about 175° C. to about 225° C.
As the pellets move through the module 22A, coarse dust particles are created by abrasion of the relatively fragile pellets. These particles become entrained in the flue gas exiting the module 22A. In fact, the module can exhibit a negative collection efficiency with regards to total particulate material, the outlet mass flow rate of particulate material exceeding the inlet. However, the inlet particulates are of submicron sizes, while the entrained dust particles generally have a diameter greater than 10 μm and hence are more easily removed by mechanical means such as a cyclone separator, as described hereinafter.
Warm flue gases exiting module 22A are then directed to the warm diverter valve 24 and subsequently to fan 25 which provides the underpressure required for gases to flow through module 22A. From the fan 25, gases are split and a portion as determined by valve 26 are mixed with the inlet hot flue gases and recycled back to module 22A. This recycle gas tempers the hot flue gas so that temperatures are not excessive, and also increases the velocity of gases in module 22A which has the effect of improving heat transfer rate and dust capture efficiency.
The remainder of the flue gases (with a mass flow rate equal to the incoming hot flue gas) are passed through a cyclone dust collector 29 or equivalent device, where the coarse dust particles created by pellet abrasion in module 22A are removed. The purpose of the cyclone 29 is to prevent these coarse dust particles from entering module 22B, the filter module. From the cyclone 29, warm flue gases are directed by hot diverter valve 20 to ionizer 21B and subsequently module 22B, the filter module. Ionizer 21B is identical to ionizer 21A in both construction and function. Its purpose is to ensure that a high percentage of the dust particles entrained in the warm flue gas are electrostatically charged to a high degree. The purpose of module 22B is to remove dust particles with a high efficiency. The temperature of the ionized exhaust gases entering module 22B is less than about 450° C. and preferably less than about 250° C.
Wiper bar feeder valve 23B is closed, preventing the flow of pellets. Module 22B is therefore a static bed with no pellet motion. In addition, the high voltage electrode 27B is energized, which electrically polarizes the pellets in collector module 22B. This dramatically improves the dust reduction efficiency of the module to a level of at least about 50%, desirably up to about 80%, and preferably from about 90% to about 95%, by weight. It should be noted that the duplicate high voltage electrode 27A in preheater module 22A cannot be energized. The electrical conductivity of pellets is strongly dependent on temperature, and at the higher pellet temperatures in this module, high voltage cannot be maintained without excessive electrical power requirements.
Cleaned flue gases exit the filter module 22B and are directed by warm diverter valve 24 to fan 28, which provides underpressure to draw the gases through collector module 22B and cyclone 29. Gases are ultimately discharged from fan 28 to the atmosphere.
The system operates in this way for a period of time determined by the ability of filter module 22B to function effectively. Two criteria may dictate the operating period. First, dust accumulation in the static bed of module 22B will eventually fill the interstices of the pellets and flue gas pressure drop will increase to excessive levels. Second, if the bed remains static for too long a period, the pellets will fuse together and prevent subsequent removal.
To prevent this, at a determined time interval, the functions of the two modules 22A and 22B are effectively reversed according to the following sequence:
Wiper bar control valve 23A is closed, rendering module 22A a static bed. Mixer 17A is provided with sufficient capacity so that batch supply to the melter will not be interrupted.
The system runs this way for a short period of time (about 5-10 minutes), during which any free coarse dust in module 22A is blown off and carried downstream. The hot diverter valve 20 and warm diverter valve 24 are both reversed, directing hot flue gases to module 22B and cooled flue gases to module 22A. Shortly thereafter, wiper bar control valve 23B is opened, allowing pellet flow through module 22B.
After a suitable period of time, when module 22A has cooled enough and module 22B has heated enough, the high voltage electrode 27B is deenergized while simultaneously the high voltage electrode 27A is energized. At this point, the function of the two modules are reversed, with module 22B becoming the preheater module and module 22A becoming the filter module.
A detailed illustration of the module design is made with reference to FIG. 3. Since this module design is descriptive of both modules 22A and 22B, the letter designations "A" and "B" will not be used. Pellets fill the module from charge hopper 13 through infeed pipes 30 which distribute the pellets across the cross-section of the module.
Infeed pipes 30 extend somewhat into the interior of the module. This creates a void region at the top of the module which then serves as a gas outlet plenum for gas exiting the top of the pellet bed. An outlet duct is provided at the side of the module. A sufficient number of infeed pipes are provided to assure good pellet distribution across the cross-section of the module.
The cylindrical module shell 31 contains the pellet bed and functions as a ground electrode. It must be electrically conductive and connected to an electrical ground potential. Discharge cone 32 is connected at the bottom of the shell 31 and functions to provide uniform flow of pellets through the module. Wiper bar control valve 33 is connected to the discharge pipe 34. The angle of deflection determines the pellet flow rate through the module. Pellets fall into mixer 17 where cullet is introduced via cullet infeed pipe 35. The pellet-cullet mixture flows by gravity to the charger 19 via discharge pipe 36. A chunk-breaker 37 is provided in discharge cone 32 to break up any pellet agglomerates which may have formed in the module and which could block pellet flow through the discharge pipe 34 and wiper bar control valve 33.
Flue gas enters the module 22 via inlet pipe 38. Inlet pipe 38 is preferably a conduit concentric with the module shell 31 and which also functions as a ground electrode. In this preferred arrangement, the inlet pipe 38 must be electrically conductive and is connected to an electrical ground potential. The inlet distribution nozzle 39 connects to the bottom end of the inlet pipe and forms a diverging conical nozzle to allow the inlet flue gases to enter the pellet bed at velocities sufficiently low enough to result in only moderate pressure drop.
Flue gas exits the inlet distribution nozzle 39 and flows upward through the pellet bed which fills the region between the module shell 31 and inlet pipe 38. A high voltage electrode 40 is concentrically suspended between the module shell 31 and inlet pipe 38. Electrode 40 is an electrically conductive cylinder and extends from a position somewhat above the upper end of the distribution nozzle 39 to a position somewhat below the bottom edge of the gas outlet pipe 41. The electrode 40 is mechanically supported by insulators 42 and connected to a suitable high voltage power supply 43.
Electrode 40 may comprise an annular member or a plurality of rods forming a concentric ring. A concentric electrode is preferred, since it provides for the greatest area for generation of the electrical field. Pelletized glass batch is provided in the annulus between the electrode 40 and the module shell 31, and in the annulus between the exhaust gas inlet pipe 38 and the electrode 40. Other electrode arrangements are also feasible, such as a single solid electrode arranged either concentrically or asymmetrically within the module shell 31. In these other electrode arrangements, inlet pipe 38 need not be electrically conductive, nor extend into the module shell 31.
Gases enter the pellet bed through the discharge nozzle 39 which provides a very large opening size. The gas incident surface can be further increased by including inverted "V" channels 44 in a spoke-like arrangement between the discharge nozzle 39 and the module shell 31. The incident surface of gas contact with pellets is constantly renewed by the pellet motion through the module. Pellets are discharged through the discharge cone 32, and the walls of the cone are desirably at an angle steep enough to assure uniform pellet flow across the cross-section of the module.
The active region for electrostatic filter operation is defined by the high voltage electrode 40. All of these structures must be electrically conductive in order to function as effective electrodes, the gas inlet tube 38 and module shell 31 being at electrical ground potential. The height of the electrode 40 (and correspondingly this portion of the module) will be determined by both the electrostatic filter operation and the preheat operation. Preferably, this height is between about 1 and about 3 meters. The high voltage electrode is suspended from above via suitable ceramic insulators 42. There should be no other connections from the electrodes to the module, otherwise electrical short circuiting will occur.
The diameter of the module is determined by the desired gas flow throughput in order to maintain optimum gas velocities in the bed. It is conceivable, and within the scope of the invention, to use a series of modules. This may be required if the design criteria for a single module requires a diameter of greater than about 3.5 feet. Generally, the module is sized by specifying a superficial velocity and calculating the square footage of the bed necessary to handle the exhaust gas output from the furnace at the specified velocity. The superficial velocity of exhaust gas through the bed is generally between about 0.2 and about 1.0 m/sec, preferably between about 0.3 and about 0.7 m/sec, and preferably between about 0.4 and 0.6 m/sec.
The wiper bar control valve 23 is periodically opened by a pneumatic operator to a predetermined position to allow pellet flow. The frequency of opening is determined by batch demand to the furnace. The chunk-breaker is activated simultaneously to assure pellet flow.
Use of electrostatic granular bed (EGB) filter technology for capture of particulate matter has been known in the art using gravel as the filtration media. The substitution of pelletized glass batch material for gravel in the filter media, however, was not believed feasible for several reasons.
First, as described previously, pelletized glass batch is very fragile compared to gravel. When subjected to motion through the filter bed, abrasion between pellets creates dust particles. The flue gas flowing through the bed will entrain these particles into the outlet gas stream, thus negating the desired reduction in particulate emissions of the filter. It has been discovered that only a static bed of pelletized glass batch can exhibit the desired particulate emissions reduction.
Second, the electrical conductivity of pelletized glass batch is strongly dependent on temperature. At normal flue gas temperatures for glass furnace exhaust gases, the electrical conductivity of the pellets precludes the economical application of voltage to the bed. Application of this voltage is a fundamental requisite of proper electrostatic granular bed operation. While flue gases could be cooled upstream of the pellet bed in order to achieve the desired operating temperature, this would negate the desired pellet preheating.
Third, the pellet bed must be a moving bed while it is being heated. Since the pellets necessarily include water-soluble binder materials and other chemically reactive components, thermal excursions in a static bed of pellets will result in pellet fusion at the contact points. Subsequently, the pellets would be incapable of being removed from the bed.
Fourth, a pellet bed designed for preheating would be much smaller than an electrostatic pellet bed for particulate capture. While a series combination of a preheater bed followed by a filter bed could be used, their functions could not be interchanged as in the present invention.
Fifth, the art had recognized that particulate capture for pellet beds of reasonable design are quite poor, generally in the range of 30-40%. It has also been discovered that this particulate capture can be dramatically improved by the inclusion of an electrostatic ionizer upstream of the pellet bed. The ionizer functions to impart electrostatic charge onto the dust particles. Electrostatically charged dust particles experience an attractive force to any sufficiently electrically conductive surface. Hot pellets are sufficiently electrically conductive to exhibit such behavior. The effect of such an attractive force is to increase the capture of electrostatically charged dust particles compared to uncharged particles. For glass furnace exhaust gases, the particulate reduction can be improved significantly, from 30-40% up to 70-80% by weight.
This becomes an important effect in the design of a preheater/filter system. Optionally, the design particulate reduction efficiency of the system will be at least about 95%. FIG. 4 shows that this efficiency is related to the electrostatic collection parameter K, which in turn (all other parameters being equal) is related to the pellet collection surface area. Pellet surface can be increased only by supplying more pellets, or in other words, a larger piece of equipment. A stand alone electrostatic pellet filter of 95% efficiency would have to be 50% larger than one of 87% efficiency.
To achieve an overall efficiency of 95%, an electrostatic pellet bed filter will require a design efficiency of only 87% if it is preceded by another filter of 63%. Thus substantial savings can be realized by improving the collection efficiency of the preheater bed. In fact, this allows the design to proceed in such a way that the preheater bed and the filter bed can be identical, allowing their functions to be periodically reversed as described above.
Improvement of the particulate capture of the preheater bed can be realized using an upstream ionizer. This ionizer could be of identical design to that incorporated in the electrostatic pellet bed filter, so again the concept of identical equipment holds. Two factors are significant with respect to design of the ionizer. First, effective corona discharge in flue gases (which is essential for proper ionizer operation) can only be maintained up to temperatures of about 450° C. Second, both heat transfer rates and particulate capture rates in the preheater bed are improved with increased gas flow rate. This is exactly the opposite of electrostatic pellet bed filters, where particulate capture rates are improved with decreased gas flow rate.
This design disparity can be reconciled by the implementation of recycled gas flow, where a portion of the cooled gas exhausted from the preheater bed is recycled back to the inlet of the preheater bed. This cooled gas tempers the hot incoming gas to temperatures consistent with effective ionizer operation, and improves the heat transfer and particulate capture rates in the preheater bed.
Recycled gas flow also has the desired effect of allowing control of the preheater bed outlet gas temperature. In cases where gas velocity is low and pellet flow rate is high in the preheater bed, the gases can be cooled to below acid dew point with resulting adverse effects on downstream equipment. By recycling gas, the outlet gas temperature can be maintained above the acid or water dew point.
The aspect of particle entrainment from the preheater bed is a significant problem addressed by the invention. While the preheater bed with upstream ionizer will exhibit some 70% reduction in the incoming submicron particulate, blow-off of coarse particle dust from the bed can reduce the overall efficiency to zero or even to negative efficiencies. However, the entrained dust particles are of a very large size and easy to capture in conventional mechanical devices, such as a cyclone. For this reason, a cyclone collector or equivalent device may be positioned between the preheater bed and the filter bed to capture the coarse dust. With a cyclone, the particulate loading into the filter bed will be some 70% less than the particulate loading into the preheater bed.
The duplicate module arrangement allows for a significant operating feature of the process. Inevitably, such equipment will require internal maintenance at some time during operation of the glass furnace. It is highly desirable to maintain reasonable pollution reduction during any maintenance period. The inclusion of the evaporative quencher in the hot flue gas stream allows the flue gas to be cooled to temperatures consistent with electrostatic pellet bed filter operation even when the preheater function is disabled. Then one of the modules can be completely isolated from the flue gas stream and drained of pellets to allow internal maintenance. The other module can remain in operation as a pollution control system. The pellet preheat function would be lost during this period, but this would be a tolerable sacrifice to production efficiency. Alternatively, the preheat function could be maintained while the filter module is serviced. The latter arrangement may be used in situations where local environmental regulations and/or process conditions permit unfiltered flue gas emissions.
The operation of the modules as a preheater requires exposure to relatively high temperatures, ca. 450° C., exposure to a non-uniform vertical temperature profile, exposure to heating and cooling cycles, and exposure to a relatively high loading of dust, both submicron particulates formed from the glass melt and coarse particle dust blown off from the bed. The primary concern becomes one of maintaining open gas inlet and outlet passages to the pellet bed. The batch material consists of water-soluble species and chemicals which can form eutectic mixtures at relatively low temperatures. These eutectics can form liquid phases which when combined with dust can plug conventional louver structures used in granular bed filters. Because of this a countercurrent shaft preheater/filter design is desirable.
Although the present invention has been described in connection with preferred embodiments of the invention, it will be appreciated by those skilled in the art that additions, substitutions, modifications and deletions not specifically described, may be made without departing from the spirit and scope of the invention as defined in the appended claims.
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A method and apparatus for glass manufacture is described having batch preheating and reduced pollution emission. The apparatus includes two modules containing pelletized glass and/or cullet. One module functions as a pelletized glass preheater, and the other as a filter for removing pollution emissions from furnace exhaust gases. The modules are switchable, such that the preheating module can be converted to a filter module, and the filter module converted to a preheating module, thus allowing periodic cleaning and routine maintenance.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. §119(e) of U.S. provisional application Ser. No. 60/557,642, filed Mar. 30, 2004, entitled Trim System.
BACKGROUND
[0002] The present invention relates generally to suspended ceiling systems, and more particularly, to a suspended ceiling system which includes trim elements along its perimeter. The trim elements of the invention can be utilized in floating ceiling systems, in order to bridge the construction clearance between a perimeter grid element and a soffit or soffit-type wall.
[0003] Suspended ceilings often have a plurality of perimeter grid elements which extend parallel to the wall perimeter but are terminated at a location spaced from the wall. One way to eliminate this space is to construct a soffit which extends down from the primary building structure above to the level of the ceiling perimeter. However, in some instances, due to the difficulties of constructing and leveling a soffit, a construction clearance may be visible between the soffit and perimeter grid elements.
[0004] One solution of eliminating the visibility of the construction clearance between a soffit and a perimeter grid element extending parallel thereto is to attach a conventional L-shaped beam member, or right angle, to the soffit. In this well known configuration, the upper leg of the wall angle is placed in abutting relation and is fixedly attached to the soffit. The lower leg of the wall angle extends in a direction perpendicular to the upper leg and fits under the flange of a perimeter grid element. As previously mentioned, due to construction imperfections, the soffit is rarely level across its entire span. As a result, gaps are frequently visible between the wall angle and soffit, resulting in a nonuniform, undesirable appearance at the ceiling perimeter. To eliminate these gaps, using the L-shaped wall angles would require custom sizing. Also utilizing a wall angle having a wide lower leg may be aesthetically undesirable if its width is greater than the flanges of the grid elements which are visible at the interior of the room.
[0005] The present ceiling system provides a solution for covering any construction clearance between a soffit and a perimeter grid element where such grid element extends parallel to the soffit. At the same time, the ceiling system preserves the aesthetic appeal of the ceiling system and eliminates the need for custom wall angles.
SUMMARY
[0006] The ceiling system of the invention includes a grid framework having perimeter grid elements spaced from, and preferably running parallel to, a soffit-type wall. A construction clearance is provided between the perimeter grid elements and the soffit. The ceiling system further includes a trim strip which conceals the construction clearance between the perimeter grid element and the soffit. The trim strip can either be mounted onto the perimeter grid element or attached to the underside of a soffit.
[0007] There are several advantages of the system of the invention including the ability of the trim strip of the invention to compensate for construction inaccuracies in the construction of the soffit. Also, the system is economical to use, as it eliminates the cost of manufacturing custom wall angles or specials. The invention possesses many other advantages, and has other purposes which may be made more clearly apparent from consideration of the example embodiments. The example embodiments are shown in the accompanying drawings and form part of the specification. The example embodiments will now be described in detail for the purpose of illustrating the general principles of the invention, but it is to be understood that the description of the example embodiments should not be considered limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a cross-sectional view of a trim strip in accordance with an example embodiment of the invention mounted onto a perimeter grid element having a screw-slot panel supporting flange which is open on the lower side thereof, the trim strip being positioned to cover the construction clearance between the soffit and grid element.
[0009] FIG. 2 is a perspective view of the example embodiment of FIG. 1 .
[0010] FIG. 3 is a perspective view of the example embodiment of FIG. 1 further showing the trim mechanically attached to the underside of a soffit.
[0011] FIG. 4 is a cross-sectional view of a trim strip in accordance with the example embodiment shown in FIGS. 1-3 , the trim strip being mounted onto a grid element having a bolt-slot panel supporting flange which is open on the lower side thereof.
DETAILED DESCRIPTION
[0012] The following description of the invention is provided as an enabling teaching of the invention in its best, currently known embodiment. Those skilled in the relevant art will recognize that many changes can be made to the embodiments described while still obtaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be obtained by selecting some of the features of the present invention without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present invention are possible and may even be desirable in certain circumstances and are a part of the present invention. Thus, the following description is provided as illustrative of the principles of the present invention and not in limitation thereof, since the scope of the present invention is defined by the claims.
[0013] Referring now in greater detail to the Figures, wherein like numerals refer to like parts throughout the drawings. FIGS. 1-4 illustrate a trim strip, also referred to herein as a trim member, in accordance with an example embodiment. The trim member 20 has first and second opposed legs, 22 and 24 respectively, and an intermediate section 26 integrally connecting the first and second opposed legs 22 , 24 . The first leg 22 , second leg 24 and intermediate section 26 form a grid receiving channel 28 . The grid receiving channel 28 is dimensioned to conform generally to a panel supporting flange of a perimeter grid element so that the trim member can be mounted onto an adjacent grid element as described in greater detail below.
[0014] FIGS. 1-3 illustrate a perimeter grid element, available from Armstrong World Industries, Inc., having a screw-slot panel supporting flange 12 which is open on the lower side thereof. FIG. 4 illustrates a second type of perimeter grid element, also available from Armstrong World Industries, Inc., having a bolt-slot panel supporting flange 12 ′ which is open on the lower side thereof. As shown in each of FIGS. 1-3 , the geometry of the grid receiving channel 28 of the trim strip 20 conforms substantially to the geometry of a first portion 14 of the screw slot flange 12 . As a result, the trim element 20 , via the grid receiving channel 28 , can be force fit onto the first portion 14 of flange 12 . The same trim element 20 can be attached to flange 12 ′, shown in FIG. 4 , in a similar manner due to the box-like configuration of the flange 12 ′.
[0015] For further positive engagement of the trim element 20 to the grid element 10 , the second leg 24 of the trim element 20 may contain a tab 30 extending from the second leg 24 and into the grid receiving channel 28 . Upon insertion of the first portion 14 of flange 12 into the grid receiving channel 28 of trim strip 20 , tab 30 snaps over the top side of first portion 14 . When viewed from below, the intermediate section 26 will cover the bottom side of first portion 14 , and, thus, have the appearance of the bottom portion of flange 14 .
[0016] As shown in FIGS. 1-4 , the trim strip 20 further includes a clearance covering portion 32 which extends outwardly from the second leg 24 of the trim element 20 . The clearance covering portion 32 has a step configuration which includes a first horizontal step 34 , a second horizontal step 38 and an intermediate vertical step 36 which integrally connects the first and second horizontal steps. The first horizontal step extends 34 outwardly from the second leg 24 of the trim element 20 in a direction substantially parallel to, but offset from, the intermediate portion 26 of the trim element 20 . The intermediate vertical step 36 extends downwardly from the first horizontal step 34 to the level of the intermediate section 26 . The second horizontal step 38 extends horizontally from the intermediate vertical step 36 . Although not required, when the trim element 20 is attached to a perimeter grid element 10 , the second horizontal step 38 of the clearance covering portion 32 will preferably lie in abutting relationship with the underside of an adjacent soffit 40 . As shown in FIGS. 1-4 , the second horizontal step 38 can have a tapered configuration to promote further a seamless transition.
[0017] It should be noted that the second horizontal step 38 of the clearance covering portion 32 can be mechanically fastened to the soffit, such as by a screw 50 as shown in FIG. 3 . If desired for aesthetical purposes, the fastening means 50 can be covered up applying joint compound 45 over the second horizontal step 38 , as shown in FIG. 4 , so that the fastener 50 will not be visible. Additionally, whether or not a mechanical fastener 50 is used, joint compound 45 can be applied to the second horizontal step 38 , and painted over, so that the soffit 40 will look as though it extends up to and abuts the intermediate vertical step 36 . As a result, the perimeter solution has the ability to maintain its floating nature while giving the impression of a wall-to-wall system which is permanently attached to or fit tight against a soffit.
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A suspended ceiling system having a trim strip which conceals a construction clearance between a perimeter grid element and a soffit-type wall. The trim strip can be mounted onto the perimeter grid element, attached to the underside of the soffit-type wall or both.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of interactive video games.
2. Background Art
Existing video games have the disadvantage of lack of physical interaction with the game. Typically only the player's hands are used to manipulate controllers, such as a joystick, buttons, trackballs, etc. As a result, the games are relatively sedentary. The feedback from a prior art video game is only visual and or auditory. When a goal is accomplished during play of the game, such as "shooting" a space ship, "striking" a displayed opponent, etc. the act itself is displayed, and a confirming sound or musical cue is generally reproduced.
Some prior art video games provide movement of the player in response to play of the game. For example, video games that involve driving or flying may include, for example, a cockpit in which the player sits. Movement of the joystick causes the cockpit itself to tilt left or right, or possibly to pitch forward and back, in association with movement of a display element or icon. Even in such a system, the player is relatively passive, all movement being initiated by movement of the joystick. In addition, there is no other event feedback in the event of collisions, etc.
Some prior art video games employ a stylized "motorcycle" on which a player sits. By leaning left or right, and turning the handlebars, the player "steers" a displayed motorcycle. Such a system is limited to left and right movement of the player and lacks tactile event feedback.
Another disadvantage of prior art video games is the limited number of players that can participate simultaneously. In prior art video games, typically two players alternate play, with no interaction between them. In some games, players can compete simultaneously as a team or sometimes as opponents. However, prior art video games do not provide the ability for large numbers of players to participate simultaneously.
SUMMARY OF THE INVENTION
An interactive video game with physical feedback is described. A plurality of icons are provided on a display. Each icon represents one of a plurality of players. A plurality of positioning devices, one for each player, are provided in front of the display. Each player stands on the positioning device, and the positioning device reacts to shifts in weight of the player and tilts in the direction in which the player shifts. Movement of the positioning device causes the display icon corresponding to the positioning device to move accordingly. When the player shifts left, the positioning device shifts left, and the display icon moves left. Each player moves the player's own positioning device to control and move the player's corresponding display icon.
Each player attempts to cause collisions with the icons of other players and avoid the icons of players attempting to cause collisions. In one embodiment, each player begins with a predetermined number of points. A player on the receiving end of a collision loses points, A player causing a collision does not lose points. At the end of a predetermined time period, the player with the most points is the winner.
In addition to the display icons representing each player, the display includes planets, galaxies, and meteor showers. Colliding with any of these objects results in loss of points. The meteor shower occurs at random one or more times during active game play.
When there is a collision involving a display icon or the edge of the display, a feedback mechanism causes a composite jolt to the positioning device in one of a number of possible ways, depending on the type and speed of collision. This tactile feedback adds realism to the playing of the game. In addition to the auditory and visual cues of a collision, the player actually feels the bumps indicating a collision. The collision is affected on the positioning device itself, requiring the player to recover or attempt to hold a desired course during game play.
In addition to the objects with which a player's icon may collide, there are also areas on the display representing regions of turbulence. These regions are found around certain planets and gas clouds.
When a player's icon enters one of these turbulent regions, the feedback mechanism causes the positioning device to vibrate at varying speeds and in a number of possible ways depending upon the area of turbulence and the speed of motion of players' icons. This tactile feedback also adds realism to the playing of the game.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a block diagram of the game system of the present invention.
FIG. 1B is a top view of a positioning means.
FIG. 1C is a perspective view of a positioning means.
FIG. 1D illustrates the platform and game axes.
FIG. 2 is a flow diagram of the overall operation of the invention.
FIG. 3 is a flow diagram of the attract mode of the invention.
FIG. 4 is a flow diagram of the game play mode of the invention.
FIG. 5 is a flow diagram of the initialization process.
FIG. 6 is a flow diagram illustrating the calculation of acceleration and velocity.
FIG. 7 is a flow diagram illustrating the identification of collisions.
FIG. 8 is a flow diagram illustrating a method for identifying the type of a collision.
FIG. 9A is a flow diagram illustrating the scoring of the invention.
FIG. 9B illustrates velocity normal to the collision point.
FIG. 10 is a flow diagram illustrating screen update.
FIG. 11 is a flow diagram illustrating the end of game sequence.
FIG. 12 illustrates display region crossover.
FIG. 13 illustrates the arrangement of the positioning devices with respect to the display.
FIG. 14 illustrates the display of the present invention.
FIG. 15 illustrates the beam splitter of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A method and apparatus for providing an interactive video game with physical feedback is described. In the following description, numerous specific details are set forth in order to provide a more thorough description of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without these specific details. In other instances, well-known features have not been described in detail so as not to obscure the invention.
The present invention is a video game for multiple simultaneous participation. Each player "rides" his own joystick or positioning device. A perspective view of a positioning device that can be used with the present invention is illustrated in FIG. 1C. Referring to FIG. 1C, a steering mechanism 182 is mounted on the top surface of a support platform 180. The steering mechanism 182 is mounted to the top surface of upper platform 180 at a radial position near the periphery of circular platform 180. A player stands on support platform 180 and holds the handlebars of steering mechanism 182. By shifting the players weight, the support platform is tilted about a central pivot. Displacement of the support platform is translated into position signals that control movement of a display icon.
FIG. 13 illustrates one arrangement of positioning devices in the present invention. Eleven positioning devices 1-11 are disposed in an array of three rows of four, three, and four positioning devices respectively. The plurality of positioning devices 1-11 are disposed in front of a display 1300. One display icon is displayed on the display 1300 for each positioning device in the array.
FIG. 14 illustrates the display 1300 of FIG. 13. The display 1300 displays a plurality of icons 1-11 that correspond to each of positioning devices 1-11. To aid a player in identifying his associated display icon, each icon includes a number corresponding to the number of the player's positioning device. In addition, each display icon has a different geometric border and/or color than any other icon, so that each display icon has a unique appearance. In the present invention, the display icons may be thought of as space craft or space ships that are to be piloted (i.e. "steered") by each player. The display icons are illustrated in the "begin game" orientation, to permit easy identification. During active game play, each player may move his display icon about the display 1300 by moving his associated positioning device.
The image viewable by a player includes other objects such as planets 1320 and 1330, gas cloud 1340, and meteors 1310A-1310D. These objects have special properties that affect the movement of the display icons during the active play of the game.
During the pre-game period, players are encouraged to step onto a positioning device. Each positioning device is marked with a representation of a display icon in the same shape and color, and with the associated number. In addition, the physical location of each positioning device in the array corresponds to the physical location of the display icon in the pre-game array.
During game play, each player uses shifts in body weight to move the positioning device. In response, the player's associated display icon moves in the direction in which the positioning device is tilted. In this manner, the player "steers" the display icon about the display. The player attempts to "hit" other display icons to obtain points, and to avoid collisions with other display icons, the planets 1320 and 1330, and meteors 1310A-1310D to avoid the deduction of points. The player can move the player's associated display icon for a fixed period of time. At the end of the time period, the player with the most points is the winner.
When a player's associated display icon collides with another object or the edge of the display 1300, a feedback mechanism causes a composite jolt of that player's positioning device. In this manner, the play of the game is more realistic, as auditory, visual and physical feedback is provided to the player. When the display icon of a player moves into the gas cloud 1340, the feedback system provides continuous shaking and vibration of the positioning device, as if the player is subjected to drag turbulence.
Positioning Device
The present invention uses a positioning device on which a player stands. The device consists of a support member and a steering bar or handle bar to be grasped by the player. The player shifts his weight on the support member and thereby displaces the support member. Position sensors coupled to each positioning device detect the displacement and translate it into x-y coordinates. One such positioning device that can be used with the present invention is described in co-pending U.S. patent application Ser. No. 08/069,566, filed May 28, 1993, entitled Apparatus for Providing Position Signals and assigned to the assignee of the present invention and incorporated herein by reference.
The positioning device provides the position and weight data and player feedback for the present invention. FIG. 1B provides a top-view of the Positioning Device 146 comprising upper platform 180, linear transducers 162A-162B, air cylinder 178, and pneumatic spring 170.
Linear transducers 162A-162B produce Y- and X-position signals 196-198, respectively, that are provided to Device Controller 150. Memory storage means within the positioning device 146 hold algorithms for converting the platform position, x-position 198 and y-position 196, and player weight, weight and pressure sensors 194, into the correct game information for transmission to CPU 100. That is, Device Controller 150 transfers Y- and X-position signals 196-198 as well as weight and pressure sensor signals 194 to computer 100 through communication channel 145.
Device Controller 150 receives weight and pressure signals 194 from air cylinder 178. The Device Controller 150 provides a fill signal 172 and a kick signal 174 to fill valve 168 and kick valve 166, respectively. Kick valve 166 controls air flow 184 to air cylinder 170 from air supply 186. Similarly, fill valve 168 controls air flow 184 from air supply 186 to platform stabilization air cylinders that are located along the periphery of platform 180.
Kick valve 166 (or pneumatic servo valve) in FIG. 1B produces various "bumps" in the system in response to a kick control signal 174 from the computer 100 through control/interface 144. The kick control signal 174 opens and closes the pneumatic servo valve 166 causing pancake air cylinder 178 to expand thereby driving platform 180 upward in a vertical direction momentarily. These "bumps" are used in the present invention to provide physical signals or cues to a player such as when the player's vehicle collides with an object in the game. This provides an added dimension of realism to the computer game.
The Device Controller 150 operates the valves 166 and 168 using kick and fill control signals 174-172, respectively. The weight and pressure sensor signal 194 is provided to Device Controller 150 from the linear transducers of air cylinder 178. User-detection sensors are incorporated in the system to detect when a user is on upper platform 180. The weight and pressure signal 194 is provided to Device Controller 150 to indicate the presence of a user. In response, Device Controller 150 provides fill control signal 172 to fill valve 168 causing it to retract.
Once the user is loaded onto upper platform 180, upper platform 180 is able to pivot smoothly through 360°. FIG. 1C illustrates the reference coordinate system for X- and Y- position signals 198-196 generated by the system. The X-Y coordinate system indicates that Y values change in the longitudinal direction along the front-back axis 192A. Accordingly, X values change in the lateral direction along the left-right axis 192B. The Y- and X-position signals 196-198 produced by linear transducers 162A-162B are provided to Device Controller 150.
In one embodiment of the present invention, linear transducers 162A-162B are mounted 45° to the front-back axis 192A and left-right axis 192B. To produce front-back and left-right X and Y vectors, the Y-and X-position signals 196-198 must be combined and rotated by Device Controller 150.
Device Controller 150 processes and transmits the position signals 196-198 to computer 100 through communication link 145. Display 164 provides a tally of the score achieved by a player during the operation of the present invention. Further, at the end of a game, each positioning device is placed in a locked, stationary position.
Positioning Calculations
If X and Y transducers 162A-162B are not placed in line with the left-to-right (i.e., X) axis or the front-to-back (i.e., Y) axis (respectively), the X and Y values must be rotated to produce X and Y vectors relative to the left-to-right and front-to-back axes of the platform of the positioning device.
If linear transducers 162A-162B are mounted 45° to the front-back axis 192A and left-right axis 192B of the positioning device, the Y-and X- position signals 196-198 must be combined and rotated by Device Controller 150 to produce front-back and left-right X and Y vectors. FIG. 1D illustrates the orientations of the raw input, and the positioning vectors generated by Device Controller 150. That is, X and Y input values received from the positioning device and within the platform -- x and platform -- y coordinate system must be combined and rotated to produce X and Y positional input within the game x and game -- y coordinate system as follows:
rotated.sub.-- X=(platform.sub.-- x+platform.sub.-- y)*cos(45°)
rotated.sub.-- Y=(-platform.sub.-- x-platform.sub.-- y)*cos(45°)
To increase the speed of the calculation, cos(45°) can be approximated to 707/1000. This approximation should have sufficient accuracy for game play. Thus, the resultant range of the rotation calculation is ±723. If the X and Y position values expected by the game play module are within the range of 0-254, a further scaling can be performed on the rotated value (i.e., rotated -- x or rotated -- y) to produce a game value within the expected range. The scaling calculation is as follows:
game.sub.-- value=(rotated.sub.-- value+723)*100)/569)
Further, platform readings for X and Y axes should be centered at zero when the platform is in its stabilized position. To meet this requirement, raw platform readings are normalized as follows:
platform.sub.-- x-raw.sub.-- x.sub.-- reading+x.sub.-- offset
platform.sub.-- y=raw.sub.-- y.sub.-- reading+y.sub.-- offset
where:
x -- offset and y -- offset are calculated from a series of x and y readings taken each time the positioning device is subjected to a calibration process.
Operation Overview
FIG. 2 illustrates an overview of a processing flow of the operation of the present invention. An initialization procedure is invoked at processing block 200. Once the initialization procedure is completed, the attract mode of the present invention is invoked at processing block 202. The present invention operates in the attract mode when a game is not in progress (e.g., in between games or when a game is paused). In attract mode, the present invention generates visual and audio effects to provide a center of interest for potential players. Once the attract sequence is completed and a game is not in a pause mode, the game play module is invoked at processing block 204. The system returns to attract mode after the game play module is completed.
Initialization
An initialization process is performed when the system is initially invoked. Referring to FIG. 5, Initialization reads screen calibration values from a file. These values are used to provide a smooth transition between the multiple displays used in the present invention. The present invention uses multiple rear projection screens. The output to each screen is blended with the other screen output such that the screens appear to be one screen. The blend is provided by overlapping some portion of the screens' display area. When an object moves from one screen to the next, the object appears to remain in the same position on the display, and the object's coordinates are updated to reflect its new coordinate location in the new screen.
A calibration process is performed to identify the areas of overlap, a transition point between the screens, and the offset (in pixels) from one screen to the next. The calibration process establishes the coordinates of the top left corner of each screen relative to the top left screen, and the coordinates of the dimensional props as seen by the game software.
Once the calibration has been performed, calibrations are only necessary in special cases such as when equipment is physically moved from its current location. However, the calibration process can be performed any time the game is in attract mode and paused.
The present invention provides the ability to provide objects that are viewable by the players as dimensional props positioned behind the "pepper's ghost" glass. These objects are merged with other, projected images into a single, combined image. For such objects, a calibration process further provides calibration data to indicate the location of these objects relative to the display and the projected images. This information can be used to determine, for example, when ships collide with these objects.
Referring to FIG. 5, the screen calibration data from the calibration process are read at block 500. The calibration data for dimensional prop objects (e.g., planet or gas cloud) are read at block 502. At processing block 504, the "ship" game icons are added to the system. The process of adding an icon includes drawing the icon in an offscreen memory location. The icon in memory can be copied to or erased from an onscreen location during the animation process to speed up animation during a game. At block 508, processing returns to the GamePlayModule (i.e., after processing block 406 in GamePlayModule).
To provide real-time response to the players, GamePlayModule illustrated by FIG. 4 creates a virtually simultaneous reaction to different processing stimuli such as player input, collisions between two or more icons, screen updates, and game termination. At decision block 407 (i.e., "processing necessary?"), GamePlayModule responds to processing stimuli, or waits for such stimuli.
Attract Module
Referring to FIG. 3, the Attract Module of the present invention begins, at processing block 302, to display an animation sequence and to generate sound effects. If, at decision block 304 (i.e., "attract sequence completed?"), the attraction sequence is not finished, processing continues to check for completion of the attract sequence at decision block 304. If the attract sequence is finished at decision block 304, processing continues at decision block 306.
A game may be paused during its execution for various reasons. When a pause mode is detected, the attract sequence is invoked and loops indefinitely, or until a resume mode is detected. When play is to be resumed, play starts at the end of the current attract sequence. At decision block 306 (i.e., "operator pause?"), if a pause is not detected, processing continues at decision block 308 (i.e., "end of attract sequence?"). If the current attraction sequence is not finished at decision block 304, processing continues to check for the completion of the sequence at decision block 304 (i.e., "attract sequence completed?"). When the completion of the attract sequence is detected at decision block 304, the GamePlayModule is invoked at processing block 310. When the GamePlayModule is finished, the attract sequence starts at processing block 302.
GamePlayModule
When the GamePlayModule is invoked, players are astride a positioning device of the type illustrated in FIG. 1C. A player can determine the direction and speed of an associated display icon by tilting the device (i.e., by shifting weight) in a direction. The direction of the tilt, or pivot, determines the direction of movement of the game icon. The degree of change in the tilt determines the speed (i.e., faster or slower) of the movement of the display icon.
The positioning device further provides an ability to determine a player's weight. Weight information is used to make the positioning device more responsive to each player. In addition to the weight input, the GamePlayModule receives positioning input from the player via the positioning device, and responds by providing feedback to the player (e.g., via the screen icon).
FIG. 4 provides an implementation flow of the GamePlayModule. At processing block 400, a player's weight is input from the positioning device. A player's weight affects the ease with which the positioning device is moved, and may result in a "ship" icon that moves in a sluggish manner. Compensation without reference to a player's weight may result in a ship's movement that appears to jerk in each direction. Thus, information about a player's weight can be used to customize the feedback provided to a player.
To optimize the transmission of weight input from the positioning device to the game computer, weight input can be passed to the game computer as a byte containing a value from zero to two. A zero value indicates that no player is present. A value of one indicates a lighter player, and a value of two indicates a heavier player.
A compensation factor is applied to the velocity calculation to provide more of a response from a slighter movement of the positioning device by a lighter player (e.g., children). A second weight compensation factor is applied for heavier players (e.g., adults). Weighing a player at the beginning of the game is done to identify the correct weight compensation factor to be used to scale the raw X and Y positioning input from the position device.
If the player's weight is less than or equal to a weight threshold (e.g., fifty pounds) at decision block 402 (i.e., "player's weight >50 pounds?"), a "lighter weight" compensation factor is calculated at processing block 404, and processing continues at decision block 407. If the player's weight is greater than a given weight threshold, a second weight compensation factor is selected at processing block 406, and processing continues at decision block 407. Processing continues by identifying processing requirements (e.g., input detected from a player, collision detected, screen update, or end of game) at decision block 407 (i.e., "processing necessary?"), and processing them when necessary.
Player Input
At decision block 408 (i.e., "input detected?"), the system reacts to input detected from the player. If no input is detected, processing continues by identifying other processing requirements at decision block 407 (i.e., "processing necessary?"). If input is detected at decision block 408, CalcAccellerationVelocity is invoked at processing block 410.
CalcAccelerationVelocity
Movement of a player's positioning device is used to determine the direction and speed of the player's display icon. CalcAccellerationVelocity uses this movement, or tilt, of the positioning device to calculate the speed that the player's display icon travels in the direction of the tilt.
The tilt is input in the form of x and y values. In the preferred embodiment, the tilt in either the x or y direction is a number between zero and two hundred and fifty-four (i.e., 254). A zero value represents the extreme movement on the x and y axes in the leftward or downward directions, respectively. A value of 254 represents extreme movement in the right and upward direction on the x and y axes, respectively. A value in the exact middle of the range represents no change in movement.
Referring to FIG. 6, the new tilt, Anew is obtained from the positioning device at processing block 602 by subtracting the offset for the center position (i.e., determined at calibration) from the positioning device input. The current tilt, previous tilt, and two compensation factors (i.e., a weight compensation factor and a derivative control) are used to calculate a new velocity. The new velocity is calculated at processing block 604 as follows:
V.sub.new =V.sub.old +K.sub.1 (A.sub.new +K.sub.2 (A.sub.new -A.sub.old))
where:
V new is the velocity computed in this calculation;
V old is the velocity computed in the previous calculation;
A old is the positioning device input used in the calculation of V old ;
A new is the most-recent positioning device input;
K 1 is the weight compensation factor; and
K 2 is a scaling factor to adjust the amount of derivative control.
Once the new velocity is calculated, V old and A old are updated with the present velocity and tilt values, V new and A new , respectively. Processing returns to GamePlayModule at block 608 (i.e., decision block 407 in GamePlayModule).
Game Object Collisions
Scoring is determined based on the number and type of collisions. A player causing a collision with another player is awarded points. A player that is collided with by another player, or by an asteroid, or who collides with a planet, loses points. So, for each collision, the type of collision is determined, and, in the case of a player to player collision, the "winner" of the collision is determined. The winner of a collision is the player whose display icon has the highest velocity.
In the GamePlayModule of FIG. 4, collisions between one or more game icons provide feedback to each player of a game object involved in a collision. At processing block 414, IdentifyCollisions is invoked to identify any collisions. FIG. 7 provides an implementation flow of IdentifyCollisions. Each game icon is examined with respect to all of the other game icons until all icon combinations are examined. At decision block 702 (i.e., "processed all objects?"), if all game icons have been examined, no collision exists, and processing returns to GamePlayModule at block 720. If all of the game icons have not been examined, processing continues at block 706 to get the next icon combination.
The process used to detect a collision depends on the footprint of each icon in the icon combination. Each game icon can be contained in a spherical or non-spherical object. The type is examined at decision block 708 (i.e., "type of objects?"). If the objects are spherical, a collision is detected by calculating the difference between the center points at processing block 710. The difference is compared to the sum of the radii at decision block 714 (i.e., "difference<sum of objects' radii?"). If the difference is greater than or equal to the sum of the objects' radii, no collision has occurred, and processing continues at decision block 702 (i.e., "processed all objects?"). If the difference is less than the sum of the radii, a collision condition exists and processing returns to GamePlayModule at block 720 (i.e., decision block 416 in GamePlayModule) to process the collision.
If the object is non-spherical at decision block 706 (i.e., "type of objects?"), a scan is performed to-determine if the objects' footprints overlap. The result of the scan is examined at decision block 716 (i.e., "scanline process detect collision?") to determine whether a collision exists. If an overlap is not present, a collision has not occurred, and processing continues at decision block 702 (i.e., "processed all objects?"). If an overlap exists, a collision condition exists and processing returns to GamePlayModule at block 720 (i.e., decision block 416 in GamePlayModule) to process the collision.
Referring to the GamePlayModule illustrated by FIG. 4, if a collision condition is not detected in IdentifyCollisions, processing continues by identifying other processing requirements at decision block 407. Decision block 416 (i.e., "collision detected?"), determines whether a collision was detected by IdentifyCollisions. If a collision condition does not exist at decision block 416, processing continues at decision block 407 (i.e., "processing necessary?") to identify other processing requirements. If a collision is detected by IdentifyCollisions, Collision is invoked at processing block 418 to process the collision and provide feedback to the player.
Ship-Ship Collision
Referring to FIG. 8, the type of game objects involved in a collision determines the type of output generated by the system to simulate a collision. Thus, at decision block 802 (i.e., "type?"), the type of objects involved in the collision is examined. If two ships collide, sparks are generated at processing block 804.
A collision further provides audio feedback. The present invention includes a MIDI sound effects generation means to provide additional player feedback. Each positioning device used in the present invention has an associated MIDI channel. When two ships collide, the sound associated with the collision is sent over each of the channels assigned to the involved ships at processing block 806.
Further, in the present invention ships are treated as having equal mass. Thus, the ships rebound from one another at block 808. A "bump" signal is sent to the positioning device's controller at block 810. The "bump" commands results in a slight jolt of the positioning device of each player of a ship involved in the collision. This provides additional feedback that a collision has occurred. Finally, a command is generated to flash strobe lights associated with each positioning device at block 812. Scoring is invoked to at processing block 813 to determine the score modifications for each ship. Processing returns to GamePlayModule at block 860 (i.e., processing block 407 in GamePlayModule).
Ship-Planet Collision
If it is determined at decision block 802 of FIG. 8 that a ship and a planet are involved in the collision, processing continues at processing block 814. An explosion is generated at processing block 814. The sound associated with a collision between a ship and planet is sent over the channel assigned to the involved ship at processing block 816. The ship is deflected from the planet (i.e., repelled) at block 818. A "bump" signal is sent to the positioning device controller associated with the ship at block 820. The "bump" commands results in a slight jolt of the positioning device on which the ship's player stands. The ship's score is decremented at processing block 821. Processing returns to GamePlayModule at block 860 (i.e., decision block 407 in GamePlayModule).
Ship-Asteroid Collision
If it is determined at decision block 802 of FIG. 8 that a ship and an asteroid are involved in the collision, processing continues at processing block 822. An explosion is generated at processing block 822. The sound associated with a collision between a ship and an asteroid is sent over the channel assigned to the involved ship at processing block 824. The asteroid is broken up into fragments at block 826. The ship is deflected from the asteroid at processing block 828. As the fragments of the asteroid reach the edge of the combined display, the pieces are removed from the display at processing block 828. As a further result of the collision, a "bump" signal is sent to the positioning device controller associated with the ship at block 832. The "bump" commands results in a slight jolt of the positioning device upon which the ship's player stands. Further, the ship's score is decremented at processing block 834. Processing returns to GamePlayModule at block 860 (i.e., decision block 407 in GamePlayModule).
Ship-Edge Collision
If it is determined at decision block 802 of FIG. 8 that a ship and an edge of the combined display are involved in the collision, processing continues at processing block 836. The sound associated with a collision between a ship and edge is sent over the channel assigned to the involved ship at processing block 836. The ship is deflected from the edge at block 838. A "bump" signal is sent to the positioning device controller associated with the ship at block 840. The "bump" commands results in a slight jolt of the positioning device upon which the ship's player stands. Processing returns to GamePlayModule at block 860 (i.e., decision block 407 in GamePlayModule).
Ship-Gas Cloud Collision
If it is determined at decision block 802 of FIG. 8 that a ship and a gas cloud are involved in the collision, processing continues at decision block 842. If, at decision block 842 (i.e., "entered gas cloud?"), the ship has not entered the gas cloud, processing returns to GamePlayModule at block 860 (i.e., decision block 407 in GamePlayModule). If the ship has entered the gas cloud, processing continues at processing block 844. The sound associated with a collision between a ship and planet is sent over the channel assigned to the involved ship at processing block 844. The ship is able to travel through a gas cloud. However, the ship experiences a turbulent effect while inside the gas cloud. Thus, at processing block 846, a signal is generated to the positioning device's controller to start the turbulence. At decision block 848 (i.e., "exited gas cloud?"), if the ship has not exited the gas cloud, processing continues at processing block 860 to return to GamePlayModule at block 860 (i.e., decision block 407 in GamePlayModule). If the ship has exited the gas cloud, the sound is terminated at processing block 850, the turbulence is terminated at processing block 852, and processing returns to GamePlayModule at block 860 (i.e., decision block 407 in GamePlayModule).
Collision and Turbulence Variations
To provide the collision and turbulence effects, the Device Controller 150 pulses the kick cylinder at various rates. To vary the feedback generated by the present invention, the effects provided by the present invention can be based on one or more factors such as the player's weight, type of collision, or the involvement of more than one collision type. Using the table driven method including a collision table and a turbulence table, various collision and turbulence effects can be produced.
The collision and turbulence tables are three-dimensional arrays containing type, weight, and index data. In the collision and turbulence tables, type defines the number of different collision or turbulence (respectively) types to be implemented, weight is the number of weight ranges, and index is the number of on/off pulse times required to produce the desired effect.
The positioning device can provide the algorithms for producing the various collision and turbulence feedback effects for the game player. The two extensible three-dimensional collision and turbulence arrays are used to provide an instance of a series of on and off pulse times to be used to activate kick valve 166 in order to produce a wide variety of possible feedback effects. The instance (i.e., row/column) of the array to be used for a required effect is determined in the present invention by the weight of the player and the speed of collision or turbulence as specified by CPU 100 via communications channel 145. The algorithm steps through the selected array, pulsing kick valve 166 either on or off for the specified duration in the requisite array entry.
For example, once the weight and type are determined, the Device controller can provide collision feedback by pulsing the kick cylinder as specified in the table until the end of the on/off pulse times are reached or a kick limit is detected. In the case of the turbulence effects, the device controller can continue to cycle the on/off pulse train until the game computer signals the end of the turbulence. If a kick limit is triggered during the effect generation, the kick cylinder signal will be turned off and the device controller will step to the first off pulse time in the column.
Scoring
The GamePlayModule must determine whether a collision should result in a score tally change. While detection of any collision can result in a score tally change, the preferred embodiment of the present invention modifies a score based on three types of collisions: ship-ship, ship-planet, and ship-asteroid. A collision between a ship and a planet or asteroid results in a decrement of the ship's score at processing blocks 821 and 831 (i.e., FIG. 8), respectively.
A collision between two ships results in an increase in the score of one of the involved ships. The other ship's score is decreased. FIG. 9A, illustrates a process flow for determining the score modifications for each ship. The ship that has the higher velocity normal to the point of collision is identified at processing block 902. Referring to FIG. 9B, the velocity normal for each ship (i.e., V 1Normal and V 2normal ) involved in the collision is determined relative to the point of collision. For example, V 1Normal is normalized to the same horizontal plane in which the collision took place. Similarly, V 2Normal 's velocity is normalized to the collision plane. Because Ship 1'a V Normal is greater than Ship 2's V Normal , Ship 1's score will be incremented, and Ship 2's score will be decremented.
The ship with the higher velocity normal is identified at processing block 902. At decision block 904 (i.e., "processed all ships in collision?"), if the score for each ship involved in the collision has been updated, processing returns to GamePlayModule at block 906 (i.e., decision block 407 in GamePlayModule).
If all of the scores have not been updated, processing continues at block 906 to get the next ship. At decision block 910 (i.e., "highest velocity normal?") if the ship being processed is determined to have the highest velocity normal to the point of collision, the ship's score is incremented by the number of points associated with a ship-to-ship collision at processing block 912. If not, the ship's score is decremented by the number of points associated with a ship-to-ship collision at processing block 914. In either case, processing continues at block 916 to generate a score tally change sound for the ship. Processing continues at decision block 904 (i.e., "processed all ships in collision?").
Display Update
Referring to FIG. 4, if a display update is not necessary at decision block 424 (i.e., "screen update?"), processing continues at decision block 407 (i.e., "processing necessary?") to identify other processing requirements. If a screen update is necessary, ScreenUpdate is invoked at processing block 426. The present invention updates the screen by moving the game objects across the combined display according to the direction input received from a player, and the acceleration and velocity calculations derived from a player's input. Based on the input, a ship appears to be traveling in the direction of the player's movement, and at a speed that corresponds with the degree of tilt of the position device.
Display System
The present invention presents a relatively large display surface to the players. For example, in one embodiment of the invention, the display region is approximately six feet by eight feet in area. In this invention, the video portion of the display is accomplished by projecting images from a two by two array of monitors onto a reflective "pepper's ghost" beam splitter. An example of the arrangement of the invention is illustrated in FIG. 15. Monitors 1510A and 1510B project a video image onto reflective glass 1520. The projected image is reflected to the players 1530A-1530C in front of the display.
Three dimensional props may be disposed behind glass 1520. Such objects are visible to viewers on the other side of the glass 1520 and are merged with the projected images into a single combined image. Referring to FIG. 14, the planets 1320 and 1330 are not necessarily visible on the display. However, they represent the boundaries of the three dimensional props illustrated in FIG. 15. When a ship encounters a boundary, it appears to collide with the prop and then bounces off. In other words, project planets 1320 and 1303 are registered with their respective props.
There is an overlap of the images projected by the array of four monitors. The present invention provides an ability to generate a seamless transition between the multiple video projectors tiled together to create a combined display. FIG. 12 illustrates a combined display that is comprised of four screens tiled together in a quadrant pattern. The Top Left (TR) screen is the screen in the top left quadrant of the display. The Top Right (TR) is in the top right. The Bottom Left (BL) and Bottom Right (BR) screens are in the bottom left and bottom right screens of the display.
The top half of the combined display is delimited by the top edge of the top left and right screen, and the bottom edge of the top left and top right screens (i.e., TL and TR screens). Similarly, the bottom half of the combined display is delimited by the top edge and bottom edges of the bottom left and bottom right screens (i.e., BL and BR screens). The left half of the combined display is delimited by the left edges of the top left and bottom left screens (i.e., TL and BL screens). Similarly, the right half of the combined display is delimited by the right edges of the top right and bottom right screens (i.e., TR and BR screens).
A screen object is positioned in the TL screen and is moving in the direction of the TR screen. Thus, its current screen position is TL. The x and y coordinates represent the position of the object in the TL screen. The coordinates are taken at the center of the object, and the object is assumed to be approximately circular as shown in FIG. 12. If the object reaches the TRtoTLboundary, the present invention transfers the object to the TR screen. To transfer an object, the object's current screen designation is changed to TR. Further, the x and y coordinates are updated to reflect the coordinates in the TR screen.
The top left corner of the top left screen is considered to have a (0,0) x-y coordinate value. Each object has two sets (i.e., and x and y value) of coordinates: XY currscrn (i.e., x-y coordinates relative to the top left corner of the object's current screen), and XY topleft (i.e., x-y coordinates relative to the top left corner of the top left screen). Further, each screen has a set of coordinates locating its top left corner relative to the top left corner of the top left screen. The coordinates of the object within a particular screen can be computed by subtracting XY currscrn from XY topleft .
FIG. 10 provides an implementation flow for transferring a game object across multiple screens. At decision block 1002 (i.e., "object in TL screen and object.x>TLtoTRboundary?"), if the game object is located in the TL screen and the object's x coordinate is greater than TLtoTRboundary (i.e., the object has crossed the TLtoTRboundary), the object is transferred to the TR screen at processing block 1004. That is, the object's current screen designation is updated to TR. Further, the object's x coordinate is modified by the TLtoTRdeltax value, and the object's y coordinate is modified by the TLtoTRdeltay value. Processing returns at 1034 to GamePlayModule.
If the object is not in the TL screen or the game object has not crossed the TLtoTRboundary, processing continues at decision block 1006. At decision block 1006 (i.e., "object in TL screen and object.y>TLtoBLboundary?"), if the game object is located in the TL screen and the object's y coordinate is greater than the TLtoBLboundary (i.e., the object has crossed the TLtoBLboundary), the object is transferred to the BL screen at processing block 1008. That is, the object's current screen designation is updated to BL. Further, the object's x coordinate is modified by the TLtoBLdeltax value, and the object's y coordinate is modified by the TLtoBLdeltay value. Processing returns at 1034 to GamePlayModule.
If the object is not in the TL screen or the game object has not crossed the TLtoBLboundary, processing continues at decision block 1010. At decision block 1010 (i.e., "object in TR screen and object.x<TRtoTLboundary?"), if the game object is located in the TR screen and the object's x coordinate is greater than the TRtoTLboundary (i.e., the object has crossed the TRtoTLboundary), the object is transferred to the TL screen at processing block 1012. That is, the object's current screen designation is updated to BL. Further, the object's x coordinate is modified by the TRtoTLdeltax value, and the object's y coordinate is modified by the TRtoTLdeltay value. Processing returns at 1034 to GamePlayModule.
If the object is not in the TR screen or the game object has not crossed over into the TL screen limits, processing continues at decision block 1014. At decision block 1014 (i.e., "object in TR screen and object.y>TRtoBRboundary?"), if the game object is located in the TR screen and the object's y coordinate is greater than the TRtoBRboundary (i.e., the object has crossed the TRtoBRboundary), the object is transferred to the BR screen at processing block 1016. That is, the object's current screen designation is updated to BR. Further, the object's x coordinate is modified by the TRtoBRdeltax value, and the object's y coordinate is modified by the TRtoBRdeltay value. Processing returns at 1034 to GamePlayModule.
If the object is not in the TR screen or the game object has not crossed the TRtoBRboundary, processing continues at decision block 1018. At decision block 1018 (i.e., "object in BL screen and object.x>BLtoBRboundary?"), if the game object is located in the BL screen and the object's x coordinate is greater than the BLtoBRboundary (i.e., the object has crossed the BLtoBRboundary), the object is transferred to the BR screen at processing block 1020. That is, the object's current screen designation is updated to BR. Further, the object's x coordinate is modified by the BLtoBRdeltax value, and the object's y coordinate is modified by the BLtoBRdeltay value. Processing returns at 1034 to GamePlayModule.
If the object is not in the BL screen or the game object has not crossed the BLtoBRboundary, processing continues at decision block 1022. At decision block 1022 (i.e., "object in BL screen and object.y<BLtoTLboundary?"), if the game object is located in the BL screen and the object's y coordinate is less than the BLtoTLboundary (i.e., the object has crossed the BLtoTLboundary), the object is transferred to the TL screen at processing block 1024. That is, the object's current screen designation is updated to TL. Further, the object's x coordinate is modified by the BLtoTLdeltax value, and the object's y coordinate is modified by the BLtoTLdeltay value. Processing returns at 1034 to GamePlayModule.
If the object is not in the BL screen or the game object has not crossed the BLtoTLboundary, processing continues at decision block 1026. At decision block 1026 (i.e., "object in BR screen and object.x>BRtoBLboundary?"), if the game object is located in the BR screen and the object's x coordinate is greater than the BRtoBLboundary (i.e., the object has crossed the BRtoBLboundary), the object is transferred to the BR screen at processing block 1028. That is, the object's current screen designation is updated to BR. Further, the object's x coordinate is modified by the BRtoBLdeltax value, and the object's y coordinate is modified by the BRtoBLdeltay value. Processing returns at 1034 to GamePlayModule.
If the object is not in the BR screen or the game object has not crossed the BRtoBLboundary, processing continues at decision block 1030. At decision block 1030 (i.e., "object in BR screen and object.y>BRtoTRboundary?"), if the game object is located in the BR screen and the object's y coordinate is greater than the BRtoTRboundary (i.e., the object has crossed the BRtoTRboundary), the object is transferred to the TR screen at processing block 1032. That is, the object's current screen designation is updated to TR. Further, the object's x coordinate is modified by the BRtoTRdeltax value, and the object's y coordinate is modified by the BRtoTRdeltay value. Processing returns at 1034 to GamePlayModule. If the object is not in the BR screen or the game object has not crossed the BRtoTRboundary, processing returns at 1034 to GamePlayModule.
End of Game
Referring to FIG. 4, if an end of game is not detected at decision block 428 (i.e., "end of game?"), processing continues at decision block 407 (i.e., processing necessary?") to identify other processing requirements. If an end of game is detected at decision block 428, GameEndProcessing is invoked at processing block 430.
Referring to FIG. 11, a signal is generated to place the positioning device in a locked position at processing block 1102. A signal is sent to the MIDI device to generate a tractor beam sound for each ship at processing block 1104. A gravitational force is generated to pull each ship back to its home position at processing block 1106. At processing block 1108, a repulsive force is placed around each planet to repel any ship as it passes by or within a planet's path on its way back to its home position. If all ships are not in home position at decision block 1110 (i.e., "each ship in home position?"), processing continues at processing block 1112. At processing block 1112, any ships not already in home position are moved to home position using the previously described forces.
After all ships are determined to be in home position at decision block 1110 (i.e., "each ship in home position?"), the high score is identified at processing block 1114. The high score is displayed on the combined display along with the associated ship icon at processing block 1116. At processing block 1118, a ten-second wait is invoked. At processing block 1120, a zoom-out animation of the ships is performed. Processing returns to GamePlayModule at block 1122 (i.e., block 432 in GamePlayModule). Referring to FIG. 4, processing returns at block 432. Referring to FIG. 2, the system returns to attract mode to attract another group of players. Further, while a game is not active, the positioning devices are placed in their locked, stationary positions.
System Overview
FIG. 1A illustrates the components of the present invention. In the preferred embodiment, Computer 100 is an IBM PS/2-95 and Central Processing Means (CPU) is a 80486 microprocessor. CPU 102 executes the main algorithms of the present invention with controller 150 executing algorithms to perform collision and turbulence feedback effects. CPU 102 is connected to a bi-directional communications bus 147 via line 101. Memory Storage Means 142 stores the variable information, and other information of the present invention. Memory Storage Means 142 is coupled to bus 147 via line 141.
Graphics Controller 104 provides program control to Video Projection Means 106A-106N via lines 105A-105N. In the preferred embodiment, Graphics Controller 104 is an XGA graphics adapter. Video Projection Means 106A-106N are tiled together to provide an expanded, combined display. For example, four Video Projection Means can be tiled together in a quadrant pattern to form a nine foot by fifteen foot combined display. The present invention provides the ability to synchronize the video output to each tile such that the tiled display appears to be one, continuous display.
Additional output is provided by Monitors 114A-114N. Monitors 114A-114N receive video input from Laser Disc 112A-112N through 113A-113N, respectively. In the preferred embodiment, Monitors 114A-114N form two display arrays on either side of the combined display formed by Video Projection Means 106A-106N. Monitors 114-114N receive video signals through lines 113A-113N from Laser Discs 112A-112N, respectively. Video Controller 110 provides control signals to Laser Discs 112A-112N through lines 111A-111N, respectively. Computer 100 interfaces with Video Controller via Serial I/O Interface 108 and serial channel 109.
Audio output is provided from Speaker 120 and Speaker 122 that are placed on either side of the two arrays formed by Monitors 114A-114N. Speaker 120 receives input from Amplifier 116 through line 117. Amplifier 116 receives signal 115B from Laser Disc 112A. Similarly, Speaker 122 receives audio input from Amplifiers 118 through line 119. Amplifier 118 receives signal 115A from Laser Disc 112A.
The present invention provides the ability to control objects displayed on the combined display formed by Video Projection Means 106A-106N using positioning devices 146A-146N. Positioning devices 146A-146N are coupled to Positioning Device Controllers 144A-144N through lines 145A-145N, respectively. Positioning Device Controllers 144A-144N communicate with Serial I/O Interface 108 via serial channels 143A-143N, respectively.
Additional audio output is provided by Speakers 132A-132N, 36A-136N, and Speaker 140. One of speaker Speakers 132A-132N and 36A-136N is positioned in close proximity to each of the positioning devices 46A-146N. Speakers 132A-132N receive input 131A-131N, respectively, from amplifier 130. Amplifier 130 receives signal 129 from Digital Audio Storage Means 126. Digital Audio Storage Means is coupled to Computer 100 through line 125 and MIDI interface 124. Speakers 136A-136N receive input 135A-135N, respectively, from amplifier 134. Amplifier 134 is coupled to Digital Audio Storage Means 128 via 133A. Digital Audio Storage Means 128 receives input from Computer 100, and Digital Audio Storage Means 126 through line 127.
Speaker 140 is positioned near the center of the combined display formed by Video Projection Means 106A-106N. In the preferred embodiment, speaker 140 is a sub-woofer. Speaker 140 receives input from amplifier 138 through line 139. Amplifier 138 is coupled to Digital Audio Storage Means 128 via 133B. Digital Audio Storage Means 128 receives input from Computer 100 and Digital Audio Storage Means 126 through line 127.
Game Computer--Device Communications
The device controller provides information to the game computer to allow the game computer to respond to a player's movements and pilot the player's icon around the game screen. The game computer sends commands to the device controller to perform game-related and maintenance-related activities.
In the preferred embodiment of the present invention, normal messages sent by the device controller to the game computer consist of the following:
<FF><Code><Status><Weight><X><Y>, where:
FF is a message start/synch byte;
Code is a message code;
Status is the status of the device controller (e.g., turbulence effect in progress, game play in progress, or error reading x or y input);
Weight is the current player's weight input;
X is the x-coordinate positioning information; and
Y is the y-coordinate positioning information.
Messages sent from the game computer to the device controller are either of the form:
<FF><command> or <FF><command><data>, where FF has the same function as above. The command field contains the commands for the device controller such as start, stop, score, collision, turbulence, or calibrate, shutdown. The data field(s) are used to pass data generated by the game computer to the device controller. For example, a score command includes a player's score to be updated. The collision and turbulence commands include speed information.
Thus, a method and apparatus for an interactive video game with physical feedback has been provided.
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An interactive video game with physical feedback is described. A plurality of icons are provided on a display. Each icon represents one of a plurality of players. A plurality of positioning devices, one for each player, are provided in front of the display. Each player stands on the positioning device, and the positioning device reacts to shifts in weight of the player and tilts in the direction in which the player shifts. Movement of the positioning device causes the display icon corresponding to the positioning device to move accordingly. Each player attempts to cause collisions with the icons of other players and avoid the icons of players attempting to cause collisions. In one embodiment, each player begins with a predetermined number of points. A player on the receiving end of a collision loses points, A player causing a collision does not lose points. At the end of a predetermined time period, the player with the most points is the winner. In addition to the display icons representing each player, the display includes planets, galaxies, and meteor showers. Colliding with any of these objects results in loss of points. The meteor shower occurs at random one or more times during active game play. When there is a collision involving a display icon, a feedback mechanism causes the positioning means to shake. This tactile feedback adds realism to the playing of the game.
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BACKGROUND AND SUMMARY OF THE INVENTION
The natural human lens effects accommodation, as between near and far vision, by ciliary muscle contraction and relaxation under brain control to dispose the lens in varying thicknesses at various locations along the axis of the eye.
The present invention provides improved, increased posterior vaulting of a lens optic by elongation of haptics disposed oppositely of the optic, while reducing the optic dimension in the longitudinal direction of the haptics.
Referring to FIG. 2 of the drawings, wherein the natural capsular bag is omitted for clarity, it will be understood from the geometrical relations of the ciliary muscle, the haptics and the optic, that the more elongated the haptics, the greater the posterior vaulting of lens haptics for accommodation.
The present invention provides an intraocular accommodating lens wherein an asymmetrical optic is of substantially greater dimension transversely of the longitudinal direction of haptics extending therefrom, and is of lesser dimension in the longitudinal direction of the haptics. With each haptic elongated to extend be tween the capsular bag equator and the optic, increased posterior vaulting of the optic is provided.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a preferred form of accommodating lens according to the invention;
FIG. 2 is a sectional view of the lens of FIG. 1 disposed in an eye, showing the lens optic in a generally anterior position and in a posteriorly vaulted position;
FIG. 3 is an elevational view of another preferred embodiment;
FIG. 4 is an elevational view of another embodiment; and
FIG. 5 is an elevational view of another embodiment wherein a generally annular glare-reducing component is disposed about an optic.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, particularly FIGS. 1 and 2, a preferred embodiment 10 of the accommodating lens of the invention is shown as comprising an optic 12 and haptics 14 , 16 extending oppositely therefrom and having loops 18 extending transversely thereof for engagement in the equator or rim of a capsular bag of an eye.
As shown, the lens is shortened in the longitudinal direction of haptics 14 , 16 extension and elongated in the transverse direction, and the haptics are elongated in the longitudinal direction. From the geometry of the features and components, including the ciliary muscle 20 , the haptics and the optic, it will be understood that the elongated haptics provide increased posterior vaulting of the optic, as indicated in FIG. 2 .
The optic thus has a somewhat oval configuration, with flat straight portions 21 , 22 hinged to the haptics.
The lens of the invention provides improved, enhanced accommodation by increased posterior vaulting of the optic, while maintaining a maximal optical zone for accurate vision.
The optic 12 , while relatively wide and enlarged in the direction transverse to the longitudinal direction of the haptics, and relatively short in the longitudinal direction, nevertheless has a full optical zone to provide full optical effect transmitted to the retina of the eye.
Whereas artificial intraocular lenses typically have optical zones of less than 5.0 mm in diameter, particularly lenses with haptics staked into optics, the present invention provides optical zones of about 6.0 mm transversely and about 4.5 mm longitudinally.
FIGS. 3 and 4 show embodiments of the invention wherein generally circular optics have indented linear portions 28 , to which haptics 24 , 26 are hingedly connected.
FIG. 4 shows a lens with indentations 28 at which are hingedly mounted haptics of generally rectilinear rod-like configuration, the haptics having plate elements 32 hingedly mounted to the optic.
FIG. 4 also illustrates a loop haptic portion 34 extending transversely from an outer edge portion of a haptic 36 to aid in centering the lens within the capsular bag of the natural human lens. A haptic 30 without a loop haptic portion 34 in mounted on the other side of the lens.
FIG. 5 shows an embodiment wherein haptics are hingedly mounted relative to an optic, and disposed about an optic 36 is a thin, annular transparent or translucent light-transmitting member 40 which reduces edge glare imposed on the retina.
It will be understood that various changes and modifications may be made from the preferred embodiment discussed above without departing from the scope of the present invention, which is established by the following claims and equivalents thereof.
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An intraocular lens has a lesser dimension longitudinally of haptics attached thereto than in the longitudinal direction to provide increased posterior vaulting for accommodation.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of Korean Patent Application No. 2003-053836, filed Aug. 4, 2003, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a projector, particularly to a projector having a simple structure, to prevent a phase shift caused by a temperature difference between a plurality of light sources and to easily control temperatures of the light sources.
2. Description of the Related Art
A projector generally displays a desired picture by projecting image beams onto a screen, and is applied in a projection television having a similar projecting apparatus to form a picture.
The projector may be either a transparent-type projector to form a picture with light passing through a display device, or a reflection-type projector to form a picture onto a screen with light reflected by the display device.
A liquid crystal projector using an LCD panel as the display device of the projector has been developed. As various technologies are developed for an optical lamp device affecting color and resolution of a displayed picture, the liquid crystal projector generally may be either an SLPS (single LCD panel system) using one LCD panel, or a TLPS (triple LCD panel system) to split light from the optical lamp device into three primary colors and project the light using the LCD panels corresponding to the three primary colors.
FIG. 1 is a schematic view of a projector according to a conventional TLPS method. As illustrated, the projector using three LCD panels includes a light source 100 to emit light, two fly-eye lenses 200 to synthesize and split the light emitted from the light source 100 , and a PBS array 300 . The projector further includes two primary light collection lenses 400 , four total reflection mirrors 500 , two dichroic mirrors 510 , a magnifying lens 520 , and secondary light collection lenses 600 a, 600 b, and 600 c to improve the straightness of the light reflected by the mirrors. The projector further includes three LCD panels 610 a, 610 b, and 610 c to transform the light having the straightness improved by the secondary light collection lenses 600 a, 600 b, and 600 c into respective colored lights having color signals R, G, and B, an optical synthesizer 700 to synthesize the colored lights having color signals R, G, and B from the LCDs 610 a, 610 b, and 610 c, and a projection lens 800 to magnify and project the light synthesized by the optical synthesizer 700 .
An operation of the projector having the above configuration will be described hereinbelow. The light emitted from the light source 100 is synthesized and split through the fly-eye lenses 200 , the PBS array 300 , the primary light collection lenses 400 , the total reflection mirror 500 , the dichroic mirrors 510 , and the magnifying lens 520 . Also, the light split by the dichroic mirrors 510 goes through a light modulation process by the LCD panels 610 a, 610 b, and 610 c representing the color signals R, G, and B, respectively.
The respective colored lights representing the color signals R, G, and B by the LCD panels 610 a, 610 b, and 610 c are synthesized by the optical synthesizer 700 . The light synthesized by the optical synthesizer 700 is magnified and projected through the projection lens 800 .
However, the projector having the above configuration has a disadvantage because a structure thereof becomes complicated and the brightness decreases due to decrease in a transmission rate of the light.
To solve this problem, Korean Patent First Publication No. 2003-57751 illustrates a projection display apparatus using an LED as a light source and providing individual lights to respective LCD panels. However, since such configuration also requires a plurality of LEDs (light emitting diodes) as the light source, a temperature difference among the plurality of LEDs causes a problem such as a phase shift which shifts the image.
SUMMARY OF THE INVENTION
Accordingly, it is an aspect of the present invention to provide a projector having a simple structure, to prevent a phase shift caused by a temperature difference between a plurality of light sources and control temperature of the plurality of light sources easily.
Additional aspects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
The foregoing and/or other aspects of the present invention are achieved by providing a projector having an optical engine, the optical engine including: an optical synthesizer; a plurality of display devices corresponding to the optical synthesizer; a plurality of light sources each in a respective vicinity of the plurality of display devices to emit light; a light guide plate provided between each light source and each respective display device; and a heat pipe contacting the light sources to reduce a temperature deviation between the light sources.
According to an aspect of the invention, the optical engine further includes: a temperature sensor installed on the heat pipe; a cooling part to cool the light sources; and a controller to control the cooling part according to a signal from the temperature sensor.
According to an aspect of the invention, the optical synthesizer is shaped like a cube and three of the display devices are provided corresponding to respective faces of the optical synthesizer.
According to an aspect of the invention, each light source includes an LED.
BRIEF DESCRIPTION OF THE DRAWINGS
These and/or other aspects and advantages of the invention will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
FIG. 1 is a schematic view illustrating a conventional projector;
FIG. 2 is a schematic view illustrating a projector according to an embodiment of the present invention;
FIG. 3 is a perspective view illustrating an optical engine of the projector of FIG. 2 ;
FIG. 4 is a perspective view illustrating a light source and a heat pipe of FIG. 2 ;
FIG. 5 is a flow diagram illustrating temperature control according to the projector of FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to the embodiments of the present invention, an example of which is illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiment is described below to explain the present invention by referring to the figures.
FIG. 2 is a schematic view illustrating a projector according to an embodiment of the present invention, and FIG. 3 is a perspective view illustrating an optical engine of the projector according to FIG. 2 . As illustrated in the drawings, the projector includes an optical engine 10 , and a cooling part 90 to cool the optical engine 10 . The optical engine 10 includes an optical synthesizer 70 , LCD panels 60 a, 60 b, and 60 c installed on three faces of the optical synthesizer 70 , light guide plates 50 a, 50 b, and 50 c respectively corresponding to rear surfaces of the LCD panels 60 a, 60 b, and 60 c, and a plurality of light sources 51 a, 51 b, and 51 c installed near upper sides and lower sides of the light guide plates 50 a, 50 b, and 50 c. Also, polarizing plates 61 a, 61 b, and 61 c are provided between the LCD panels 60 a, 60 b, and 60 c and the optical synthesizer 70 .
FIG. 4 is a partial perspective view illustrating the light sources 51 a, 51 b, and 51 c and heat pipes 52 a, 52 b, and 52 c (as shown in FIG. 3 ). Each of the heat pipes 52 a has a light source 51 a, 51 b or 51 c of a single color (red, green or blue). As illustrated in FIG. 4 , the light sources 51 a, 51 b and 51 c installed corresponding to the three faces of the optical synthesizer 70 each include a plurality of LEDs to emit the respective colored lights as an R-light source 51 a, a G-light source 51 b, and a B-light source 51 c. The plurality of light sources 51 a, 51 b, and 51 c are attached to the heat pipes 52 a, 52 b, and 52 c shaped like a bar. The heat pipes 52 a, 52 b, and 52 c are each installed with temperature sensors 53 . The heat pipes 52 a, 52 b, and 52 c are made of copper having high thermal conductivity and are filled with a small amount of liquid. The insides of the heat pipes 52 a, 52 b, and 52 c have a low pressure to lower a boiling point of the liquid inside. Accordingly, the liquid in the heat pipes 52 a, 52 b, and 52 c boils at a low temperature keeping a constant temperature across the heat pipes 52 a, 52 b, and 52 c, regardless of positions of heat sources contacting the heat pipes 52 a, 52 b, and 52 c.
FIG. 5 is a block diagram illustrating a flow of a temperature control of the projector according to the embodiment of the present invention. As illustrated in the drawing, the temperature sensors 53 installed on the heat pipes 52 a, 52 b, and 52 c transfer temperature information of the light sources 51 a, 51 b, and 51 c to a controller 40 , and then the controller 40 controls an operation of the cooling part 90 according to an optimized temperature previously inputted to control the temperature of the light sources 51 a, 51 b, and 51 c.
Hereinbelow, an operation of the projector having the above configuration will be described. The lights from the light sources 51 a, 51 b, and 51 c including LEDs of colored signals R, G, and B are emitted toward the light guide plates 50 a, 50 b, and 50 c. The light guide plates 50 a, 50 b, and 50 c transfer the lights emitted from the light sources 51 a, 51 b, and 51 c to the LCD panels 60 a, 60 b, and 60 c. The lights emitted from the light sources 51 a, 51 b, and 51 c installed on the upper sides and lower sides of the light guide plates 50 a, 50 b, and 50 c can be transferred to the rear surfaces of the LCD panels 60 a, 60 b, and 60 c by the light guide plates 50 a, 50 b, and 50 c.
The optical synthesizer 70 is shaped like a cube and synthesizes the lights from the LCD panels 60 a, 60 b, and 60 c. The LCD panels 60 a, 60 b, and 60 c control the lights emitted from the light sources 51 a, 51 b, and 51 c having color signals R, G, and B to form the picture in the optical synthesizer 70 . A projection lens 80 projects the synthesized picture. The polarizing plates 61 a, 61 b, and 61 c provided between the LCD panels 60 a, 60 b, and 60 c and the optical synthesizer 70 improve the straightness of the light.
The light sources 51 a, 51 b, and 51 c thermally contact each other through the heat pipes 52 a, 52 b, and 52 c. As described above, the heat pipes 52 a, 52 b, and 52 c reduce a temperature deviation among the heat sources contacting the heat pipes 52 a, 52 b, and 52 c because of their high thermal conductivity. Accordingly, the temperature deviation among the plurality of light sources 51 a, 51 b, and 51 c is reduced by the heat pipes 52 a, 52 b, and 52 c. Thus, a phase shift caused by a temperature difference among the light sources 51 a, 51 b, and 51 c can be removed.
Additionally, the controller 40 controls an operation of the cooling part 90 to cool the heat radiated from the light sources 51 a, 51 b, and 51 c using the temperature sensors 53 installed on the heat pipes 52 a, 52 b, and 52 c. The high thermal conductivity of the heat pipes 52 a, 52 b, and 52 c enables the temperature sensors 53 to detect the temperature of the light sources 51 a, 51 b, and 51 c accurately. Accordingly, the controller 40 can keep the temperature of the light sources optimal according to the detected temperature by controlling the cooling part 90 .
The embodiment of the present invention provides a projector having a simple structure, preventing the phase shift caused by temperature differences among a plurality of light sources and controlling the temperature of the plurality of light sources easily.
Although an embodiment of the present invention has been shown and described, it would be appreciated by those skilled in the art that changes may be made in this embodiment without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents.
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A projector having an optical engine, the optical engine including: an optical synthesizer; a plurality of display devices corresponding to the optical synthesizer; a plurality of light sources emitting light; a light guide plate provided between each light source and each display device; and a heat pipe contacting the light sources to reduce a temperature deviation between the light sources.
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BACKGROUND
The present invention relates generally to the field of tunable filters. More particularly, the present invention relates to tunable filter covering an appreciable frequency range while maintaining a constant bandwidth over that range.
Tunable filters offer communications service providers flexibility and scalability never before accessible. A single tunable filter can replace several fixed filters covering adjacent frequencies. This versatility provides transceiver front end RF tunability in real time applications and decreases deployment and maintenance costs through software controls and reduced component count. Tunable filters, although typically narrow band, can cover a larger frequency band than fixed filters by tuning over a wide range. Narrowband filters at the front end are appreciated from a systems point of view because they provide better selectivity and help reduce interference from nearby transmitters.
There are many potential uses for miniaturized, low-cost, tunable filters. Examples include software reconfigurable radios, mobile communications, and wideband radar systems. However, traditional varactor or switched capacitor tuned filter approaches have limitations caused by insertion loss and/or bandwidth variation. For example, stepped impedance resonant filters, in which the resonant frequency is tuned by direct physical transmission line adjustment, use external and internal lumped element networks to vary the coupling across the tuning range in order to eliminate bandwidth variation. However this approach requires active gain elements to compensate for the loss variation. In another example, comb-line and inter-digital filters, in which the resonant frequency is tuned by indirect capacitive loading of the resonant transmission line elements, use switchable coupling capacitors along the length of the resonator lines in order to eliminate the bandwidth variation. However, these types of filters tend to be complicated.
Current methods of actively turning filters require that the coupling between resonators be tuned as the resonant frequency of resonators is tuned in order to achieve constant bandwidth across the tuning range. This coupling between resonators, whether magnetic or electric, is very small and very sensitive. Accordingly, it is challenging if not prohibitive due to manufacturing and yield costs to design tunable filters having a dynamic coupling between resonators.
What is needed is an actively tuned filter in which an inter-resonator coupling of resonators decreases as the turning frequency is increased thereby maintaining constant bandwidth. What is further needed is such a filter where only the resonant frequency of the resonators is actively tuned and complicated internal coupling networks are not required.
It would be desirable to provide a system and/or method that provides one or more of these or other advantageous features. Other features and advantages will be made apparent from the present specification. The teachings disclosed extend to those embodiments which fall within the scope of the appended claims, regardless of whether they accomplish one or more of the aforementioned needs.
SUMMARY
One embodiment of the invention relates to an actively tuned filter providing a constant bandwidth at a plurality of frequencies. The filter includes electromagnetically coupled first and second resonators, each resonator having an open end configured to receive an input and a shorted end configured to connect the resonator to a ground. The axes of the coils of the first and second resonators may be aligned along a single axis. The filter further includes a variable capacitance allowing selection of a capacitance to be applied to the first and second resonators, each variable capacitance being connected to the shorted end of the first and second resonators between the resonator and the ground.
Another embodiment of the invention relates to a filter bank including a plurality of actively tuned filters providing a constant bandwidth at a plurality of frequencies. The filter bank includes at least two actively tuned filters the actively tuned filters configured to provide complementary tuning ranges. Each actively tuned filter includes electromagnetically coupled first and second resonators, each resonator having an open end configured to receive an input and a shorted end configured to connect the resonator to a ground, and a variable capacitance allowing selection of a capacitance to be applied to the first and second resonators. Each variable capacitance is connected to the shorted end of the first and second resonators between the resonator and the ground. The axes of the coils of the first and second resonators are aligned along a single axis.
Yet another embodiment of the invention relates to an actively tuned filter providing a constant bandwidth at a plurality of frequencies. The filter includes a first resonator having an open end configured to receive an input and a shorted end configured to connect the resonator to ground and a first variable capacitance allowing selection of a capacitance to be applied to the first resonator. The variable capacitances are connected to the shorted end of the first resonator between the resonator and the ground. The filter further includes a second resonator having an open end configured to provide an output and a shorted end configured to connect the resonator to ground and a second variable capacitance allowing selection of a capacitance to be applied to the second resonator, the variable capacitance is connected to the shorted end of the second resonator between the resonator and the ground. The filter may be configured such that the first resonator and the second resonator coils are aligned along a single axis and are connected by an electromagnetic coupling and configured to perform a filtering function.
Alternative examples and other exemplary embodiments relate to other features and combinations of features as may be generally recited in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will become more fully understood from the following detailed description, taken in conjunction with the accompanying drawings, wherein like reference numerals refer to like elements, in which:
FIG. 1A is an actively tuned filter in which the shorted ends of associated resonator coils are connected to ground through variable capacitance, according to an exemplary embodiment;
FIG. 1B is a simplified electrical circuit diagram of the actively tuned filter shown in FIG. 1A , according to an exemplary embodiment;
FIG. 1C is first and second graphs of decibels vs. frequency illustrating operation of the actively tuned filter of FIG. 1A in comparison with a prior art actively tuned filter, according to an exemplary embodiment;
FIG. 2A is an actively tuned filter including first and second resonators and further including a varactor diode associated with each resonator, according to an exemplary embodiment;
FIG. 2B is an actively tuned filter including first and second resonators and further including a drop in capacitor, according to an exemplary embodiment;
FIG. 3A is an actively tuned filter configured to enable continuous tuning with selectable bandwidth, according to an exemplary embodiment;
FIG. 3B is a graph of decibels vs. frequency showing various bandwidths at single frequency that occurs when utilizing inductors with the variable capacitance, according to an exemplary embodiment; and
FIG. 4 is an actively tuned filter bank including a plurality of actively tuned filters, according to an exemplary embodiment
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before describing in detail the particular improved system and method, it should be observed that the invention includes, but is not limited to, a novel structural combination of conventional data/signal processing components and communications hardware and software, and not in particular detailed configurations thereof. Accordingly, the structure, methods, functions, control, and arrangement of conventional components and circuits have, for the most part, been illustrated in the drawings by readily understandable block representations and schematic diagrams, in order not to obscure the disclosure with structural details which will be readily apparent to those skilled in the art, having the benefit of the description herein. Further, the invention is not limited to the particular embodiments depicted in the exemplary diagrams, but should be construed in accordance with the language in the claims.
Referring first to FIGS. 1A and 1B , an actively tuned filter 100 in which the shorted end of associated resonator coils 101 , 102 , 103 , and 104 are connected to ground through variable capacitance are shown, according to an exemplary embodiment. Actively tuned filter 100 , having capacitance connected to the shorted end of the resonators, allows a user to vary the pass band frequency of the filters without requiring separate tuning of the coupling between the two resonators. Although filter 100 is shown as including four resonators, one of ordinary skill in the art would understand that filter 100 may include more or less resonator coils.
In contrast, traditional tunable filters have variable capacitance connected to an open end of each resonator. Although varying capacitance may be selected, the coupling capacitance of filter 100 remains constant such that the effective bandwidth increases. To maintain a constant bandwidth at various frequencies, the coupling between the resonators would need to be varied. However, varying this coupling may be difficult because the coupling is typically in the 10 to 50 pico farad (pF) range. The capacitance is further subject to parasitic inductance that can cause additional difficulties in varying the coupling.
Various structures can be used to construct the filter and resonators, such as microstrips, strip lines, coaxial lines, dielectric resonators, resonator cavities, waveguides, etc. Coiled resonators that may be used to implement filter 100 may include printed circuit boards (PCB), wire wound coils, etc. According to an exemplary embodiment, the coil axes of resonators 101 - 104 may be aligned in an end to end configuration along the axes to facilitate tuning. Further, although filter 100 is shown and described in a low temperature co-fired ceramics (LTCC) implementation, the method taught herein is equally applicable to other technologies.
Referring now to FIG. 1B , a simplified electrical circuit diagram 110 of two of the resonators 102 and 104 of the actively tuned filter 100 is shown, according to an exemplary embodiment. The shorted end of resonator coils 102 and 104 are connected to ground through a variable capacitance 120 and 130 , respectively. Variable capacitances 120 and 130 allow a user to load the resonator 102 and 104 with different capacitors to change the resonant frequency of the filter and therefore the center frequency of the passband of the filter. Variable capacitance 120 and 130 are shown with three capacitors having unique capacitance. According to an exemplary embodiment, capacitances 120 and 130 include a first capacitor 122 and 132 of 100 pF, a second capacitor 124 and 134 of 2.0 pF, and a third capacitor 126 and 136 of 0.3 pF. The selection of the capacitance may be controlled by a FET switch as shown in FIG. 1B or any other switchable element such as a microelectromechanical switch (MEMS).
Actively tuned filter 100 includes first resonator coil 102 and second resonator coil 104 . Resonators 102 and 104 are configured to resonate at a designated frequency which defines the center frequency of the filter 100 . The amount of the coupling between resonators 102 and 104 defines the bandwidth.
Connecting the variable capacitance on the shorted end of the resonator changes the effective inductance of the coils to cause a change in the resonance of the resonators. However, by orienting the coil in a horizontal direction as shown in FIG. 1A , the coupling changes as the resonant frequency of the resonators changes. Over an appreciable tuning range, the coupling changes such that the bandwidth remains relatively constant. Although actively tuned filter 100 is shown in FIG. 1A in a horizontally coiled orientation with the axes of the resonator coils aligned along a single axis, filter 100 may alternatively be implemented in a vertically coiled orientation according to an alternative embodiment.
Connecting resonator coils 102 and 104 to ground through variable capacitance has the effect that the coupling of the resonators changes as the resonant frequency of the resonators is varied. Accordingly almost constant bandwidth can be maintained across the tunable range using actively tuned filter 100 . Advantageously, the resonator coupling of actively tuned filter 100 does not need to be tuned and the frequency shift associated with filter 100 is not as sensitive to the value of the shorted capacitor as would otherwise be expected.
Referring now to FIG. 1C , a first graph 140 of decibels vs. frequency showing expanding bandwidth at a plurality of frequencies that occurs when utilizing a prior art actively tuned filter and a second graph 150 of decibels vs. frequency showing constant bandwidth at a plurality of frequencies utilizing actively tuned filter 100 is shown, according to an exemplary embodiment. As see in the first and second graph, connecting the variable capacitance to the shorted end of a resonator in a horizontal position allows for a constant bandwidth even at increasing frequencies.
Referring to FIGS. 2A-B , actively tuned filter 100 is shown using different variable capacitance, according to alternative embodiments. Referring first to FIG. 2A , an actively tuned filter 200 is shown including first and second resonators 102 and 104 and further including a varactor diode 210 associated with each resonator. A variable capacitor is configured to provide variable capacitance dependent on the voltage applied across the diode to provide a continuous range of capacitance. This implementation allows continuous tuning across a frequency band. Advantageously, constant bandwidth can be produced at any frequency within the frequency range of the varactor. Referring now to FIG. 2B , an actively tuned filter 220 is shown including first and second resonators 102 and 104 and further including a “drop-in” capacitor 230 . Actively tuned filter 220 may configured such that any capacitor may be used as capacitor 230 , allowing the user to a variety of a specific desired frequency band dependent on the capacitor used as capacitor 230 .
Referring now to FIG. 3A , an actively tuned filter 300 configured to enable continuous tuning with selectable bandwidth is shown, according to exemplary embodiment. Actively tuned filter 300 includes resonators 102 and 103 and variable capacitance 120 and 130 further include inductors 310 associated in series with each capacitor in variable capacitance 120 and 130 to allow variance of bandwidth at a fixed frequency. Actively tuned filter 300 features capacitors and inductors in series to vary the filter bandwidth while maintaining a constant center frequency. According to an alternative embodiment, the variable capacitance 102 and 103 may be replaced with a varactor, to provide a variable pass band with variable bandwidth. For example, a first inductor, L 1 , may be selected with the varactor to have a wideband filter with a range of, for example, 1-2 GHz. Referring to FIG. 3B , a graph 320 of decibels vs. frequency showing various bandwidths at single frequency that occurs when utilizing inductors 310 with the variable capacitance 102 and 103 is shown, according to an exemplary embodiment. As seen in the graph 320 , connecting the inductors to the variable capacitance of a resonator allows for variable bandwidth at a constant frequency.
Referring now to FIG. 4 , an actively tuned filter bank including a plurality of actively tuned filters 100 is shown, according to an exemplary embodiment. Each filter 100 may be selected to have finite, but complimentary tuning range. According to current limitations, which may change over time, the current frequency range may be approximately an octave. FIG. 4 illustrates an actively tuned filter bank having three actively tuned filters. The filters may be switched in with an RF switch. One of ordinary skill in the art would easily understand that the number and/or range of these filters can be varied.
While the detailed drawings, specific examples and particular formulations given describe preferred and exemplary embodiments, they serve the purpose of illustration only. The inventions disclosed are not limited to the specific forms shown. For example, the methods may be performed in any of a variety of sequence of steps. The hardware and software configurations shown and described may differ depending on the chosen performance characteristics and physical characteristics of the computing devices. For example, the type of resonator, number of capacitors, or inductors used may differ. The systems and methods depicted and described are not limited to the precise details and conditions disclosed. Furthermore, other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the exemplary embodiments without departing from the scope of the invention as expressed in the appended claims.
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An actively tuned filter providing a constant bandwidth at a plurality of frequencies. The filter includes first and second electromagnetically coupled coiled resonators, each resonator having an open end configured to receive an input and a shorted end configured to connect the resonator to a ground. The filter further includes a variable capacitance allowing selection of a capacitance to be applied to the first and second resonators, each variable capacitance being connected to the shorted end of the first and second resonators between the resonator and the ground where the axes of the coils of the first and second resonators are aligned along a single axis.
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This is a continuation, of application Ser. No. 149,970 filed 05/15/80, which is a continuation of application Ser. No. 731,655 filed on 10/12/76 both now abandoned.
BACKGROUND OF THE INVENTION
I. Field of the Invention
This invention relates generally to computer output terminals of the type using an endless loop band having characters thereon for being impacted by a hammer for printing the character upon a paper surface adjacent thereto. In particular, this invention relates to an apparatus for controlling the elevation of the endless loop printing band for controlling the vertical spacing between adjacent printed lines.
II. Description of the Prior Art
Various prior art systems have been utilized for locating the position of a moving element relative to a reference position. Brown in U.S. Pat. No. 3,431,425 discloses a sensing system using dual light emitting elements for generating an error signal which is used to control a two phase servo motor, which then energizes a hydraulic valve control positioning mechanism to realign the traveling printing web. This system uses AC signals throughout for controlling a servo motor as opposed to the use of DC torque motors or stepping motors. Rempert in U.S. Pat. No. 3,598,978 discloses a method and apparatus for locating a preferred position on a workpiece. The workpiece is moved first in one direction and then in the opposite direction to determine with the aid of a light sensing element the distances between the initial position of the light sensing element and two of the workpiece edges.
Bessonny and Bowen in U.S. Pat. No. 3,432,672 disclose an automatic web registration control for use in printing presses. The control system employs a pair of photocells spaced apart by the distance equal to the separation between a pair of indicia. Pulse generation circuits are coupled to the photocells for generating paired pulses of opposite polarity, with the duration of the pulses being different when the web is out of registration. Mechanical means are provided for adjusting the position of the web responsive to the pulserations. Schneider in U.S. Pat. No. 3,525,872 discloses a system for detecting the arrival of a register mark on material traveling along a longitudinal axis, and responsive thereto generates a first control signal for triggering the performance of a work function on the work piece at a point in registration with the registration with the reference point. Hall and Beddell in U.S. Pat. No. 3,956,632 disclose a control system utilizing dual photoelectric sensors spaced on opposite sides of a longitudinally moving conveyor. Control signals are generated responsive to a transverse movement of the conveyor for reorienting the guiding sensors. Scanlon in U.S. Pat. No. 3,395,285 discloses a pinhole detector which automatically inspects very thin sheets of metal for minute perforations.
In contrast with these analog prior art systems, the present invention utilizes two pairs of optical sensors located adjacent to at least one edge of the moving printing band. The optical sensors could be placed adjacent opposite edges of the printing band if the variation in the width of the printing band were small with respect to the allowed position variation. The analog output signals from these sensors are then digitized to be input compatible with a digital computer which compares the sensor signals with a predetermined logic pattern. The digital computer generates a digital correction signal which operates a digital step motor for moving the printing band in incremental steps to correct the positioning error.
SUMMARY OF THE INVENTION
This invention relates to a band positioning apparatus for vertically positioning a high-speed endless loop printing band of the type used on impact band printers. The band positioning apparatus comprises a first sensor for generating, at an output thereof, a first signal responsive to the edge of the endless loop printing band drifting to one side of a reference line, with the reference line being defined by the correct position of the edge of the endless loop printing band. A second sensor is provided for generating, at an output thereof, a second signal responsive to the edge of the endless loop printing band drifting to the other side of the reference line. A microprocessor type computer is provided for receiving the first and second signal and for generating a correction signal responsive thereto. Step motor means are actuated responsive to the correction signals for moving the edge of the endless loop printing band toward the reference line.
The band positioning apparatus further includes conditioning means interposed between the first and second sensors and the computer means for converting the first and second signals from an analog type to a digital type signal. The computer means then periodically samples and compares the first and second signals with respect to a predetermined logic pattern and generates the correction signals responsive thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the present invention will be apparent from a study of the written description and the drawings in which:
FIG. 1 illustrates a perspective view of the first second sensor assemblies positioned adjacent to the edge of the endless loop printing band.
FIG. 2 illustrates a schematic block diagram of the band positioning apparatus.
FIG. 3 illustrates a cross-section elevational view of the pulley and stepping motor assembly; and
FIG. 4 shows a partially cutaway view of the stepping motor illustrating the threaded aperture.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A first preferred embodiment of the band positioning apparatus in accordance with the present invention is illustrated schematically in FIG. 2. As illustrated in FIGS. 1 and 2, a first sensor 10 comprises a first light source 11, an LED, and a first photodetector 12 aligned coaxially therewith but spaced on opposite sides of a lower edge section of an endless loop printing band 100. The printing band 100 includes thereon a plurality of character impressions 102 and a plurality of timing marks 104 paired therewith for signaling an impact hammer (not shown) to impact the character impressions 102 for imprinting the character on a paper adjacent thereto. The axis between the first light source 11 and the first photodetector 12 is displaced just below an edge surface 106 of the endless loop printing band 100. The preferred or nominal position of the edge surface 106 of the endless loop printing band 100 may be referred to as a reference line or reference position 110. As the edge surface 106 moves below the reference line 110, the transmission of light between the first light source 11 and the first photodetector 12 will be interrupted. A change in the light incident upon the first photodetector 12 will cause a signal to be transmitted down the circuit line 14 to a first input of a signal amplifier and conditioner 30.
A second sensor, illustrated generally as 20, comprises a second light source 21 and a second photosensitive detector 22 coaxially arranged adjacent to the edge surface 106 of the endless loop printing band 100. However, in contrast with the first sensor 10, the axis between the second light source 21 and the second photodetector 22 intersects the endless loop printing band 100 at a point just vertically above the edge surface 106 and the reference line 110, such that under normal conditions the light is not transmitted to the second photodetector 22. However, if the edge surface 106 of the endless loop band 100 drifts in a vertically upward direction, the light from the second light source 21 will be received by the second photodetector 22 causing a signal to be transmitted over the circuit conductor 24 coupled to a second input of the signal amplifier and conditioner 30.
The first sensor 10 and the second sensor 20 are each removably attached to a main frame 112 which in turn is coupled to the printer base 114. Each of the mounting plates 16 and 26 may be adjusted in height by placing shims thereunder. Also, the height of both the first and second sensors 10 and 20 may be simultaneously adjusted by inserting shims between the main frame 112 and the printer base 114. Generally, no axial alignment of the light source and the photodetector either of the first or second sensors are required since each element is rigidly mounted to a common mounting plate, 16 and 26 respectively.
The first signal received from the first sensor 10 and the second signal received from the second sensor 20 are separately conditioned and amplified in the signal amplifier and conditioner circuitry 30. The signal amplifier and conditioner 30 comprises well known circuitry for removing impulse and Gaussian noise from the first and second signals. The signal amplifier and conditioner circuitry 30 comprises an active network for digitizing the analog input signals. Each section of the circuit 30 provides a digital output representative of a one or a zero indication responsive to the respective input signals. The circuit 30 includes a hysteresis lag for time averaging the input signals.
The first signal is coupled from a first output of the signal amplifier and conditioner through a circuit conductor 32 to a first input of a microprocessing computer 40. The second signal is coupled from a second output of the signal amplifier and conditioner 30 through a second conductor 34 to a second input of the microprocessor 40.
The microprocessor 40 comprises a digital circuit having an internal clock for, among other things, comparing the first signal and the second signal at the respective inputs thereof to a preprogrammed logic table. For example, if each of the first and second sensors 10 and 20 generates a logic 1 responsive to receiving light from its paired light source, then the lower edge surface 106 of the endless loop printing band 100 will be in the correct position when the first signal is a 1 and the second signal is a 0. When the edge surface 106 lies above the reference line 110, then the first signal and the second signal will both be ones. When the edge surface 106 drifts below the reference line 110, both the first and second signals will be zeros. Of course, there is an allowable increment of movement of the edge surface 106 about the reference line 110 without actuating the microprocessor 40 to produce the error signal. This is caused by various mechanical and electrical inaccuracies including among others, the effective apertures of the first and second photodetectors 12 and 22, the electrical digitizing accuracy of the signal amplifier and conditioner 30 together with the sampling rate of the microprocessor 40. The microprocessor 40 is programmed to provide at an output thereof a correction signal responsive to the first and second input signals being compared with the preprogrammed logic table. In a first preferred embodiment of the present invention these correction signals comprise a plurality of parallel digital lines for carrying digital pulses of unit amplitude which are coupled from first outputs of the microprocessor 40 into first inputs of a power driver circuit 50 by first circuit lines 46. Generally, the digital signals are formatted as a "Johnson counter" signal which provides a digital indication of the magnitude and the direction of change required to bring the edge surface 106 back toward the reference line 110. Also, an enable line 48 is coupled from a second output of the microprocessor 40 to a second input of the power driver circuitry 50. The enable line 48 is actuated by the home pulse on the printing band, that is once per band revolution, for updating the correction or error signal subputs from the microprocessor 40. The periodic enable signal from a second output of the microprocessor 40 also reduces the power consumption of the power by the power driver circuitry.
The power driver circuitry 50 comprises standard power amplifier circuits for controlling the power applied through the circuit lines 52 and 54 to the stepping motor 60. As previously discussed, no power is applied to the stepping motor 60 unless the enable signal is received from the microprocessor 40.
The stepping motor 60 comprises a 4 phase electro-mechanical device for receiving the amplified correction signals, which have a Johnson counter digital format, through the circuit conductors 52 and 54 and responsive thereto incrementally varying the neight of a lead screw 70. The height is adjusted by one increment during each revolution of the printing band 100. As illustrated in FIG. 3, the lead screw 70, having an idler pulley 74 coupled thereto, communicates coaxially through the stepping motor 60 as seen in the cutaway view of stepping motor 60 of FIG. 4. A first end of the lead screw extends through a captured bearing 80 which in turn is coupled coaxially to the idler pulley 74. The distended end 71 of the lead screw 70 coupled to the stepping motor 60 communicates through an aperture in a reinforcing bar positioned above the idler pulley 74. The idler pulley 74 rotates freely about the bearing 80 but is not free to move longitudinally along the lead screw 70. A center section of the lead screw 70 includes therein a plurality of threads for being engaged by the sides of a threaded aperture within the stepping motor 60. The lead screw 70 includes through the center section thereof a longitudinal slot 73. A pin 86 coupled to the fixed frame 82 communicates within the longitudinal slot 73 for preventing the rotation of the lead screw 70 about its longitudinal axis. In this manner, when the stepping motor 60 is actuated, the motor assembly will engage the lead screw 70 and move the center threaded section in either an upward or downward direction depending upon the correction signal provided thereto. The second end 72 of the lead screw 70 includes thereon a manually operated handle for initially adjusting the edge surface 106 of the endless loop printing band 100 with respect to the reference line 110.
The operation of the band positioning apparatus in accordance with the present invention will now be explained with reference to FIGS. 2 and 3. First, power is applied to a drive motor 90 having coupled thereto a drive pulley 92 for driving at high speed the endless loop printing band 100. After the endless loop printing band 100 has achieved its operational speed, the operator adjusts the handle 76 coupled to the lead screw 70 for positioning the lower edge surface 106 of the endless loop printing band 100 within an accepted tolerance limit of the reference line 110. As long as the edge surface 106 stays within the tolerance limits adjacent the reference line 110, the band positioning system will be generally inoperative. However, if the edge surface 106 of the endless loop printing band 100 drifts above the reference line 110 by a distance exceeding the predetermined tolerance level, the first and second signal inputs to the microprocessor 40 will both be 1, since both the first and second photodetectors 12 and 22 will receive the light from their paired light sources 11 and 21 respectively. The microprocessor 40 will periodically compare the first and second input signals with the preprogrammed logic table and responsive to these signals will generate the correction signals to the power driver circuitry 50. This correction signal will be correct in both direction and amplitude for actuating the stepping motor 60 to drive the edge surface 106 of the endless loop printing band 100 back toward the reference line 110. However, power will be provided from the power drive circuitry 50 to the stepping motor 60 only periodically during one revolution of the printing band 100 for incrementally actuating the stepping motor 60. Generally, the power driver circuitry 50 is actuated only once per revolution of the printing band 100 by the passage of a home signal past a reference point. The power driver circuitry 50 will drive the stepping motor 60 in the proper rotational direction to retract the length of the lead screw 70. Since the idler pulley 74 is coupled to the first end 71 of the lead screw 70, the idler pulley 74, having the endless loop printing band 100 coupled thereto, will be drawn in a downward direction, thereby forcing the edge surface 106 into the predetermined tolerance limits adjacent the reference line 110. If further incremental correction is required, it will be initiated during the next actuating period. In a similar manner the band positioning apparatus will drive the idler pulley 74 in a vertical direction to compensate for the edge surface 106 deviating below the reference line 110 beyond the allowable incremental distance.
Thus, a first preferred embodiment of a band positioning apparatus has been discussed as an example of the invention as claimed. However, the present invention should not be limited in its application to the details illustrated in the accompanying drawings and the specification since this invention may be practiced and constructed in a variety of different embodiments. Also, it must be understood that the terminology and descriptions employed herein are used solely for the purpose of describing the general operation of the preferred embodiment and should not be construed as limitations on the operability of the invention.
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This invention relates to a system for positioning a high-speed endless loop printing band of the type used on impact band printers. The band positioning apparatus includes a first sensor for being placed adjacent the edge of the endless loop band for detecting the drift of the edge to one side of a reference line. A second sensor is provided adjacent an area of the endless loop printing band for detecting the drift of the edge to the other side of the reference line. A microprocessor is coupled to the first and second sensors for generating a correcting output signal to a step motor. The step motor is coupled to a pulley in guiding communication with the endless loop printing band for displacing the pulley toward the reference line, thereby correcting the undesired movement of the edge of the endless loop printing band.
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TECHNICAL FIELD
[0001] The invention relates to methods of modifying fibers, such as glass fibers. The modified fibers can be used, for example, in a lead acid battery.
BACKGROUND
[0002] Batteries are commonly used as energy sources. Typically, a battery includes a negative electrode (anode) and a positive electrode (cathode). The anode and cathode are often disposed in an electrolytic solution. During discharge of a battery, a chemical reaction can occur that oxidizes an active anode material and reduces an active cathode material. During the reaction, electrons flow from the anode to the cathode, and ions in the electrolytic solution flow between the anode and the cathode. Certain batteries can be recharged by running the chemical reaction in reverse.
[0003] One type of battery is a lead acid battery. In a lead acid battery, lead is usually an active anode material, and lead dioxide is usually an active cathode material. Generally, lead acid batteries also contain sulfuric acid, which serves as an electrolyte and participates in the chemical reaction. A typical discharge reaction for a lead acid battery reaction is:
Anode: Pb( s )+HSO 4 − ( aq )→PbSO 4 ( s )+H + +2 e −
Cathode: PbO 2 ( s )+3H + ( aq )+HSO 4 − ( aq )+2 e − →PbSO 4 ( s )+2H 2 O
Net: Pb( s )+PbO 2 ( s )+2H + ( aq )+2HSO 4 − ( aq )→2PbSO 4 ( s )+2H 2 O
SUMMARY
[0004] The invention relates to methods of modifying fibers, such as glass fibers. As an example, the modified fibers can be used in one or more of the electrodes in a battery (e.g., anode(s) and/or cathode(s) in a lead acid battery). Alternatively or additionally, the modified fibers can be disposed in a paste used to form one or more of the electrodes in a lead acid battery (e.g., anode(s) and/or cathode(s) in lead acid batteries).
[0005] In one aspect, the invention features a method of modifying a plurality of fibers. The method includes applying pressure at more than one angle to the plurality of fibers. The plurality of fibers has an average length of greater than 1.5 millimeters before applying pressure and an average length of less than 1.5 millimeters after applying pressure.
[0006] In another aspect, the invention features a method of modifying a plurality of fibers. The method includes applying pressure to the plurality of fibers. The plurality of fibers has a first average length before applying pressure and a second average length after applying pressure. The first average length is at least 15 times greater than the second average length.
[0007] In another aspect, the invention features a method of modifying a plurality of fibers. The method includes applying a first pressure to the plurality of fibers, and
[0008] removing the first pressure from the plurality of fibers. The method further includes rotating the plurality of fibers, and applying a second pressure to the plurality of fibers. The plurality of fibers has a first average length before applying the first pressure and a second average length after applying the second pressure. The first average length is greater than the second average length.
[0009] In another aspect, the invention features a composition that includes an active lead electrode material and fibers. The fibers have an average length of from 0.1 millimeter to 1.5 millimeters.
[0010] In another aspect, the invention features a paste that includes a lead material and fibers. The fibers have an average length of from 0.1 millimeter to 1.5 millimeters.
[0011] In another aspect, the invention features an electrode including a support and an active lead electrode material (e.g., lead or lead dioxide) disposed on the support. The active lead electrode material includes fibers having an average length of from 0.1 millimeter to 1.5 millimeters.
[0012] In another aspect, the invention features a battery that includes an anode and a cathode. The anode includes a support and an active electrode material disposed on the support. The active electrode material includes lead and fibers having an average length of from 0.1 millimeter to 1.5 millimeters.
[0013] In another aspect, the invention features a battery that includes an anode and a cathode. The cathode includes a support and an active electrode material disposed on the support. The active electrode material includes lead dioxide and fibers having an average length of from 0.1 millimeter to 1.5 millimeters.
[0014] In another aspect, the invention features a method that includes combining a lead material and fibers. The fibers have an average length of from 0.1 millimeter to 1.5 millimeters. The method can further include combining the lead material and fibers with water. The method can also include mixing the lead material, fibers and water. In addition, the method can include adding an acid (e.g., sulfuric acid).
[0015] In another aspect, the invention features a method that includes combining fibers and water, and combining the water and fibers with a lead material. The fibers have an average length of from 0.1 millimeter to 1.5 millimeters. The method can further include mixing the lead material, fibers and water. The method can also include adding an acid (e.g., sulfuric acid).
[0016] In another aspect, the invention features a composition that includes an active lead electrode material and fibers. The fibers have an average length of less than 1.5 millimeters and average diameter of at least one micron. The composition can be used, for example, in a battery electrode (e.g., anode and/or cathode of a lead acid battery).
[0017] In another aspect, the invention features a plurality of glass fibers having an average length of from 0.1 millimeter to 1.5 millimeters.
[0018] In another aspect, the invention features a plurality of glass fibers having an acid absorption of less than 1350%.
[0019] Generally, the fibers (e.g., glass fibers) are individual fibers that are grouped together. For example, the fibers (e.g., glass fibers) can be included in an enclosure that can be sold to a customer.
[0020] In certain embodiments, an electrode material containing the modified fibers can exhibit relatively high strength, such as by measured using vibration testing. This can reduce the pressure used to maintain good electrical contact between the electrode material and separators, which can reduce the likelihood of encountering problems associated with using larger pressures to maintain good electrical contact between the electrode material and separators.
[0021] In some embodiments, electrode material containing the modified fibers can exhibit relatively high initial specific capacity. This can be advantageous, for example, in applications where it is desirable to obtain a relatively large amount of energy from a lead acid battery in a relatively short period of time.
[0022] In certain embodiments, anode material containing the modified fibers can be relatively active toward oxidation. This can enhance the ability of the anode material to undergo oxidation (e.g., assist the formation of lead oxide from lead).
[0023] In some embodiments, electrode material containing the modified fibers can have a relatively open structure. This can, for example, assist in allowing the participants in the chemical reaction to access the electrode material.
[0024] In certain embodiments, electrode material containing the modified fibers can exhibit a relatively high charge acceptance.
[0025] Features, objects and advantages of the invention are in the description, drawings and claims.
DESCRIPTION OF DRAWINGS
[0026] FIG. 1 is a partially cut away perspective view of an embodiment of a lead acid battery;
[0027] FIG. 2 is a partial cross-sectional view of an embodiment of an anode plate for a lead acid battery;
[0028] FIG. 3 is a partial cross-sectional view of an embodiment of a cathode plate for a lead acid battery;
[0029] FIG. 4 is a cross-sectional view of an embodiment of an apparatus for modifying the average length of an association of fibers;
[0030] FIG. 5 is an illustration of an embodiment of a pasting apparatus;
[0031] FIG. 6 is an illustration of an embodiment of a pasting apparatus;
[0032] FIG. 7 is an X-ray diffraction scan of a discharged anode plate;
[0033] FIG. 8 is an X-ray diffraction scan of a charged anode plate;
[0034] FIG. 9 is a scanning electron micrograph of a discharged anode plate skeleton taken at 800× magnification;
[0035] FIG. 10 is a scanning electron micrograph of a discharged anode plate skeleton taken at 3,000× magnification;
[0036] FIG. 11 is a scanning electron micrograph of a discharged anode plate skeleton taken at 3,000× magnification;
[0037] FIG. 12 is a scanning electron micrograph of a dried, pasted anode plate (before curing) taken at 500× magnification;
[0038] FIG. 13 is an X-ray diffraction scan of a discharged anode plate;
[0039] FIG. 14 is an X-ray diffraction scan of a charged anode plate;
[0040] FIG. 15 is a scanning electron micrograph of a discharged anode plate skeleton taken at 800× magnification;
[0041] FIG. 16 is a scanning electron micrograph of a discharged anode plate skeleton taken at 3,000× magnification;
[0042] FIG. 17 is a plot of measured nominal charge acceptance for certain batteries;
[0043] FIG. 18 shows measured nominal reserve capacity values for certain batteries;
[0044] FIG. 19 shows measured nominal cold crank values for certain batteries;
[0045] FIG. 20 shows measured nominal cold crank values for certain batteries; and
[0046] FIG. 21 is a bar graph of the capacity versus discharge rate data for certain batteries.
DETAILED DESCRIPTION
[0047] FIG. 1 shows a lead acid battery 100 including a case 102 with a top 104 having a boss 106 disposed therein. Case 102 contains anode plates 110 connected to a negative terminal 112 , and cathode plates 120 connected to a positive terminal 122 . Separators 130 are disposed between adjacent anode and cathode plates 110 and 120 , respectively. Case 102 also contains sulfuric acid (e.g., an aqueous sulfuric acid solution).
[0048] FIGS. 2 and 3 are partial cross-sectional views of anode and cathode plates 110 and 120 , respectively. Anode plate 110 includes a support 112 with a grid 113 having an anode composition 114 disposed thereon, and cathode plate 120 includes a support 122 with a grid 123 having a cathode composition 124 disposed thereon.
[0049] Anode composition 114 and/or cathode composition 124 can include glass fibers having an average length of from 0.1 millimeter to 1.5 millimeters. A fiber refers to an entity having a ratio of length to diameter (i.e., aspect ratio) of at least two.
[0050] Without wishing to be bound by theory, it is believed that including the glass fibers in anode composition 114 and/or cathode composition 124 can enhance the performance (e.g., enhance the initial specific capacity) of battery 100 . It is believed that the glass fibers can increase the ability of the sulfuric acid to access the active electrode material in battery 100 because the fibers can extend from the interior of the electrode material into the sulfuric acid solution to form a pathway for one or more reactant participants (e.g., sulfuric acid) to penetrate the interior of the electrode material, thereby increasing the amount of the electrode material that can readily participate in the chemical reaction(s) of battery 100 . It is further believed that the glass fibers can increase the mobility of ions with respect to their ability to get into and out of the electrode material (e.g., by providing a hydrophilic route for ion transmission), which can enhance the rate at which energy can be withdrawn from battery 100 . It is also believed that the glass fibers can reduce the size and/or formation of domains of relatively inactive material (e.g., PbSO 4 ) present at the surface of anode composition 114 and/or cathode composition 124 , which can also increase the amount of electrode material that can readily participate in the chemical reaction(s) of battery 100 . It is further believed that the glass fibers can exhibit good electrical conductivity along their length when wet (e.g., when in contact with an aqueous sulfuric acid solution) so that the glass fibers do not a have a substantial undesirable impact on the electrical conductivity of the electrode material, and can actually enhance the conductivity of the electrode material in some embodiments. It is also believed that some glass fibers are capable of releasing certain ions (e.g., nickel, platinum, barium, cobalt, antimony, bismuth and/or tin) which are believed to be capable of enhancing battery performance when present in the sulfuric acid solution. It is believed that one or more of these features can be particularly advantageous, for example, when the battery is used in high discharge rate conditions.
[0051] Generally, the glass fibers are formed of one or more siliceous materials. While various types of glass fibers can be used, typically the glass fibers typically are relatively inert to lead acid battery storage and use conditions. In some embodiments, at least some (e.g., all) of the glass fibers contain a relatively small amount (e.g., less than one weight percent, less than 0.5 weight percent, less than 0.1 weight percent) of barium and/or zinc compounds (e.g., barium oxide, zinc oxide). In certain embodiments, at least some (e.g., all) of the glass fibers are formed of a type of glass commonly referred to as C glass.
[0052] Glass fibers are commercially available from, for example, Owens Corning (Toledo, Ohio), Johns Manville (Denver, Colo.), PPG (Pittsburgh, Pa.), Nippon Sheet Glass (Tokyo, Japan), Evanite Fiber Corporation (Corvallis, Oreg.), and Hollingsworth & Vose Company (East Walpole, Mass.). Examples of commercially available glass fibers include PA-01 glass fibers (Hollingsworth & Vose), PA-10 glass fibers (Hollingsworth & Vose Company), PA-20 glass fibers (Hollingsworth & Vose Company), Evanite 408 glass fibers (Evanite Fiber Company), Evanite 609 glass fibers (Evanite Fiber Company), Evanite 610 MB glass fibers (Evanite Fiber Company) and Evanite 719 glass fibers (Evanite Fiber Company).
[0053] In general, the glass fibers have an average length of less than 1.5 millimeters (e.g., less than 1.4 millimeters, less than 1.3 millimeters, less than 1.2 millimeters, less than 1.1 millimeters, less than one millimeter, less than 0.975 millimeter, less than 0.950 millimeter, less than 0.925 millimeter, less than 0.900 millimeter, less than 0.875 millimeter, less than 0.850 millimeter, less than 0.825 millimeter, less than 0.800 millimeter, less than 0.775 millimeter, less than 0.750 millimeter, less than 0.725 millimeter, less than 0.700 millimeter, less than 0.675 millimeter, less than 0.650 millimeter, less than 0.625 millimeter, less than 0.600 millimeter, less than 0.575 millimeter, less than 0.550 millimeter, less than 0.525 millimeter, less than 0.500 millimeter, less than 0.475 millimeter, less than 0.450 millimeter, less than 0.425 millimeter, less than 0.400 millimeter, less than 0.375 millimeter, less than 0.350 millimeter, less than 0.325 millimeter, less than 0.300 millimeter, less than 0.275 millimeter, less than 0.250 millimeter, less than 0.225 millimeter, less than 0.200 millimeter, less than 0.175 millimeter, less than 0.150 millimeter, less than 0.125 millimeter, less than 0.100 millimeter) and/or an average length of at least 0.100 millimeter (e.g., at least 0.125 millimeter, at least 0.150 millimeter, at least 0.175 millimeter, at least 0.200 millimeter, at least 0.225 millimeter, at least 0.250 millimeter, at least 0.275 millimeter, at least 0.300 millimeter, at least 0.325 millimeter, at least 0.350 millimeter, at least 0.375 millimeter, at least 0.400 millimeter, at least 0.425 millimeter, at least 0.450 millimeter, at least 0.475 millimeter, at least 0.500 millimeter).
[0054] The average length of a sample of fibers is determined as follows. The fibers are placed on a slide and the fiber lengths are measured by visual inspection using a Leica DMLS microscope with a video camera (Meyer Instruments, Inc., Houston, Tex.) using a magnification of from 20× to 200×. The average length is then calculated as the arithmetic mean of the measured fibers lengths.
[0055] In certain embodiments, the ability of the glass fibers to be processed into a paste is increased as the average length of the fibers is decreased. It is believed that this is due to certain enhanced flow characteristics achieved by reducing the average length of the fibers. As an example, Table I shows the flow characteristics of glass fibers having different average lengths. The average length of the PA-10 was 359 microns, and the average length of the PA-20 was 154 microns. The data in Table I was measured by: placing a given weight of a sample of glass fibers on a mesh having a given size; shaking the sample for five minutes at 42 Hz using a Syntron shaker; and weighing the amount of the glass fibers that passed through the screen. This test is referred to herein as the shake test. As indicated in Table I, for a given mesh size, the ability of the glass fibers to pass through the screen increased as the average fiber length was decreased.
TABLE I % Sample Fibers Mesh Size Sample Wt Wt Passed Passed PA-01 6 × 6 5.047 g 0.002 g 0.04 PA-01 4 × 4 5.087 g 0.005 g 0.10 PA-10 10 × 10 5.052 g 0.091 g 1.80 PA-10 8 × 8 5.038 g 0.759 g 15.07 PA-10 6 × 6 5.053 g 4.161 g 82.35 PA-10 4 × 4 5.045 g 4.243 g 84.10 PA-10 4 × 4 5.098 g 4.558 g 89.41 PA-20 10 × 10 5.098 g 3.777 g 74.09 PA-20 8 × 8 5.053 g 4.538 g 89.81 PA-20 6 × 6 5.045 g 4.307 g 85.37
[0056] In certain embodiments, at least one weight percent (e.g., at least two weight percent, at least five weight percent, at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 30 weight percent, at least 40 weight percent, at least 50 weight percent, at least 60 weight percent, at least 70 weight percent) of the glass fibers pass through a 10×10 mesh during the shake test.
[0057] In some embodiments, at least five weight percent (e.g., at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 30 weight percent, at least 40 weight percent, at least 50 weight percent, at least 60 weight percent, at least 70 weight percent, at least 80 weight percent, at least 90 weight percent) of the glass fibers pass through an 8×8 mesh during the shake test.
[0058] In certain embodiments, at least five weight percent (e.g., at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 30 weight percent, at least 40 weight percent, at least 50 weight percent, at least 60 weight percent, at least 70 weight percent, at least 80 weight percent, at least 90 weight percent) of the glass fibers pass through a 6×6 mesh during the shake test.
[0059] In certain embodiments, at least five weight percent (e.g., at least 10 weight percent, at least 15 weight percent, at least 20 weight percent, at least 30 weight percent, at least 40 weight percent, at least 50 weight percent, at least 60 weight percent, at least 70 weight percent, at least 80 weight percent, at least 90 weight percent) of the glass fibers pass through a 4×4 mesh during the shake test.
[0060] In some embodiments, more than six weight percent (e.g., at least seven weight percent, at least eight weight percent, at least nine weight percent, at least 10 weight percent, at least 11 weight percent, at least 12 weight percent, at least 13 weight percent at least 14 weight percent) of an association of the glass fibers is lost during the hand sheet test. The hand sheet test is performed as follows. An association of fibers is placed in a Hamilton Beach seven speed blender, and 550 milliliters of deionized (reverse osmosis) water is added to the blender. An amount of aqueous sulfuric acid (22 volume percent sulfuric acid) is added to the blender so that the mixture obtain a pH of 2.8. The blender is set to high and blended for 10 seconds. The blended mixture is poured into a TAPPI semiautomatic hand sheet mold with a 150 mesh screen, and the mold is turned on so that the blended mixture is formed into a hand sheet on the 150 mesh screen. The mold is then turned off, and the hand sheet is couched from the 150 mesh screen using 6.5 pounds per square inch pressure. The hand sheet is rolled five times using a 25 pound roller, and then put in an oven at 187° C. until dry. The mass of the dried hand sheet is then measured. The percent weight loss is the ratio of the mass of the dried hand sheet to the initial mass of the association of fibers.
[0061] The glass fibers can have an average diameter of less than 40 microns (e.g., less than 35 microns, less than 30 microns, less than 25 microns, less than 20 microns, less than 15 microns, less than 10 microns, less than five microns, less than three microns, less than 2.9 microns, less than 2.75 microns, less than 2.5 microns, less than 2.25 microns, less than 2.5 microns, less than 2.25 microns, less than two microns, less than 1.75 microns, less than 1.5 microns, less than 1.25 microns, less than one micron) and/or an average diameter of at least one micron (e.g., at least 1.25 microns, at least 1.5 microns, at least 1.75 microns, at least two microns, at least 2.25 microns, at least 2.5 microns, at least 2.75 microns, at least three microns, at least 3.5 microns, at least four microns). In certain embodiments, the glass fibers have an average diameter of from 0.7 microns to 6.25 microns (e.g., 0.9 microns, 1.35 microns, 2.9 microns, 2.8 microns, 6.1 microns).
[0062] The average diameter of a sample of fibers is determined using the BET method and argon gas.
[0063] The glass fibers can have an average aspect ratio of less than 1,500 (e.g., less than 1400, less than 1,300, less than 1,200, less than 1,100, less than 1,000, less than less than 900, less than 800, less than 700, less than 600, less than 500, less than 400, less than 300) and/or an average aspect ratio of at least two (e.g., at least five, at least 10, at least 50, at least 60, at least 70, at least 80, at least 90, at least 100, at least 110, at least 120, at least 130, at least 140, at least 150, at least 160, at least 170, at least 180, at least 190, at least 200, at least 250, at least 300, at least 350, at least 400).
[0064] The average aspect ratio of a sample of fibers refers to the ratio of the average length of the sample of fibers to the average diameter of the sample of fibers.
[0065] In certain embodiments, the glass fibers can have a relatively low acid absorption. For example, the glass fibers can have an acid absorption of less than 1,350% (e.g., less than 1,300%, less than 1,250%, less than 1,200%, less than 1,150%, less than 1,100%, less than 1,500%, less than 1,000%, less than 950%, less than 900%, less than 850%, less than 800%, less than 750%, less than 700%, less than 650%, less than 600%, less than 550%, less than 500%, less than 450%, less than 400%, less than 350%, less than 300%, less than 250%, less than 200%, less than 150%, less than 125%, less than 100%) and/or at least 50% (e.g., at least 100%, at least 150%, at least 200%, at least 250%, at least 300, at least 350%).
[0066] The acid absorption of a sample of fibers is measured as follows. One gram of the sample of fibers is placed in a dish (e.g., a petri dish). An amount of 1.28 specific gravity sulfuric acid sufficient to wet and cover the fibers is placed on the fibers. The fibers are soaked in the sulfuric acid for five minutes. The fibers are removed from the sulfuric acid, placed on a screen and drained for one minute. The mass of the fibers is then measured to determine the wet mass of the fibers. The acid absorption is determined by the following equation.
Acid absorption=((wet mass of fibers in grams−one gram)/(one gram))*(100%))
[0067] At least some of the glass fibers can be substantially noncoated. A substantially noncoated fiber means a fiber which, prior to being incorporated into anode material 114 or cathode material 124 , has a coating (e.g., a metal coating, a metal oxide coating, an alloy coating) on less than 90 percent (e.g., less than 80 percent, less than 70 percent, less than 60 percent, less than 50 percent, less than 40 percent, less than 30 percent, less than 20 percent, less than 10 percent, less than five percent, less than four percent, less than three percent, less than two percent, less than one percent) of its surface.
[0068] At least some of the glass fibers can be substantially nonhollow. A substantially nonhollow fiber, as referred to herein, means a fiber which has an internal volume that is at least 10 percent (e.g., at least 20 percent, at least 30 percent, at least 40 percent, at least 50 percent, at least 60 percent, at least 70 percent, at least 80 percent, at least 90 percent, at least 95 percent, at least 96 percent, at least 97 percent, at least 98 percent, at least 99 percent) solid.
[0069] At least some of the glass fibers can be substantially nonporous. A substantially nonporous fiber, as referred to herein, means a fiber which has a surface with less than 95 percent (e.g., less than 90 percent, less than 80, less than 70 percent, less than 60 percent, less than 50 percent, less than 40 percent, less than 30 percent, less than 10 percent) formed of pores.
[0070] In general, the amount of the glass fibers included in anode material 114 and/or cathode material 124 can be varied as desired. For example, anode material 114 and/or cathode material 124 can include at least 0.02 weight percent (e.g., at least 0.05 weight percent, at least 0.1 weight percent, at least 0.2 weight percent, at least 0.3 weight percent, at least 0.4 weight percent, at least 0.5 weight percent, at least 0.6 weight percent, at least 0.7 weight percent, at least 0.8 weight percent, at least 0.9 weight percent, at least one weight percent, at least 1.1 weight percent, at least 1.2 weight percent, at least 1.3 weight percent, at least 1.5 weight percent, at least 1.6 weight percent, at least 1.7 weight percent, at least 1.8 weight percent, at least 1.9 weight percent, at least two weight percent) and/or less than 20 weight percent (e.g., less than 15 weight percent, less than 10 weight percent, less than five weight percent, less than four weight percent, less than three weight percent, less than 2.75 weight percent, less than 2.5 weight percent, less than 2.25 weight percent, less than two weight percent, less than 1.75 weight percent, less than 1.5 weight percent) of the glass fibers relative to the amount the lead in the material (for anode material 114 ) or lead dioxide in the material (for cathode material 124 ).
[0071] Glass fibers having an average length of from 0.1 millimeter to 1.5 millimeter can be formed using various techniques. Typically, the glass fibers are formed by reducing the average length of relatively long fibers. The relatively long fibers can have an average length of, for example, at least five millimeters (e.g., at least 7 millimeters, at least 10 millimeters, at least 15 millimeters, at least 20 millimeters).
[0072] In certain embodiments, glass fibers having an average length of from 0.1 millimeter to 1.5 millimeters are prepared by crushing longer fibers. For example, a bale of the glass fibers can be put into a container, and a pressure (e.g., at least 50 pounds per square inch, at least 75 pounds per square inch, at least 100 pounds per square inch, at least 125 pounds per square inch, at least 150 pounds per square inch, at least 175 pounds per square inch, at least 200 pounds per square inch) can be applied to the fibers to crush the fibers for a certain period time (e.g., at least one second, at least two seconds, at least three seconds, at least four seconds, at least five seconds, at least six seconds, at least seven seconds, at least eight seconds, at least nine seconds, at least 10 seconds). The crushing step can be repeated as many times as desired (e.g., one time, two times, three times, four times, five times, six times, seven times, eight times, nine times, 10 times, 11 times, 12 times) until the fibers have the desired average length. In certain embodiments, the bale can be rotated through an angle (e.g., five degrees, 10 degrees, 20 degrees, 30 degrees, 40 degrees, 50 degrees, 60 degrees, 70 degrees, 80 degrees, 90 degrees) between one or more of the crushing steps (e.g., between each crushing step, between every other crushing step).
[0073] In some embodiments, the ratio of the average length of an association of glass fibers before crushing to the average length of the association of glass fibers after crushing can be at least 15 (e.g., at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 75, at least 100, at least 200, at least 250) and/or less than 500 (e.g., less than 250, less than 200).
[0074] FIG. 4 is a cross-sectional view of an apparatus 300 for forming the glass fibers. Apparatus has a compressor (e.g., a hydraulic compressor) 310 that exerts a pressure (e.g., at least 500 pounds per square inch, at least 1,000 pounds per square inch, at least 1,500 pounds per square inch, at least 1,750 pounds per square inch). Compressor 310 is in fluid communication with a cylinder (e.g., a hydraulic cylinder) 320 via a conduit 315 . Cylinder 320 is disposed within a housing 330 and includes a ram 322 that is used to transfer the pressure from cylinder 320 to a portion of a surface 342 of a platen 340 . Platen 340 , in turn, exerts a pressure against the contents (e.g., a bale of glass fibers) disposed within an opening 350 in housing 330 . Typically, the platen 340 , ram 322 and cylinder 320 are configured so that the pressure exerted by platen 340 against the contents of opening 350 is less than the pressure exerted by compressor 310 against cylinder wall 322 . For example, the pressure exerted by platen 340 against the contents of opening 350 can be less than 90% (e.g., less than 80%, less than 70%, less than 60%, less than 50%, less than 40%, less than 30%, less than 20%, less than 10%) of the pressure exerted by compressor 310 along cylinder wall 322 .
[0075] During use of system 300 , a bale of glass fibers is disposed in opening 350 ; ram 322 exerts a pressure against platen surface 342 ; and the pressure from platen 340 is exerted against the glass fibers in opening 350 for a given period of time. In certain embodiments, this step is repeated with or without rotation of the bale between steps of applying pressure to the bale. In embodiments in which the step of applying pressure is repeated, the pressures used can be varied for different pressure application steps, or they can be substantially the same in each pressure application step.
[0076] Anode material 114 and/or cathode material 124 can include additional materials, such as conventional lead acid battery electrode additives. For example, anode material 114 and/or cathode material 124 can include one or more reinforcing materials, such as chopped organic fibers (e.g., having an average length of 0.125 inch or more). Other materials that can be contained in anode material 114 and/or cathode material 124 include metal sulfate(s) (e.g., nickel sulfate, copper sulfate), red lead (e.g., a Pb 3 O 4 -containing material), litharge, paraffin oil, and/or expander(s). Generally, an expander contains barium sulfate, carbon black and lignin sulfonate as the primary components. The components of the expander(s) can be pre-mixed or non pre-mixed. Expanders are commercially available from, for example, Hammond Lead Products (Hammond, Ind.) and Atomized Products Group, Inc (Garland, Tex.). An example of a commercially available expander is Texex® expander (Atomized Products Group, Inc., Garland, Tex.). In certain embodiments, the expander(s), metal sulfate(s) and/or paraffin are present in anode material 114 , but not cathode material 124 .
[0077] In general, an electrode material is prepared by mixing lead oxide (e.g., lead oxide formed a ball mill process and/or lead oxide formed by the Barton process) and other electrode material components to form a paste, applying the paste to a support (e.g., a lead grid) to make a plate, partially drying the pasted material, curing the material, drying the cured material, forming the material (e.g., converting the lead oxide to lead for anode material 114 and converting the lead oxide to lead dioxide for cathode material. 124 ), and assembling the plates into a battery configuration.
[0078] Generally, the order of combining the components can be varied as desired. Typically, the components are added sequentially while stirring.
[0079] In certain embodiments, the paste is prepared as follows. Lead oxide, the glass fibers, water and additional components are combined in a mixer (e.g., sequentially or simultaneously), and mixed for a period of time (e.g., from one minute to 10 minutes). Sulfuric acid (e.g., 50 weight percent aqueous sulfuric acid) is added to the mixture, and mixed. In general, the sulfuric acid is added at a controlled rate to prevent the mixture from overheating, and mixing occurs while adding the sulfuric acid. For example, the sulfuric acid can be added at a rate so that the maximum temperature achieved by the mixture during the addition of the sulfuric acid is less than 70° C. (e.g., from 55° C. to 65° C.). After adding the sulfuric acid, the mixture is mixed and cooled to less than 40° C. (e.g., from 30° C. to 35° C.) to form the paste.
[0080] In some embodiments, the paste is prepared as follows. The glass fibers, water and additional components (other than lead oxide) are combined in a mixer (e.g., sequentially or simultaneously), and mixed for a period of time (e.g., from one minute to 10 minutes). The lead oxide is added to the mixture, and mixed for a period of time (e.g., from one minute to 10 minutes). Sulfuric acid (e.g., 50 weight percent aqueous sulfuric acid) is added to the mixture, and mixed. In general, the sulfuric acid is added at a controlled rate to prevent the mixture from overheating, and mixing occurs while adding the sulfuric acid. For example, the sulfuric acid can be added at a rate so that the maximum temperature achieved by the mixture during the addition of the sulfuric acid is less than 70° C. (e.g., from 55° C. to 65° C.). The mixture is then cooled to less than 40° C. (e.g., from 30° C. to 35° C.) with mixing to form the paste.
[0081] Without wishing to be bound by theory, it is believed that the glass fibers are capable of adsorbing water, and that including glass fibers in the paste composition can result in a paste that has a relatively high water content while having a relatively low cube weight.
[0082] The paste is then applied to the support. This can be done using standard techniques.
[0083] FIG. 5 is an illustration of an embodiment of a pasting apparatus 400 that can be used to apply a paste to a support and to partially dry the material. Apparatus 400 includes a mixer 410 with a mixing blade 411 and a paste hopper 412 that contains the paste. The paste exits hopper 412 and is disposed on a support 414 located on a conveyor 420 . The pasted support moves along a conveyor 421 and enters an oven 422 , where the paste is heated to reduce its water content (e.g., to less than 10 weight percent water, such as from seven weight percent to nine weight percent water). Typically, the temperature in oven 422 is from 150° C. to 345° C., and each pasted support spends from fifteen seconds to a minute in oven 422 . After exiting oven 422 , the plates are stacked on a table 423 .
[0084] FIG. 6 is an illustration of an embodiment of a pasting apparatus 500 that can be used to apply a paste to a support and to partially dry the material. Apparatus 500 includes a mixer 510 with a mixing blade 511 and a paste hopper 512 that contains the paste. Apparatus 500 also includes a support feeing station 527 , a conveyor 525 and pasting paper rolls 524 and 531 . Supports 514 move from support feeding station 527 along conveyor 525 , are covered by pasting paper from rolls 524 and 531 and move along a conveyor 526 . A knife 528 and an anvil 529 are used to cut the pasting paper between adjacent supports, and the supports then move along a conveyor 520 . As the supports pass under hopper 512 , the paste exits hopper 512 and is disposed on the supports. The pasted supports move along conveyors 520 and 521 and enter an oven 522 , where the paste is heated to reduce its water content (e.g., to less than 10 weight percent water, such as from seven weight percent to nine weigh percent water). Typically, the temperature in oven 522 is from 150° C. to 345° C., and each pasted support spends from fifteen seconds to a minute in oven 522 . After exiting oven 522 , the plates are stacked on a table.
[0085] The plates are then cured. In general, the curing process can be used to reduce the amount of lead present in the lead oxide particles present in the material disposed on the supports (e.g., to a lead content of less than four weight percent relative to the lead oxide, such as less than one weight percent lead relative to the lead oxide). The curing process can also be used to further reduce the water content of the material disposed on the supports. In certain embodiments, the plates are cured at relatively high humidity (e.g., at least 90 percent humidity, such as at least 95 percent humidity) and relatively high temperature (e.g., at least 35° C., such as from 35° C. to 50° C.) for a period of time (e.g., at least one day, such as from one day to seven days). In some embodiments, the plates are cured at relatively low humidity (e.g., less than five percent humidity, such as less than one percent humidity) and relatively high temperature (e.g., at least 35° C., such as from 35° C. to 50° C.) for a period of time (e.g., less than three days, such as less than two days). In some embodiments, curing is achieved by covering the plates and placing the covered plates in a controlled environment for a period of time (e.g., from three to five days).
[0086] Without wishing to be bound by theory, it is believed that the presence of the glass fibers in the electrode material(s) can reduce the amount of time used to cure the material. In particular, it is believed that the glass fibers are capable of adsorbing water, which is believed to act as a catalyst in the oxidation of lead, and that the water contained in the glass fibers can increase the rate of lead oxidation, thereby reducing the cure time used to obtain a desired degree of lead oxidation (e.g., as measured by the weight percent of lead relative to lead oxide). Moreover, it is believed that plates with the cured material having glass fibers can have a relatively high water content without sticking to other plates, as compared to substantially similar plates having cured material without the glass fibers.
[0087] The cured plates are formed to convert the lead oxide to lead (for anode material 114 ) or lead dioxide (for cathode material 124 ). Typically, this is done using standard electroforming processes. For example, forming can involve putting the plates and sulfuric acid in a container, and electrochemically charging the plates at appropriate potentials to convert the lead oxide to the electrode material.
[0088] After forming, the plates are removed from the container and dried. Usually, the anode plates are dried in a relatively inert atmosphere to reduce the likelihood of lead oxidation.
[0089] The dried plates are assembled into a battery using standard techniques. Typically, this includes disposing a separator between adjacent plates within a container, electrically connecting the plates (e.g., with a lead bridge) to form cells (e.g., single cells and/or series cells), and inserting the sulfuric acid into the container. Often, a DC current is passed through the cells (e.g., 500 Ampere-hours per kilogram) while the temperature of the battery is maintained below 60° C.
[0090] The following examples are illustrative only and not intended as limiting. During paste prepartion, an Oxmaster mixer (Oxmaster, Inc., located in Austel, Ga.) was used, and the mixing rate was 85 revolutions per minute. The cube weight of a paste was determined by adding an amount of the paste to fill a cup, and then calculating the density of the paste in the volume of the cup. The penetration of a paste was determined by dropping a cylindrical metal object with a point (length of six inches) from a height of six inches above the paste, and measuring the distance (inches) into the paste the object traveled. The water ratio of a paste is the ratio of the amount of water in the paste to the amount of lead oxide originally added to the mixer. The acid ratio of a paste is to the ratio of the amount of acid in the paste to the amount of lead oxide originally added to the mixer.
EXAMPLE 1
[0091] 50 pounds of glass fibers were prepared as follows.
[0092] 50 pounds of PA-01 glass fibers (Hollingsworth & Vose Company) were formed into a bale. The bale was put into an apparatus as described above (1800 pounds per square inch exerted by compressor, eight inch diameter hydraulic cylinder, four inch diameter ram, 19 inch by 25 inch platen), and a pressure of 190 pounds per square inch was applied to the fibers for five seconds. The pressure was removed, and the bale was rotated 90 degrees. A pressure of 190 pounds per square inch was again applied to the fibers for five seconds. The resulting glass fibers had an average length of 359 microns and an acid absorption of 1,097%. Five samples of the resulting glass fibers had an average weight loss of 13.85% according to the hand sheet test, whereas five samples of PA-01 glass fibers had an average weight loss of 5.15% according to the hand sheet test.
EXAMPLE 2
[0093] 50 pounds of glass fibers were prepared according to the method described in Example 1, except that the steps of applying a pressure of 190 pounds per square inch for five seconds and rotating the fiber 90 degrees between presses was repeated a total of six times. The resulting glass fibers had an average length of 183 microns and an acid absorption of 292%.
EXAMPLE 3
[0094] 50 pounds of glass fibers were prepared according to the method described in Example 1, except that the steps of applying a pressure of 190 pounds per square inch for five seconds and rotating the fiber 90 degrees between presses was repeated a total of nine times. The resulting glass fibers had an average length of 154 microns and an acid absorption of 177%.
EXAMPLE 4
[0095] 50 pounds of glass fibers were prepared according to the method described in Example 1, except that: 1.) Evanite 408 glass fibers (Evanite Fiber Corporation), having an average fiber length of 387 microns and an average fiber diameter of 0.87 microns, were used; and 2.) that the steps of applying a pressure of 190 pounds per square inch for five seconds and rotating the fiber 90 degrees between presses was repeated a total of three times. The resulting fibers had an average length of 150 microns and an acid absorption of 1,845%.
EXAMPLE 5
[0096] 50 pounds of glass fibers were prepared according to the method described in Example 4, except that the steps of applying a pressure of 190 pounds per square inch for five seconds and rotating the fiber 90 degrees between presses was repeated a total of six times. The resulting fibers had an average length of 132 microns and acid absorption of 1,577%.
EXAMPLE 6
[0097] 50 pounds of glass fibers were prepared according to the method described in Example 4, except that the steps of applying a pressure of 190 pounds per square inch for five seconds and rotating the fiber 90 degrees between presses was repeated a total of nine times. The resulting fibers had an average length of 112 microns and an acid absorption of 1,091%.
EXAMPLE 7
[0098] 50 pounds of glass fibers were prepared according to the method described in Example 4, except that the steps of applying a pressure of 190 pounds per square inch for five seconds and rotating the fiber 90 degrees between presses was repeated a total of 12 times. The resulting fibers had an average length of 115 microns and an acid absorption of 742%.
EXAMPLE 8
[0099] 50 pounds of glass fibers were prepared according to the method described in Example 1, except that: 1.) Evanite 609 glass fibers (Evanite Fiber Corporation), having an average fiber length of 258 microns and an average fiber diameter of 1.35 microns, were used; and 2.) that the steps of applying a pressure of 190 pounds per square inch for five seconds and rotating the fiber 90 degrees between presses was repeated a total of three times. The resulting fibers had an average length of 148 microns and an acid absorption of 1,274%.
EXAMPLE 9
[0100] 50 pounds of glass fibers were prepared according to the method described in Example 8, except that the steps of applying a pressure of 190 pounds per square inch for five seconds and rotating the fiber 90 degrees between presses was repeated a total of six times. The resulting fibers had an average length of 125 microns and an acid absorption of 901%.
EXAMPLE 10
[0101] 50 pounds of glass fibers were prepared according to the method described in Example 8, except that the steps of applying a pressure of 190 pounds per square inch for five seconds and rotating the fiber 90 degrees between presses was repeated a total of nine times. The resulting fibers had an average length of 108 microns and an acid absorption of 665%.
EXAMPLE 11
[0102] Glass fibers were prepared according to the method described in Example 8, except that the steps of applying a pressure of 1800 pounds per square inch for five seconds and rotating the fiber 90 degrees between presses was repeated a total of 12 times. The resulting fibers had an average length of 102 microns and an acid absorption of 430%.
EXAMPLE 12
[0103] Anode plates for a group 31 lead acid battery (12 Volts, 750 cold crank Amps, and 180 minutes of reserved capacity) were prepared as follows.
[0104] 2400 pounds of lead oxide (prepared using the Barton process), 0.75 pounds of Dynel flock (available from Cellusuede Products, Inc., located in Madison, Wis.), 12 pounds of Texex® expander (Atomized Products Group, Inc.) and 132 kilograms of water were sequentially added to the Oxmaster mixer while mixing. This combination was subsequently mixed for two minutes. 135 kilograms of aqueous sulfuric acid (specific gravity of 1.40) were was added, and the resulting combination was mixed until it reached a temperature of 45° C.
[0105] The resulting paste had a maximum temperature during preparation of 65° C., a cube weight of 70 grams per cubic inch, a water ratio of 0.133, and an acid ratio of 0.095.
[0106] The paste was belt pasted onto grids using a flash dry oven with the following parameters: the rate was 150 plates pasted per minute, the oven temperature was 420° F., the moisture in the oven was 7.1%, the plate weight was 155 grams, the grids weighed 66 grams each, and the plate count was 6000.
[0107] Two sample pasted plates were tested for porosity using the mercury intrusion method. The two pasted plates had an average total volume intrusion of 0.1211 cubic centimeters per gram (100%), an average macro pore volume of 0.0608 cubic centimeters per gram (50%), and an average micro pore volume of 0.0603 cubic centimeters per gram (50%).
[0108] The pasted plates were cured at a 90 percent humidity at 45° C. for three days.
[0109] The cured plates were dried for two days at 100° F.
[0110] A group 31 lead acid battery was prepared by stack assembling as follows. Alternating anode and cathode plates (cathode plates prepared as described above but without expander) were assembled with a separator disposed between adjacent electrodes. The plate/separator assembly was placed in a plastic battery container. The cover of the container was sealed, and the ports were burned. Sulfuric acid (specific gravity of 1.2) was added to the container, and the electrodes were charged at approximately 500 Amp-hours per kilogram for two days while maintaining the temperature below 60° C.
[0111] The assembly was then formed in a 25° C. water bath according to the schedule shown in Table II.
TABLE II Step Amps Amp-Hours Hours 1 6 6 1 2 17 14.5 8.5 3 0 0 2 4 12.2 73 5.5 5 9.3 133 14.6 6 5.5 44 8
[0112] FIGS. 7 and 8 are X-ray diffraction scans of a discharged and charged anode plate, respectively. The charged plate was exposed to atmospheric conditions for a period of time prior to taking the X-ray diffraction scan.
[0113] The pure lead component of the negative active material was isolated from the discharged negative plates by dissolution. FIGS. 9-11 are scanning electron micrographs of the discharged, isolated negative active material taken at 800×, 3,000× and 3,000× magnification, respectively.
EXAMPLE 13
[0114] Anode plates for a group 31 lead acid battery (12 Volts, 750 cold crank Amps, and 180 minutes of reserved capacity) were prepared as follows.
[0115] 12.5 pounds of PA-01 glass fibers (Hollingsworth & Vose Company), four pounds of Texex® expander (Atomized Products Group, Inc.) and 46 kilograms of water were sequentially added to the Oxmaster mixer while mixing at 85 revolutions per minute. This combination was mixed for one minute. 850 pounds of lead oxide (prepared using the Barton process) were then added, and the combination was mixed for two minutes. 48 pounds of aqueous sulfuric acid (specific gravity 1.40) were added, and the resulting combination was mixed until it reached a temperature of 110° F.
[0116] The resulting paste had a cube weight of 71.5 grams per cubic inch, and a peak temperature of 130° F.
[0117] The paste was belt pasted onto grids using a flash dry oven with the following parameters: the rate was 150 plates pasted per minute, the oven temperature was 420° F., the moisture in the oven was 7.1%, the plate weight was 155 grams, the grids weighed 66 grams each, and the plate count was 6000.
[0118] Two sample pasted plates were tested for porosity using the mercury intrusion method. The two samples pasted plates had an average total volume intrusion of 0.1353 cubic centimeters per gram (100%), an average macro pore volume of 0.0657 cubic centimeters per gram (49%), and an average micro pore volume of 0.0697 cubic centimeters per gram (51%).
[0119] Comparison of the average mercury intrusion values measured for the sample pasted plates of Examples 12 and 13 shows that including the glass fibers in the paste resulted in an increase of more than 10% in porosity of the pasted plates, and a shift toward smaller pores.
[0120] The pasted plates were dried as described in the preceding example. FIG. 12 is a scanning electron micrograph taken of a dried, pasted plate (before curing) taken at 500× magnification. The figure shows that the glass fibers extend from the interior of the paste to the exterior of the paste.
[0121] The dried, pasted plates were further processed to provide a lead acid battery using the processes described in the preceding example (cathode plates made using the paste of this example, but without expander).
[0122] FIGS. 13 and 14 are X-ray diffraction scans of the discharged and charged plates, respectively, prepared in the same manner as described in the preceding example. Prior to taking the X-ray diffraction scan, the charged plate was exposed to substantially the same conditions as the charged plate in the preceding example. Compared to FIG. 9 , FIG. 14 shows that more lead oxide (PbO) was formed by exposing the electrode material containing glass fibers to air than was formed by exposing a substantially similar plate without glass fibers to air. This indicates that the electrode material containing glass fibers are more reactive toward oxidation than substantially similar plates without glass fibers.
[0123] The pure lead component of the negative active material wag isolated from the discharged negative plates by dissolution. FIGS. 15 and 16 are scanning electron micrographs of the discharged, isolated negative active material taken at 800× and 3,000× magnification, respectively.
[0124] Compared to FIGS. 9-11 , FIGS. 14 and 15 show that the pure lead component of the discharged, negative active material from a negative plate containing glass fibers has a more open structure than the pure lead component of the discharged, negative active material from a substantially similar plate without glass fibers. FIGS. 14 and 15 also show that the pure lead components of the discharged, negative active material from a negative plate containing glass fibers has lead crystals with a platelet-like shape.
EXAMPLE 14
[0125] A series of six group 31 six cell batteries (Batteries A-F, respectively) were prepared substantially as described in Example 13, but the batteries contained amounts of PA-01 glass fibers (Hollingsworth & Vose Company) in their anodes and cathodes as indicated in Table III (weight percent relative to the amount of lead oxide added to the mixer).
TABLE III Battery Anode Cathode A 0 wt % 0 wt % B 1.5 wt % 0 wt % C 3 wt % 0 wt % D 0 wt % 1.5 wt % E 1.5 wt % 1.5 wt % F 3 wt % 1.5 wt %
[0126] The charge acceptance of Batteries A and B was measured according to Battery Council International testing procedures as follows. The batteries were discharged to 50% of their capacity; stored at 0° C. for 24 hours; and charged at 14.4 Volts for 10 minutes. The nominal charge acceptance for this test is 22.5 Amps. FIG. 17 shows the percent of nominal charge acceptance (i.e., the percent of 22.5 Amps) measured for Batteries A and B. As shown in FIG. 17 , Battery B had a 23% higher measured charge acceptance than Battery A.
[0127] The reserve capacity of Batteries A-F was measured as follows. A constant current discharge of 25 Amps was applied to each battery, and the time period for the battery to reach 10.5 Volts was measured. This test multiple times for each battery. The nominal time for this test is 30 minutes. FIG. 18 shows the maximum, average and minimum measured values for each battery.
[0128] Cold cranking testing was performed on Batteries A-F as follows. Each battery was fully charged, and stored at −18° C. for 24 hours. A discharge of 750 Amps was then applied to each battery, and the voltage was measured at 30 seconds. The nominal end of discharge voltage value for this test is 7.2 Volts. The test was repeated for each battery at a discharge rate of 850 Amps (30 second nominal end of discharge voltage of 7.2 Volts). The results are shown in FIG. 19 .
[0129] Additional cold cranking testing was performed on Batteries A-F as follows. Each battery was fully charged, and stored at −18° C. for 24 hours. A discharge of 750 Amps was then applied to each battery, and the time period to reach 7.2 Volts was measured. The nominal end of discharge time period for this test is 30 seconds. The test was repeated for each battery at a discharge rate of 850 Amps (7.2 Volts nominal end of discharge time period of 30 seconds). The results are shown in FIG. 20 .
EXAMPLE 15
[0130] Anode plates for a group 24 lead acid battery (12 Volts, 90 Amp-hours capacity (20 hours)) were prepared as follows.
[0131] 18.5 pounds of PA-01 glass fibers (Hollingsworth & Vose Company), 12.5 pounds of Hammond expander (Hammond Lead Products) and 40 kilograms of water were sequentially added to the Oxmaster mixer while mixing at 85 revolutions per minute. This combination was mixed for two minutes. 1320 pounds of lead oxide (prepared using the Barton process) and 40 kilograms of water were then sequentially added, and the combination was mixed for two minutes. 125 pounds of aqueous sulfuric acid (specific gravity 1.40) were added, and the resulting combination was mixed for seven minutes.
[0132] The resulting paste had a cube weight of 75 grams per cubic inch, a penetration of 15, and a peak temperature of 63° C., a water ratio of 0.133, and an acid ratio of 0.095.
[0133] The paste was belt pasted onto grids using a flash dry oven with the following parameters: the pasted plate weight range was 411-441 grams, the thickness range was 0.062-0.065 inch, the plate moisture after drying was seven to eight percent, the drier oven temperature was 350° F., the actual average plate weights was 450 grams, the actual plate moisture after drier oven was 8.2%, and the actual drier oven minimum temperature 260° F.
[0134] The plates were further processed using standard techniques, and a group 24 (90 Amp-hrs, VRLA-AGM) lead acid battery was prepared from the plates using standard lead acid battery processing techniques. The cathode was prepared in substantially the same way as the anode, except the cathode did not contain expander or PA-01 glass fibers (Hollingsworth & Vose Company).
EXAMPLE 16
[0135] Anode plates for a group 24 lead acid battery (12 Volts, 90 Amp-hours capacity (20 hours), with absorbance glass separators) were prepared as described in the preceding example, except that 18.5 pounds PA-10 glass fibers (Hollingsworth & Vose Company) were used instead of 18.5 pounds of PA-01 glass fibers (Hollingsworth & Vose Company).
[0136] The resulting paste had a cube weight of 72 grams per cubic inch, a penetration of 17, and a peak temperature of 64° C., a water ratio of 0.133, and an acid ratio of 0.095.
[0137] The paste was belt pasted onto grids using a flash dry oven with the following parameters: the pasted plate weight range was 411-441 grams, the thickness range was 0.062-0.065 inch, the plate moisture after drying was seven to eight percent, the drier oven temperature was 350° F., the actual average plate weights was 452 grams, the actual plate moisture after drier oven was 8.8%, and the actual drier oven minimum temperature 260° F.
[0138] A group 24 (90 Amp-hrs, VRLA-AGM) lead acid battery was prepared from the plates using standard lead acid battery processing techniques. The cathode was prepared in substantially the same way as the anode, except the cathode did not contain expander or PA-10 glass fibers (Hollingsworth & Vose Company).
EXAMPLE 17
[0139] The plates were further processed using standard techniques, and a group 24 (90 Amp-hrs, VRLA-AGM) lead acid battery was prepared substantially the same was as described in Example 15, except that the anode did not contain PA-01 glass fibers (Hollingsworth & Vose Company).
[0140] Capacity (Amp-Hours) and discharge rate (Amps) were measured for this battery (Battery A) and compared to the measurements for two different batteries (Battery B and Battery C, respectively). Battery B was prepared substantially as described in Example 15, except that the anodes contained 1.5 weight percent PA-01 glass fibers (Hollingsworth & Vose Company) relative to the amount of lead oxide added to the mixer during processing. Battery C was prepared substantially as described in Example 16, except that the anodes contained 1.5 weight percent PA-10 glass fibers (Hollingsworth & Vose Company) relative to the lead oxide added to the mixer during processing.
[0141] Table IV shows capacity data (measured in Amp-hours) for the batteries, and Table V shows discharge rate data (measured in Amps) for the batteries. The data in Tables IV and V is based on average values for at least 30 batteries. FIG. 21 shows a bar graph of the capacity (Amp-hours) versus discharge rate (Amps) data for the batteries. The batteries were discharged for five minutes at 240 Amps, for 10 minutes at 173 Amps, for 15 minutes at 132.9 Amps, for 20 minutes at 108.8 Amps, and for 300 minutes at 13 Amps.
TABLE IV Battery 240 Amps 173 Amps 132.9 Amps 108.8 Amps 13 Amps A 23.6 28.2 31.5 45.4 72.6 B 24.9 31.5 35.2 47.1 72.3 C 25.0 31.7 35.1 47.8 72.3
[0142]
TABLE V
Battery
240 Amps
173 Amps
132.9 Amps
108.8 Amps
13 Amps
A
5.91
9.78
14.26
25.01
335.2
B
6.22
10.92
15.90
25.97
333.5
C
6.26
11.00
15.83
26.37
330.1
[0143] As shown in Tables IV and V and FIG. 21 , batteries having PA-01 or PA-10 glass fibers (Hollingsworth & Vose Company) in their anodes can provide approximately 10% more capacity (Amp-hrs) at high discharge rates (Amps) than a substantially similar battery in which the anodes do not contain glass fibers.
EXAMPLE 18
[0144] Anode plates for a group 24 lead acid battery (12 Volts, 90 Amp-hours capacity (20 hours), with absorbance glass separators) were prepared as follows.
[0145] 20 pounds of PA-20 glass fibers (Hollingsworth & Vose Company), 12.5 pounds of Hammond expander (Hammond Lead Products), 1320 pounds of lead oxide (prepared using the Barton process), and 75 kilograms of water were sequentially added to the Oxmaster mixer while mixing at 85 revolutions. The combination was mixed for two minutes, and then 125 pounds of aqueous sulfuric acid were added while mixing. This combination was mixed for seven minutes.
[0146] The resulting paste had a maximum temperature during preparation of 61° C., a cube weight of 72.4 grams per cubic inch, a penetration of 17, a water ratio of 0.125, and an acid ratio of 0.095.
[0147] The paste was belt pasted onto grids using a flash dry oven with the following parameters: the pasted plate weight range was 544-574 grams (double), the thickness range was 0.079-0.083 inch, the plate moisture after drying was seven to eight percent, the actual plate moisture after drier oven was 9.2%, and the actual drier oven minimum temperature 400° F.
[0148] The plates were further processed using standard techniques, and a group 24 lead acid battery was prepared from the plates using standard lead acid battery processing techniques.
[0149] While certain embodiments have been described, the invention is not limited to these embodiments.
[0150] As an example, while glass fibers having an average length of from 0.1 millimeter to 1.5 millimeter have been described, other types of fibers with an average length of from 0.1 millimeter to 1.5 millimeters can be used. In general, such fibers can be siliceous fibers or non-siliceous fibers, synthetic fibers or nonsynthetic fibers, organic fibers or inorganic fibers, polymeric fibers or nonpolymeric fibers, coated fibers or substantially noncoated fibers, hollow fibers or substantially nonhollow fibers, porous fibers or substantially nonporous fibers, metallic fibers or nonmetallic fibers, or combinations thereof. Examples of types of polymeric fibers include substituted polymers, unsubstituted polymers, saturated polymers, unsaturated polymers (e.g., aromatic polymers), organic polymers, inorganic polymers, straight chained polymers, branched polymers, homopolymers, copolymers, and combinations thereof. Examples of polymer fibers include polyalkylenes (e.g., polyethylene, polypropylene, polybutylene), polyesters (e.g., polyethylene terephthalate), polyamides (e.g., nylons, aramids), halogenated polymers (e.g., teflons) and combinations thereof. Examples of other types of fibers include metallic fibers (e.g., fibers formed of materials containing transition metals or transition metal alloys), ceramic fibers (e.g., fibers formed of materials containing one or more metal oxides, such as titanate fibers), metal coated fibers, alloy coated fibers, sulfide fibers, carbon fibers (e.g., graphite fibers), and combinations thereof.
[0151] As another example, while the supports for the paste have been illustrated as grids having certain patterns, the supports are not so limited. The supports can be formed of a grid having any desired design. More generally, the support need not be in the form of a grid. For example, the support can be solid. Moreover, the supports can be formed of various electrically conductive material, which need not contain lead.
[0152] Other embodiments are in the claims.
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Methods of modifying fibers, such as glass fibers, are disclosed. The modified fibers can be used, for example, in a lead acid battery.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of Provisional Application 60/185,521, filed Feb. 28, 2000 by the same inventor for which priority benefit is claimed.
CROSS-REFERENCE TO RELATED PATENT
This application relates to U.S. Pat. No. 5,498,444, titled “Method for Producing Micro-Optical Components” issued Mar. 12, 1996 to Donald J. Hayes, and U.S. Pat. No. 5,707,684, titled “Method for Producing Micro-Optical Components” issued Jan. 13, 1998 to Donald J. Hayes and W. Royall Cox, both patents being incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of making arrays of micro-optical elements precisely located and having specific optical shapes.
2. Background of the Invention
Micro-optical element arrays are primarily used in the optical communication and optical imaging fields. In general, these applications require that the optical elements have several features. They require control over the shape of the individual elements; the elements must be precisely located relative to each other and other optical components; the optical properties of the elements must be precisely controlled; the elements must be alignable with other optical components; and unwanted optical beams must be blocked and optical cross-talk limited.
There are various method s of making micro-optical elements such as molding, photolithography, and MicroJet printing. However, MicroJet printing is particularly advantageous as to the type of micro-optical elements that can be created and it permits accurate placement of elements within arrays.
Unlike the other methods, the present invention meets all the requirements a precision array demands, it: allows for the creation of specific optical shapes, controls precisely the optical element location, forms an aperture to block unwanted light, allows for the alignment of other optical elements such as optical fibers, and it can use a wide range of optical materials for its manufacture.
SUMMARY OF THE INVENTION
This invention provides, for the first time, an inexpensive way of creating micro-optical elements, by utilizing the ink-jet printing method of dispensing optical material for automated, in-situ fabrication of micro-element arrays. The flexibility of this data-driven method also enables variation of the shape of the printed micro-optical element.
The first step in fabricating a micro-optical element by means of inkjet printing comprises providing a substrate. The substrate has a surface with at least one structural opening defined by an edge in the surface leading into a sup port surface. The substrate is preferably an electroform comprising nickel and the structural openings are arranged as an array. The support surface has an aperture through the substrate which is positioned centrally with respect to the edge. The edge is preferably 1 to 5 microns deep so as to define the shape of the micro-optical element. The next step is to provide a digitally-driven printhead containing a hardenable optical fluid suitable for serving as a micro-optical element, preferably an ultraviolet (UV) light-curable epoxy, ejected in response to control signals. Micro-droplets of the optical fluid are deposited into the structural opening of the substrate, preferably centrally over the aperture but if the diameter of the micro-droplets is smaller than the aperture diameter, deposition is preferable over the support surface of the structural opening. In a preferred embodiment, the printhead moves over the surface of the substrate to deposit the optical fluid. The structural opening is then filled until a desired micro-optical element is formed where the element may have a radiused upper or lower surfaces, preferably both. The last step of the process is the hardening of the element, such as by UV light when UV light-curable epoxy is used in a preferred embodiment. Other means for curing such as by heat are also contemplated.
In a preferred embodiment, the production of an array of micro-optical lens elements is described. The first step in fabricating a micro-optical element by means of ink-jet printing comprises providing a substrate. The substrate has a surface with at least one circular structural opening defined by an edge in the surface leading into a support surface. The substrate is preferably an electroform comprising nickel and the structural openings are arranged as an array. The support surface has a circular aperture through the substrate which is positioned centrally with respect to the edge. The edge is preferably 1 to 5 microns deep so as to define and control the shape of the micro-optical element. The next step is to provide a digitally-driven printhead containing a hardenable optical fluid suitable for serving as a micro-optical element, preferably an ultraviolet (UV) light-curable epoxy, ejected in response to control signals. Micro-droplets of the optical fluid are deposited into the structural opening of the substrate. In a preferred embodiment, the printhead moves over the surface of the substrate to deposit the optical fluid. The circular structural opening is then filled until a desired micro-optical element profile is formed where the element may have a radiused upper or lower surface, preferably both. The last step of the process is the hardening of the element.
In another embodiment, the production of an array of elongated micro-optical elements in the form of waveguides is described. The first step in fabricating a micro-optical element by means of ink-jet printing comprises providing a substrate. The substrate has a surface with at least one elongated structural opening defined by an edge in the surface leading into a support surface. The substrate is preferably an electroform comprising nickel and the elongated structural openings are arranged as an array. The support surface has an aperture through the substrate which is positioned centrally with respect to the edge. The edge is preferably 1 to 5 microns deep so as to define the shape of the micro-optical element. The next step is to provide a digitally-driven printhead containing a hardenable optical fluid suitable for serving as a micro-optical element, preferably an ultraviolet (UV) light-curable epoxy, ejected in response to control signals. In a preferred embodiment, the printhead moves over the surface of the substrate to deposit the optical fluid. Micro-droplets of the optical fluid are deposited into the structural opening of the substrate, preferably centrally over the elongated aperture but if the diameter of the micro-droplets is smaller than the aperture diameter, deposition is preferable over the support surface of the structural opening. The elongated structural opening is then filled until a desired micro-optical element is formed where the element may have a radiused upper or lower surfaces, preferably both. The last step of the process is the hardening of the element, such as by UV light when UV light-curable epoxy is used in a preferred embodiment. Other means for curing such as by heat is also contemplated.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages and features of the invention will become more apparent with reference to the following detailed description of presently preferred embodiments thereof in connection with the accompanying drawings, wherein like reference numerals haven been applied to like elements, in which:
FIG. 1 a is a schematic plan view showing an array of circular structural openings for producing an array of micro-optical elements according to the method of the present invention;
FIG. 1 b is a side-view of the array on lines 1 b — 1 b in FIG. 1 a.
FIG. 2 is a cross-sectional view of a structural opening from the array of FIG. 1 a on the line 2 — 2 showing the relative proportions between the structural opening, support surface, edge, and the taper of the aperture of the substrate in an embodiment of the present invention.
FIG. 3 is a schematic side-view showing the relative position of the printhead relative to the substrate as it deposits micro-droplets of optical material into the structural openings according to the method of the present invention.
FIG. 4 is a cross-sectional view showing a micro-optical element formed in the structural openings of FIG. 3 after optical material was deposited and the structural opening filled according to a preferred embodiment of the method of the present invention.
FIG. 5 is a cross-sectional view showing another micro-optical element of a different radius formed in a structural opening after optical material was deposited and the structural opening filled according to a preferred embodiment of the present invention.
FIG. 6 is a schematic perspective side-view showing the placement of the printhead relative to an array of openings of a preferred embodiment of the present invention as it deposits micro-droplets of a optical material into an elongated structural opening.
FIG. 7 is a side view on lines 7 — 7 in FIG. 6 of the array of the embodiment showing placement of the printhead relative to an array of openings of the preferred embodiment of the present invention shown in FIG. 6 .
FIG. 8 a is a plan view of an array of elongated structural openings according to a preferred embodiment of the present invention showing a close regular arrangement of structural openings.
FIG. 8 b is a cross-sectional view of FIG. 8 a on the lines 8 b — 8 b showing the arrangement of structural openings, support surface, edge, and aperture of the substrate.
FIG. 9 is a schematic drawing of a substrate like FIG. 1 a with alignment features.
FIG. 10 is a cross-sectional view showing the positioning of an optical fiber under the lower surface of the substrate in line with the aperture of the structural opening.
FIG. 11 a is a schematic side-view of a mandrel coated with a layer of photoresist.
FIG. 11 b is a schematic side-view of the mandrel of FIG. 11 a after further process to produce photoresist patterns.
FIG. 11 c is a schematic side-view of the mandrel of FIG. 11 b with the photoresist patterns surrounded as shown with a suitable electroform material to form an electroform sheet which can be used in the process of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention applies ink-jet printing technology to the fabrication of arrays of micro-optical elements for optical fibers. Shown in FIG. 1 a is a substrate 10 with an array of structural openings 14 used to make precision micro-optical elements. Although the structural openings of FIGS. 1 a and 1 b are circular, they represent only one embodiment of the present invention. Each structural opening 14 is defined by an edge 16 in the upper surface 18 of substrate 10 . Edge 16 leads into support surface 20 wherein an aperture 22 is positioned centrally with respect to the edge 16 . Edge 16 of structural opening 14 preferably has a depth of about 1 to about 5 microns. FIG. 1 b is an endview of substrate 10 that illustrates the thin profile between upper surface 18 and lower surface 24 of the substrate. A magnified representation of single structural opening 14 of array 12 is shown in FIG. 2 before filling with optical material, which also reflects the tapered bottom surface 26 of the circular structural opening embodiment to be discussed below. The aperture being positioned centrally with respect to the edge means that the edge of the aperture opening is generally the same distance from the edge of the structural opening, i.e., the aperture is centered.
Substrate 10 is preferably an electroform plate, preferably made of nickel although any suitable material is appropriate. The electroform process itself is well known and will be described later. Structural openings 14 function as a mold in the fabrication of the micro-optical element and as an attachment point for a micro-optical element and an optical fiber.
FIG. 3 shows a digitally-driven printhead 28 depositing a predetermined size and number of micro-droplets 30 of optical fluid into structural openings 14 to form micro-optical elements 32 . Apertures 22 of unfilled structural openings 14 are seen with printhead 28 moving in the direction of the arrow to fill them. Methods of operating an ink-jet printhead to deposit optical polymeric materials in a fluid state are disclosed in U.S. Pat. Nos. 5,498,444 and 5,707,684 entitled Method for Producing Micro-Optical Components by the assignee hereof, the disclosures of which are incorporated by reference. Digitally-driven printhead 28 ejects micro-droplets 30 of optical fluid through orifice 34 . The diameter of orifice 34 is preferably between about 20 μm to about 120 μm although smaller or larger orifice diameters are acceptable. The printhead preferably includes a piezoelectric device operable in a drop-in-demand mode and is heatable to control the viscosity of the optical fluid. The movement of the printhead and substrate relative to each other is computer-controlled. The substrate is positioned on a computer-controlled stage movable in the X-Y plane. The computer moves the stage so that a structural opening is positioned to receive optical fluid micro-droplets 30 deposited by the digitally-driven printhead. Ejection of micro-droplets by the printhead is preferably controlled by the same computer. After filling one structural opening, the computer moves the substrate to position the next structural opening under the ejection orifice then activates the printhead to eject the micro-droplets into the structural opening. The stage is again repositioned so the next structural opening is positioned to receive micro-droplets deposited by the digitally-driven printhead and the printhead is again activated to deposit micro-droplets of optical fluid until micro-lenses are formed in each structural opening.
The optical fluid can be any material, or combination of materials, capable of forming a relatively transparent micro-optical element after hardening. Optical epoxies are an example. Some specific commercial materials which have been suitable for forming micro-optical elements include Summers Optical SK9 (Refractive Index 1.49) by Summers Optical, Inc., P.O. Box 162, Fort Washington, Pa. 19034; Norland No. NOA-73 (Refractive Index 1.56) by Norland Products, Inc., P.O. Box 7145, New Brunswick, N.J. 08902); and Epotek No. OG-146 (Refractive Index 1.48) by Epogy Technology, Inc., 14 Fortune Drive, Billerica, Mass. 01821. In a preferred embodiment of the invention, an ultraviolet (UV) light-curable epoxy is used. When used, the diameter of the optical epoxy micro-droplets is preferably within the range of about 8 μm to about 300 μm. Most typically the micro-droplets would be around 50 microns.
In a preferred embodiment a micro-optical lenslet element 32 formed in FIG. 3 is shown in FIG. 4 situated in structural opening 14 of substrate 10 wherein the structural opening is circular. Micro-optical element 32 has a first radiused outer surface 36 formed, in the shape of a hemisphere or a section of a sphere, above support surface 20 . A pedestal portion 40 or step-down 40 coincides with the height of edge 16 above support surface 20 . A second radiused surface 38 in the shape of a hemisphere or a section of a sphere is formed below support surface 20 . Bottom surface 24 slopes upward toward upper surface 18 to form a tapered wall portion 26 at aperture 22 . The tapered wall 26 is formed naturally in the process of making the electroformed substrate 10 .
As shown in FIG. 10, taper 26 can be used to center an optical fiber 60 at the bottom surface 24 of the substrate 10 under aperture 22 of a micro-lens 32 . The axis of the core 61 of optical fiber 60 is centered with respect to the central axis of lens 32 . Edge 16 and support surface 20 control the shape of the micro-optical material upon filling the structural opening 14 and edge 16 centers the material over aperture 22 . Micro-optical element 32 typically has a diameter which coincides with the diameter of structural opening 14 . Here the diameter is slightly greater because the micro-optical element 32 is spherical and higher than the hemispherical plane. The process produces lenses with spherical outer surfaces when the structural openings are circular.
In one aspect of the present invention best seen in FIG. 4, a number of micro-droplets 30 of micro-optical element lens material was deposited so that a micro-optical element 32 forms a first radiused surface 36 above support surface 20 and, in another embodiment, a second radiused surface 38 is formed below support surface 20 . However, it is to be understood that a micro-optical element lacking both or either a first-radiused surface or second-radiused surface could be formed according to the present invention. The radius of the lenslet being formed is controlled by varying the size or number of droplets of optical material that are deposited. The structural discontinuity at the edge 16 controls the shape (diameter) of the lens that is formed.
The role of edge 16 in forming a first radiused surface 36 and in centering micro-optical element 32 over aperture 22 is shown in FIG. 5 which reflects actual data. In FIG. 5, even though lens 32 was made larger than lens 32 in FIG. 4, it was still controlled by the edge discontinuity from spreading out uncontrollably over the surface 18 . The lenslet formed in FIG. 5 was made from an optical epoxy jetted from a digitally driven printhead at about 55° C. from fluid having a viscosity of 6 to 10 centipoise. The orifice in the electroform sheet was about 45 microns. The substrate in this case was held at room temperature. The circular structural openings can be closely and precisely spaced to result in formed micro-optical lens elements also being closely and precisely spaced.
FIG. 9 shows a substrate 11 with alignment holes 62 . Alignment holes 62 permit precise location of the structural openings and precise alignment of the array relative to the printhead 28 in FIG. 3 when forming the lenslets 32 . Moreover, alignment holes 62 allow for accurate positioning of the micro-optical element array 12 relative to other optical components.
Another embodiment of the present invention is shown in FIG. 6 . Elongated structural opening 46 is defined by edge 50 in upper surface 18 of substrate 13 leading into support surface 48 . Support surface 48 has an aperture 52 extending through the substrate and positioned centrally with respect to edge 50 and support surface 48 . Elongated structural opening 46 provides a method of making micro-optical elements such as waveguides of various configurations. Although the structural openings are shown as linear, they could also be curved for special applications. Substrate 13 is an electroform plate, preferably made of nickel although any suitable material is appropriate. The process of making the electroform substrate 13 is the same as for substrate 10 , except for the shape of the openings. Structural openings 46 function as a mold in the fabrication of the micro-optical lens element. The micro-optical element material 30 in FIG. 6 is ejected from digitally-driven printhead 28 and deposited in elongated structural openings 46 to form elongated micro-optical waveguide elements 44 . The elongated structural openings 46 in FIG. 6 are precisely distanced from one another. The micro-optical waveguide elements 44 are therefore also precisely distanced from each other as shown.
FIG. 7 shows a cross-section through substrate 13 of FIG. 6 reflecting the position of digitally-driven printhead 28 over an elongated structural opening 46 as droplets 30 are being ejected to form waveguides 44 . Digitally-driven printhead 28 can be positioned directly over aperture 52 when the diameter of micro-droplets 30 is greater than the diameter 58 of aperture 52 .
FIG. 8 a shows an array of elongated structural openings 46 before filling with optical material. Thanks to the electroform process, elongated structural openings 46 can be positioned closely to each other in the array. The depth of structural openings 46 and edge 50 are preferably between about 1 μm to about 5 μm.
FIG. 8 b shows the positioning of the array of elongated structural openings 46 in cross-section. Although FIGS. 6 through 8 a illustrate micro-optical elements of uniform cross-sectional profile, the elements can be of varying cross-section as well. Since the electroform is essentially made by a photolithographic process, the structural openings can be varied in shape and size and reproduced exactly.
FIGS. 1 a - 11 c illustrate one form of the electroform process to create an electroform tuba product used as the substrate 10 , 13 in the present invention. FIG. 11 a shows a flat metal mandrel 64 coated with a layer of photoresist 66 . The photoresist layer is typically between from about 0.5 microns to about 5 microns thick. The photoresist layer is patterned with standard photolithography processes which are common in the semiconductor industry. After patterning and further processing, patterns 68 are left on the surface as shown in FIG. 11 b . Mandrel 64 is used as one of the electrodes in a plating process. A suitable metal, preferably nickel, is plated onto mandrel 64 and extends over the photoresist patterns 68 as shown in FIG. 11 c . Electroform plate 70 is peeled off the mandrel and photoresist layer 66 is then chemically removed. Although electroform products are described for use as substrates 10 and 13 , other substrate manufacturing methods such as chemical etching or stamping could also be employed.
Although the invention has been disclosed above with regard to a particular and preferred embodiment, it is not intended to limit the scope of the invention. For instance, although the inventive method has been set forth in a prescribed sequence of steps, it is understood that the disclosed sequence of steps may be varied. It will be appreciated that various modifications, alternatives, variations, etc., may be made without departing from the spirit and scope of the invention as defined in the appended claims.
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Micro-optical elements such as lenses and wave-guides are manufactured by printing a hardenable optical fluid using digitally driven ink-jet technology. An array of micro-optical elements are precisely positioned in an electroformed substrate having a surface containing structural openings which serve as molds for micro-droplets of optical fluids deposited from an ink-jet printhead. The structural openings have a stepped down edge, a shelf-like support surface below the edge and a centered aperture in the substrate. The micro-optical element formed is controlled by the shape of the edge in the surface of the substrate and the radius by the volume of micro-droplets deposited into the structural opening. The structural openings can be circular, or any desired shape which is easily and precisely formed in an electroformed substrate.
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CROSS REFERENCE TO RELATED APPLICATION
This is a division of application Ser. No. 08/582,267, filed Jan. 3, 1996 now U.S. Pat. No. 5,618,364 which is a continuation of application Ser. No. 08/542,975, filed Oct. 13, 1995, (DP-6485), being abandoned.
FIELD OF INVENTION
This invention relates to improvements in making lofty bonded battings, such as are used as filling material and insulation.
BACKGROUND ART
Polyester fiberfill filling material (sometimes referred to herein as polyester fiberfill) has become well accepted as a reasonably inexpensive filling and/or insulating material for filled articles, such as cushions and other furnishing materials, including bedding materials, such as mattress pads, quilts, comforters and including duvets, in apparel, such as parkas and other insulated articles of apparel and sleeping bags, because of its bulk filling power, aesthetic qualities and various advantages over other filling materials, so is now manufactured and used in large quantities commercially.
Filling materials are often of staple fiber, sometimes referred to as cut fiber in the case of synthetic fiber, which is first crimped, and is provided in the form of continuous bonded batts (sometimes referred to as battings) for ease of fabrication and conversion of staple into the final filled articles. Traditionally, bonded batts have been made from webs of parallelized (staple) fiber that preferably comprise a blend of binder fibers as well as of regular filling fibers, which can consequently be referred to as load-bearing fibers, such as poly(ethylene terephthalate) homopolymer, often referred to as 2G-T. These webs are made on a garnett or other type of card (carding machine) which straightens and parallelizes the loosened staple fiber to form the desired web of parallelized, crimped fibers. The webs of parallelized fibers are then built up into a batt on a cross-lapper. The batt is usually sprayed with resin and heated to cure the resin and any binder fiber to provide the desired bonded batt. The resin is used to seal the surface(s) of the batt (to prevent leakage) and also to provide bonding. The use of binder fiber intimately blended with the load-bearing fiber throughout the batt has generally been preferred because- such heating to activate the binder material (of the binder material) can provide a "through-bonded" batt. If binder fiber is used, and if a suitable shell fabric can prevent leakage of fibers, then the resin treatment may be omitted, and is in some instances, for example, for some sleeping bags. This simplified explanation is the normal way most bonded batts are now made, because it is not expensive and is adequate for many purposes, especially when dense batts are desired. There has been a limit, however, to the ability to make lofty batts, such as are often desirable for some end-uses, by this normal procedure.
Consequently, some have preferred to use an air-laying process for preparing a lofty batt, which is then bonded. Such an air-laying process does indeed provide a way to overcome the deficiency mentioned of the normal batt-making process that has been used hitherto for making dense batts. Air-laying is, however, more costly and requires different equipment, so it has been desirable to find a less expensive way to overcome the deficiencies of the normal batt-making process without the need for more expensive equipment.
As indicated, the staple fiber is crimped for use as fiberfill. Indeed, the crimp is important in providing the filled articles with bulk and support. Generally, the crimp has been provided mechanically, by stuffer box crimping of a precursor continuous filamentary tow, as has been described in the art, as this is a reasonably inexpensive way of imparting crimp to an otherwise linear synthetic filament.
SUMMARY OF THE INVENTION
The present invention provides a new and improved way to make bonded batts by using essentially the same equipment used previously in the normal batt making process, but also providing an ability to provide loftier (less dense) bonded batts, and thus to overcome the important deficiency mentioned above. Improved loft is provided, according to the invention, by using a blend of mechanically-crimped fibers and of bicomponent fibers of helical configuration (often referred to simply as "helical crimp" or "spiral crimp" in the art and herein) and/or the provision of lofty webs by use of a randomizer in the carding step, otherwise following essentially the normal process of making bonded batts, especially "through-bonded" batts. These aspects may be used separately or in combination.
According to one aspect of the present invention, therefore, I provide a preferred process for preparing a bonded batt, comprising forming a feed blend of mechanically-crimped staple fibers intimately mixed with bicomponent staple fibers having a helical configuration, in amount by weight about 5 to about 30% of the blend, preparing a continuous batt from said feed blend by carding the feed blend to provide a web of parallelized fibers, passing the resulting carded web to a randomizer to provide a web of randomized fibers, cross-lapping one or more webs of randomized fibers to provide a batt, said batt having an upper face and a lower face, advancing said batt through a spray zone, whereby at least one face of the batt is sprayed with resin, in total amount about 5 to about 30% of the weight of the sprayed batt, including the resin, heating the sprayed batt in an oven to cure the resin, and cooling the resulting batt.
According to another aspect, I provide a process for preparing a bonded batt, comprising forming a feed blend of mechanically-crimped staple fibers intimately mixed with bicomponent staple fibers having a helical configuration, in amount by weight about 5 to about 30% of the blend, preparing a continuous batt from said feed blend by carding the feed blend to provide a web of fibers, cross-lapping one or more webs of such fibers to provide a batt, said batt having an upper face and a lower face, advancing said batt through a spray zone, whereby at least one face of the batt is sprayed with resin, in total amount about 5 to about 30% of the weight of the sprayed batt, including the resin, heating the sprayed batt in an oven to cure the resin, and cooling the resulting batt.
Preferably, to provide "through-bonded" batts, such feed blends comprise, intimately mixed therein, binder fibers having binder material that bonds at a temperature that is lower (i.e., has a softening point lower) than any (i.e., lower than the lowest) softening point of the said staple fibers in the feed blend, in amount by weight about 5 to about 30% of the blend, and the sprayed batt is heated in the oven to activate the binder material as well as to cure the resin.
As indicated, in certain instances, resin-spraying may be omitted. So, according to another aspect, I provide a process for preparing a bonded batt, comprising forming a feed blend of mechanically-crimped staple fibers, in amount by weight about 40 to about 90%, intimately mixed with bicomponent staple fibers having a helical configuration, in amount by weight about 5 to about 30%, and with binder fibers having binder material that bonds at a temperature that is lower than the lowest softening point of the said staple fibers in the feed blend, in amount by weight about 5 to about 30%, preparing a continuous batt from said feed blend by carding the feed blend to provide a web of parallelized fibers, passing the resulting carded web to a randomizer to provide a web of randomized fibers, cross-lapping one or more webs of randomized fibers to provide a batt, heating the batt in an oven to-soften the binder material, and cooling the resulting batt.
According to a further aspect, likewise, I provide a process for preparing a bonded batt, comprising. forming a feed blend of mechanically-crimped staple fibers, in amount by weight about 40 to about 90%, intimately mixed with bicomponent staple fibers having a helical configuration, in amount by weight about 5 to about 30%, and with binder fibers having binder material that bonds at a temperature that is lower than the lowest softening point of the said staple fibers in the feed blend, in amount by weight about 5 to about 30%, preparing a continuous batt from said feed blend by carding the feed blend to provide a web of fibers, cross-lapping one or more webs of such fibers to provide a batt, heating the batt in an oven to soften the binder material, and cooling the resulting batt.
As will be seen, merely randomizing the fibers provides an improvement, so, according to this aspect, there is provided a process for preparing a bonded batt, comprising carding feed fibers to provide a web of parallelized fibers, passing the resulting carded web to a randomizer to provide a web of randomized fibers, cross-lapping one or more webs of randomized fibers to provide a batt, said batt having an upper face and a lower face, advancing said batt through a spray zone, whereby at least one face of the batt is sprayed with resin, in total amount about 5 to about 30% of the weight of the sprayed batt, including the resin, heating the sprayed batt in an oven to cure the resin, and cooling the resulting batt.
Further provided is such a process wherein said feed fibers comprise, also, intimately blended therewith in amount by weight about 5 to about 30%, binder fibers having binder material that bonds at a temperature that is lower than the lowest softening point of the said feed fibers, whereby a continuous batt is prepared from the resulting blend by carding the resulting blend to provide a web of parallelized fibers, passing the resulting carded web to a randomizer to provide a web of randomized fibers, cross-lapping one or more webs of randomized fibers to provide a batt, advancing said batt through a spray zone and oven, whereby the sprayed batt is heated in the oven to cure the resin and to soften the binder material, and cooling the resulting batt.
Also provided, likewise, according to another aspect, is a process for preparing a bonded batt, comprising forming a feed blend of mechanically-crimped staple fibers intimately mixed with binder fibers having binder material that bonds at a temperature that is lower than the lowest softening point of the said staple fibers in the feed blend, in amount by weight about 5 to about 30% of the blend, preparing a continuous batt from said feed blend by carding the feed blend to provide a web of parallelized fibers, passing the resulting carded web to a randomizer to provide a web of randomized fibers, cross-lapping one or more webs of randomized fibers to provide a batt, heating the batt in an oven to soften the binder material, and cooling the resulting batt.
"Through-bonded batts" are preferred, such as are made by incorporating binder fibers in amounts of about 5 to about 30% by weight in the feed blend of staple fibers, such as polyester fibers, which are themselves preferred staple fibers, but the invention has also shown advantages with feed fibers that do not include binder-fibers as indicated with fiber "A" in Example 1, hereinafter.
Sheath/core bicomponent fibers are preferred as binder fibers, especially bicomponent binder fibers having a core of polyester homopolymer and a sheath of copolyester that is a binder material, such as are commercially available from Unitika Co., Japan (e.g., sold as MELTY). Preferred proportions of the resin sprayed are about 5 to about 18%, on the inidicated basis, while preferred amounts of binder fiber are about 10% to about 20% (by weight of the feed blend) and correspondingly about 90 to about 80% of the (other) staple fibers, which are preferably polyester, and may be 2G-T, together with any bicomponent fibers of helical configuration.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic illustration of how a garnett with a randomizer roll may be operated according one aspect of the invention.
FIG. 2 is a schematic illustration of how a garnett may be operated according to such aspect of the invention with a pair of randomizer rolls.
FIG. 3 is a schematic illustration of a cross-lapper operation.
DETAILED DESCRIPTION OF THE INVENTION
As indicated hereinabove, the process of the invention is essentially similar to the normal process of making bonded batts used conventionally hitherto, but with important exceptions. The improvements in thickness (lowered density) and increased insulation are significant and are shown hereinafter by the comparative data in the Examples.
Thus, the fibers in the carded web are preferably randomized, and preferably by being processed by a randomizer after the carding step and preferably before the cross-lapping step. A randomizer is not an expensive addition to a carding machine. Indeed, nonwoven random cards have been suggested to turn the fibers into the cross-direction (CD), and thus increase the CD:MD (cross-direction:machine direction) of the fibers in webs for flat nonwovens and so randomizing rollers have been available, e.g., from John D. Hollingsworth-on-Wheels in Greenville, S.C., from Ramisch Kleinewefers, Spinnbau Bremen, Germany, and from Ta You Machinery Co. Ltd., in Tao-Yuan, Taiwan. When randomizing rollers have been used in prior processes for making webs for flat non-wovens, the randomized fibers in the webs have subsequently been flattened, for instance by calendering during a calender-bonding process or by compressing the non-woven web after saturation with resin during a saturation-bonding process. Randomizers are not believed to have been used for making lofty bonded baits, nor to overcome the deficiencies of the equipment hitherto normally used for making lofty bonded batts. This is surprising in view of the improvements I have achieved and in view of the simplicity of my change from the normal process.
This aspect of the invention will now be described with reference to the accompanying drawings, in which like elements are referred to by similar numerals. FIG. 1 illustrates the arrangement of three cylinders (sometimes referred to as rolls) arranged in juxtaposition for a garnetting step according to this aspect of the invention with their axes horizontal, showing from the left a main cylinder 11, a doffer 12, and a randomizer 13, rotating in the directions indicated (main cylinder and randomizer clockwise, with doffer counterclockwise), and with their cylindrical surfaces covered with appropriate card clothing, with teeth oriented as indicated (main cylinder teeth 21 oriented in direction of rotation, but doffer teeth 22 and randomizer teeth 23 opposite to directions of rotation). Thus, a (carded) web 14 is carried by the teeth 21 on main cylinder 11, stripped therefrom by the teeth 22 on doffer 12, and then transferred from the doffer teeth 22 to the randomizer's teeth 23. The randomizer 13 is rotated at a surface speed that is much reduced from the surface speed of the doffer 12, so the parallelized fibers in the web 14 become rearranged in the nip 15 between the doffer 12 and the randomizer 13, and the resulting web 16 carried by the teeth 23 on the randomizer 13 is loftier and contains randomly-oriented fibers, many of which are at significant angles to the machine direction (direction of travel of the web), and can be considered to be vertical or at least have a significant vertical component in relation to a horizontal web. The surface speed of the randomizer 13 should generally be less than 2/3 that of the doffer 12, i.e., doffer surface speed being at least about 1.5X that of randomizer, and often about 2.5X or more, which is generally at the higher end of the range that has been used (for different purposes in making flattened fibrous masses with increased CD:MD ratios for non-wovens). When making lofty bonded batts according to my invention, I do not want to flatten the web, i.e., to remove this vertical component or orientation of the randomized fibers, in contrast to prior processes for making flat non-woven webs that have used a randomizer and then compressed the web to flatten the randomized fibers. This randomized web 16 then drops onto a horizontal conveyor 17, and is transferred to the next stage.
The garnett illustrated in FIG. 2 is essentially similar to that of FIG. 1, except that two randomizers 13 and 18 are located in series between doffer 12 and conveyor 17, the second randomizer 18 rotating in a counterclockwise direction, with its teeth 24 oriented opposite to the direction of rotation. This alternative is illustrated because machinery with a pair of randomizer rolls has been available commercially in relation to carding flat webs, because it has provided a capability for better control of CD:MD (cross-direction:machine direction) fibers in a flat horizontal web (by varying the relative speeds of the randomizer rolls), but I do not believe that using a second randomizer roll offers significant benefit according to the present invention, which derives benefit from increasing and maintaining vertical components of orientation and providing a lofty web, rather than a flat web. I prefer to operate any second randormizer 18 at a slightly slower surface speed than that of the first randornizer 13.
FIG. 3 illustrates a conventional cross-lapper, and further description appears to be unnecessary.
Other features of the invention are mostly conventional, except in regards to the improvement in lofty bonded batts obtained by using a proportion of fibers having helical crimp blended into the feed fiber, as described herein. Hernandez et al. U.S. Pat. No. 5,458,971 and application Ser. No. 08/542,974 filed Oct. 13, 1995 (respectively DP-6320 and DP-6320-C) describe preferred bicomponent fibers having helical configuration and their use as filling fibers. Such fibers, or other fibers-having helical crimp (configuration), are preferably blended into the feed fiber in amount about 5 to about 30% of the feed fiber, especially about 10 to about 20%, by weight. Several bicomponent fibers having a helical configuration are disclosed in the art. This configuration has often been referred to as crimp (because most synthetic fibers obtain their desired non-linear configuration by being mechanically-crimped). In fact, the term "spiral crimp" has been used extensively, although the term "helical" is more correct. The configuration is derived from the eccentric arrangement of the components of the fiber. A side-by-side arrangement is generally preferred.
The invention will be further described in more detail with reference to polyester fiberfill, which is preferred, and to other preferred elements and features, such as preferred binder fibers and helically-crimped fibers, although it will be recognized that other fibers may also be used and there is no reason to limit the invention only to those fibers that are preferred.
Reference may be made to the art, such as referred to herein, for conventional features such as preferred feed fibers (their deniers, cross-sections, blends thereof), and equipment and processing features, including U.S. Pat. No. 5,225,242 and application Ser. No. 08/396,291, filed Feb. 28, 1995 (Frankosky et al. DP-6045 and DP-6045-A), and the art referred to therein. Frankosky et al. application Ser. No. 08/406,355, filed Mar. 17, 1995, now allowed, discloses useful binder materials and fibers. Kerawalla, U.S. Pat. Nos. 5,154,969 and 5,318,650 discloses useful binder fibers and processes. Other disclosures of batts, batt-making and their features include, for example, U.S. Pat. Nos. 5,104,725 (Broaddus), 5,064,703 (Frankosky et al.), 5,023,131 (Kwok), 4,999,232 (LeVan), 4,869,771 (LeVan), 4,818,599 (Marcus), 4,304,817 (Frankosky), and 4,281,042 (Pamm), and the references disclosed therein.
The invention is further illustrated in the following Examples; all parts and percentages are by weight unless otherwise indicated. The garnett was supplied by Ta You Machinery Co. Ltd., Tao-Yuan, Taiwan ROC. The cross-lapper used was supplied by Asselin SA, Elbeuf, France. Randomizer rolls were supplied by Ta You Machinery Co. Ltd., and by John D. Hollingsworth on Wheels, Greenville, S.C. CLO ratings are conventional and described, e.g., by Hwang in U.S. Pat. No. 4,514,455.
EXAMPLE 1
Staple fiber and blends as indicated hereinafter in the following Table 1 and explanatory notes were processed into bonded battings by the following procedures, with and without using a randomizer roll, for comparison, and otherwise following essentially the procedure described in Example 5 of copending application Ser. No. 08/542,974 (DP-6320-C) filed Oct. 13, 1995 by Hernandez et al. In other words, both for making battings according to the invention (using a randomizer roll and/or bicomponent fiber of helical configuration) and for comparisons, the blends were processed on a garnett and then cross-lapped and sprayed with half the indicated amount of an acrylic resin on the top side and carried by conveyor to the first path of a three-path oven to cure the resin and activate the binder fiber at 150° C.; at the exit of the first path, the batting was turned upside-down and the-other side of the batting was sprayed with the other half of the same acrylic resin to make up the total resin pickup; the batting was carried by another conveyor to the second path of the oven and
For making battings according to the randomizer aspect of the invention during the garnetting process, the web that was removed from the main cylinder of the garnett by the doffer was delivered from the doffer to a randomizer roll, as shown in FIG. 1 of the accompanying drawings, at a speed 2.6X the surface speed of the randomizer roll . Because the speed of the doffer was so much faster than the speed of the randomizer, the orientation of the fibers in the web was rearranged from a flat parallelized web to a loftier, thicker web with randomized fibers, several being oriented in a vertical direction (at right angles to both the machine and cross-directions, referred to generally as MD and CD). This loftier web (loftier than the comparison webs made by garnetting without any randomization) was then cross-lapped (to build up basis weight) and sprayed with resin, and heated in similar manner to the comparison webs.
The improvements in thickness and insulating properties achieved by use of the invention can be seen from the data given in Table 1. It will be noted that the improvements obtained by the invention were step-wise, improvements being achieved by using either the randomizer (Rand), or by incorporating fiber of helical crimp in minor amount in a blend of feed fiber; as indicated under BiC (for BiComponent), and the best results were obtained by using both aspects.
TABLE 1______________________________________ CLOStaple BiC Resin BW Thickness CLO/Rand Type % % (oz) in in/oz/yd.sup.2 CLO oz/yd.sup.2______________________________________No A 0 12.3 4.82 0.89 0.18 2.58 0.54Yes 0 12.1 4.51 0.87 0.19 2.55 0.57Yes 15 9.8 4.39 0.89 0.20 2.62 0.60No B 0 20.9 4.65 0.71 0.15 2.63 0.57Yes 0 26.2 4.95 1.02 0.21 2.99 0.60Yes 15 25.0 4.66 1.04 0.22 2.89 0.62______________________________________
EXAMPLE 2
Staple fiber blends as indicated in Table 2 were processed into bonded batts according to the invention following essentially similar procedures as described in Example 1, except that the web was passed from the doffer to the first of a pair-of randomizer rolls as illustrated in FIG. 2 herein, and then to the second randomizer roll, which was operated at a slightly slower speed. Details and measurements of properties are given in Table 2.
TABLE 2______________________________________ CLOStaple BiC Resin BW Thickness CLO/Rand Type % % (oz) in in/oz/yd.sup.2 CLO oz/yd.sup.2______________________________________Yes C 0 11.0 3.17 0.48 0.15 1.75 0.55Yes 15 14.1 2.86 0.52 0.18 1.70 0.59Yes 30 10.1 2.92 0.56 0.19 2.06 0.71______________________________________
Explanatory Notes
The following abbreviations were used in the Examples:
"Rand" indicates whether a randomizer was used, or the experiment was a comparison performed without randomizing, but under otherwise similar conditions;
"BIC" indicates the amount of bicomponent fiber, which was the 9 dpf, 3 inch, slickened, 3-void, helical crimp bicomponent polyester fiber of Example 1 of U.S. Pat. No. 5,458,971;
"BW" indicates the "Batting Weight" of the batt, i.e., after spraying on resin, the total percentage amount sprayed being indicated under "Resin";
"Thickness" and "CLO" are both given in absolute values and after being normalized to equivalent batting weights per unit area;
"Staple" fibers and blends are available commercially, as follows:
A--slickened 5.5 dpf, 3-inch cut length (7.5 cm), 7-hole
B--55% slickened 3.6 dpf, 2.5-inch cut length (6.3 cm), hollow 27% slickened 1.65 dpf, 2.5-inch cut length (6.3 cm) 18% 4 dpf, 2.5-inch cut length (6.3 cm) MELTY 4080
C--55% slickened 1.65 dpf, 2-inch cut length (5 cm) 27% 1.65 dpf, 2-inch cut length (5 cm) 18% 4 dpf, 2-inch cut length (9 cm) MELTY 4080
The regular fiberfill above, i.e., other than binder fiber, was 2G-T polyester of solid cross-section, unless otherwise indicated; MELTY 4080 is a sheath/core binder fiber, referred to in the art, and commercially available from Unitika Co., Japan; the fibers used were all of round periphery and none were slickened unless indicated.
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Lofty battings are prepared by a process involving carding to make one or more webs of fibers, preferably using a blend of mechanically-crimped filling fibers with bicomponent fibers of helical configuration, and that preferably also contains binder fibers, the fiber orientations preferably being randomized in the web(s) before cross-lapping to build up the batt, and preferably followed by spraying with resin and curing, thus providing a bonded batt in which the loft is improved by the presence of the different crimp configurations and/or randomized orientations that are fixed in the fibers in the bonded batt.
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This application is a divisional of application Ser. No. 08/480,018, filed Jun. 7, 1995, now U.S. Pat. No. 5,594,330, which is a divisional of application Ser. No. 07/898,216, filed Jun. 12, 1992, now issued as U.S. Pat. No. 5,481,184, which is a continuation-in-part of application Ser. No. 07/816,628, filed Dec. 31, 1991, now issued as U.S. Pat. No. 5,269,882, which is a continuation-in-part of application Ser. No. 07/647,659, filed Jan. 28, 1991, now issued as U.S. Pat. No. 5,106,455.
BACKGROUND OF THE INVENTION
This invention relates to systems for effecting movement of an object and, in desired applications, sensing the movement of objects, especially of micro-structures.
With recent developments in non-planar lithography, the fabrication of micro-structures, including both three-dimensional mechanical parts and three-dimensional electrical components, has become more readily achievable. See, for example, U.S. Pat. No. 5,106,455 and co-pending application, Ser. No. 816,628, filed Dec. 12, 1991. Such micro-structures are finding use in a variety of areas including medical devices, robotics, navigation equipment, motors and similar equipment. It is oftentimes desired in such applications to cause the controlled movement of very small mechanical parts, such as fibers or filaments, and also to detect the movement of mechanical parts, both the degree or extent of such movement and the direction.
SUMMARY OF THE INVENTION
It is an object of the invention to provide systems for effecting movement in micro-structural elements.
It is also an object of the invention to provide systems for detecting or sensing movement of micro-structural elements, including the degree and direction of such movement.
It is a further object of the invention to provide such systems which are especially adapted for effecting movement of micro fibers or micro filaments, and for sensing movement therein.
The above and other objects of the invention are realized in a specific illustrative embodiment of a movement actuator which includes an elongate fiber, and one or more strips of actuable material disposed on the surface of the side of the fiber. The actuable material is responsive to an actuation signal for changing its shape to thereby cause the fiber to move to accommodate the change in shape of the material. An actuation signal generator is also provided for selectively applying actuation signals to the strip or strips of actuable material to cause them to change shape and thereby cause the fiber to move as desired.
The strips of actuable material may be placed lengthwise on the fiber and caused to shorten to thereby cause the fiber to bend. Alternatively, the strips may be placed helically about the fiber and again caused to shorten to thereby cause the fiber to twist. Other patterns for the strips of actuable material may also be provided to cause various kinds of movements of the fiber.
The strips of actuable material may be so-called shape memory alloys which change from one shape to another when external heat or an electrical current which causes heat to be generated internally, is applied thereto. When the heat or electrical current is removed and the internally generated heat dissipates, the strips then return to their original shape. Alternatively, the strips of actuable material may be comprised of bimetals, i.e., two layers of different metals with different coefficients of thermal expansion, so that when heated, the strips are caused to change shape and thereby cause movement of the fiber.
In accordance with one aspect of the invention, the fibers may be made of a piezoelectric material and the strips of actuable material may consist of conductive elements positioned on the side of the fiber so that as voltage signals are applied to the conductive elements, the fiber is caused to bend. Various patterns of conductive elements could be provided to cause bending of the fiber, shortening or lengthening of the fiber, etc.
Alternatively, flexible fibers may be coated with piezoelectric strips so that when voltages are applied to the strip the strips bend and cause the fiber to bend.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the invention will become apparent from a consideration of the following detailed description presented in connection with the accompanying drawings in which:
FIGS. 1A and 1B show schematic, perspective views of two embodiments of an actuator for causing movement of a rod or filament, utilizing shape memory alloys, made in accordance with the principles of the present invention;
FIGS. 2A and 2B show schematic, perspective views of two embodiments of actuators for causing movement of a rod or filament, utilizing piezoelectric materials;
FIG. 3 is a schematic, perspective view of a sensor system for sensing movement, both the degree and direction, of a rod or filament, in accordance with the present invention;
FIG. 4 is a schematic, perspective view of an actuator for causing rotational movement of an object;
FIG. 5 is a schematic, perspective view of an actuator for causing the bending of a rod or filament at several locations along the length thereof;
FIG. 6 is a schematic, perspective view of a feedback control system for causing controlled bending of a rod or filament;
FIG. 7 is a schematic, perspective view of an electrical generator for generating electricity from a piezoelectric rod or filament;
FIG. 8 is a schematic, perspective view of a slit tube valve made in accordance with the principles of the present invention;
FIG. 9 is a side, cross-sectional view of a valve, utilizing two tubes, made in accordance with the present invention;
FIG. 10 is a side, cross-sectional view of another embodiment of a valve, utilizing a bendable rod or filament, in accordance with the present invention;
FIG. 11 is a side, cross-sectional view of an accelerometer, made in accordance with the principles of the present invention; and
FIG. 12 is a side, cross-sectional view of another embodiment of an accelerometer, also made in accordance with the principles of the present invention.
DETAILED DESCRIPTION
Referring to FIG. 1A, there is shown a schematic, perspective view of one embodiment of a movement actuator made in accordance with the present invention. The actuator is comprised of a rod 4 (the terms "rod", "bar", "fiber" and "filament" are used interchangeably herein to indicate an elongate element). The bar 4 is attached or anchored at one end to a fixedsupport 8, with the other end being free to move in accordance with the present invention. The other end is shown to be pointed and is positioned adjacent a scale 12 to indicate where on the scale the free end of the baris pointing. Disposed on one side of the bar 4 is a strip 16 of shape memory alloy which has the capability of changing its shape upon the application of external heat or electric current (which generates internalheat) to some other shape and then assuming the original shape when cooled or electric current is removed and the heat dissipates. Example of such shape memory alloy is nitonol comprised of about 50 percent nickel and 50 percent titanium. The bar 4 is made of a laterally flexible material such as ceramic, metal or plastic, so that when the shape memory alloy strip 16is caused to change shape, such as contract along its length, the bar will be caused to bend as indicated by the double headed arrow 20.
An electrical current source 24 is coupled to the strip of shape memory alloy 16 to selectively supply electrical current thereto to cause the strip to change its shape. The amount of current supplied to the strip 16 determines the degree to which the strip changes shape and thus the degreeto which the rod 4 is bent or deflected.
An alternative to use of the strip of shape memory alloy 16 is the use of abimetal laid down in the same location as the strip 16 on the bar 4. A bimetal is comprised of two layers of different metals having different thermal coefficients of expansion. Thus, when heat or an electrical current is supplied to the bimetal strip it is caused to bend to, in turn,cause the bar 4 to bend. Bimetals are well known. Still another alternativeis the use of piezoelectric strips on the bar 4 to cause bending of the barin response to applied voltages.
Although the diameter of the bar 4 is shown to be relatively large comparedto the length, these proportions are used for purposes of illustration onlyand it should be understood that generally the diameter would be much smaller compared to the length, and would more often resemble a thin fiberor filament, such as the fibers used in fiber optic applications. The stripof shape memory alloy 16 could be deposited upon the bar 4 using techniquesdisclosed in copending patent application, Ser. No. 07/816,628, filed Dec. 31, 1991.
FIG. 1B shows a schematic, perspective view of another actuator having a rod 28 anchored at one end in a base 32 and having a strip of shape memoryalloy 36 disposed in a helical pattern around the rod. When a current source 40 selectively supplies electrical current to the strip 36, the strip is caused to contract (or elongate) to thereby cause the free end ofthe bar 28 to twist or rotate as indicated by the double headed arrow 44. Apointer 48 is mounted on the free end of the bar 28 to indicate by a scale 52 the amount of rotation occurring at the free end.
It will be evident that a variety of shape memory alloy patterns could be provided on the side exterior of rods or filaments to cause the rods or filaments to bend, elongate, twist, contract, etc. For example, if a stripof shape memory alloy is disposed on a bar to extend from near the anchor end longitudinally and partially circumferentially about the bar, the bar may be caused to both bend and twist.
FIGS. 2A and 2B show two embodiments of movement actuators utilizing piezoelectric material. FIG. 2A is a schematic, perspective view of such amovement actuator having an elongate bar 56 anchored at one end to a base 60, and being made of a piezoelectric material such as PZT. Disposed on one side of the bar 56 in a longitudinal array are a plurality of electrically conductive elements or electrodes 64. A voltage source 68 selectively supplies a voltage of one polarity to alternate ones of the elements 64 and a voltage of opposite polarity to the remaining elements to thereby produce a localized electric field which will cause the bar 56 to bend as generally indicated by the double headed arrow 72. Piezoelectric materials, of course, are well known to change shape physically in response to application of electrical voltages and to produce electrical voltages when distorted, squeezed, bent, etc.
FIG. 2B shows an alternative embodiment of a movement actuator again utilizing an elongate bar 76 made of a piezoelectric material. In this embodiment, conductive strips 80 (only two of which are shown in FIG. 2B with two others not shown being formed on the other side of the bar) are disposed to extend longitudinally on the bar 76. A voltage source 84 selectively supplies voltage signals to the strips 80 to establish electric fields in the bar 76 to cause the bar to contract or extend longitudinally as indicated by the double headed arrow 88.
It should be noted that both configurations in FIGS. 2A and 2B could be adapted to be movement sensors by simply replacing the voltage sources 68 and 84 with sensing circuitry. Then, when the piezoelectric bars 56 and 76were bent or longitudinally compressed respectively, voltages would be developed in the bars and these voltages would be detected by the sensing circuitry to thereby sense movement of the respective bars.
FIG. 3 is a schematic, perspective view of a sensor system for sensing movement, including determination of the degree of movement and the direction of movement, of a flexible rod 92. The rod 92 is anchored at oneend in a base 102 so that the free end of the rod is subject to forces in various directions indicated by the arrows 106. Disposed circumferentiallyabout the bar 92 are four strain gauges 110, such as those disclosed in U.S. Pat. No. 4,964,306. The strain gauges 110 produce signals whose magnitudes are an indication of the degree of strain occurring at the location of the strain gauges. Thus, as a force is applied to the free endof the rod 92, to cause it to bend, the bar strains differently at different circumferential locations about the rod and these strains, at least at the location of the strain gauges 110, are detected and signals indicating the amount of strain are supplied to a microprocessor 114. The microprocessor 114, in turn, calculates the direction of bending of the rod 92 and the degree of the bend, from the magnitude of the signals received from the four strain gauges 110. The use of three or more strain gauges spaced circumferentially about the rod 92 are sufficient to determine the direction and degree of bend of the rod. This is because when the rod 92 is bent, there will always be at least one strain gauge which is subject to compression (being more on the side of the rod in the direction of the bend), and one strain gauge will be subject to expansion (being on the side of the rod more away from the direction of the bend).
FIG. 4 is a schematic, perspective view of an actuator for causing rotational movement of an object, in this case a disk 120. The actuator includes four flexible bars 124 having fixed ends attached to a base 128 at circumferentially spaced-apart locations. The bars 124 extend outwardlyfrom the base 128, generally in parallel with one another, to join the disk120. Strips of shape memory alloy 132 are disposed on the rods 124 on sidesin line with the circumferential spacing of the rods, as shown, and the strips are each coupled to a current source 136. When current is applied to the strips 132, the strips cause the rods 124 to bend in a direction inline with the circumferential spacing to thereby cause the disk 120 to rotate in the direction indicated by the arrow 140.
FIG. 5 shows a flexible elongate rod 144 with shape memory alloy patches 148 disposed at longitudinally spaced-apart locations along the bar. A current source 152 is coupled by way of a buss 156 to each of the patches 148 to selectively supply current thereto. Thus, the bar 144 can be causedto bend at various locations along the length thereof as determined by the current source 152.
FIG. 6 shows a feedback control system for effecting controlled bending of a flexible rod 160 anchored at one end to a base 164. Disposed on one sideof the rod 160 is a strip of shape memory alloy 168 coupled to a current source 172 which operates to supply current to the strip 168 under controlof a logic unit 176. Disposed on the other side of the bar 160 is a strain gauge 180 coupled to a sensor circuit 184. The sensor circuit 184 producesa signal whose magnitude is indicative of the strain to which the bar 160 is subjected and this signal is supplied to a summing circuit 188. A signal source 192 also supplies a signal to the summing circuit 188 in which the signal's value represents a degree of bending desired for the rod 160. The summing circuit 188 effectively compares the two input signals and if there is a difference, it signals the logic circuit 176 as to the amount of this difference and the logic circuit, in turn, signals the current source to cause further bending (or unbending) of the rod 160 so that the output signal of the sensor 184 will move closer in value to the signal supplied by the signal source 192. This is a conventional feedback control circuit for ensuring that a result represented by an input signal is more accurately achieved, the result in this case being the bending of the rod 160.
FIG. 7 is a schematic, perspective view of an electricity generator composed of an elongate, flexible piezoelectric filament 200 disposed and held in place by bearings 204 and 208 located at the ends of the filament so that the filament follows an arc-shaped locus of points. A power source212 is coupled to the filament 200 to cause the filament to rotate about anaxis coincident with the arc-shaped locus of points. As a result, the filament 200 is continually stressed and compacted (that portion of the rod on the concave side of the arc being compacted and that portion of therod on the convex side of the arc being stressed) to thereby develop voltages which are supplied to wiper elements or electrodes 216 disposed on opposite sides of the filament. In this manner, electrical voltage, andthus electrical current, may be developed or generated from a mechanical rotation of the piezoelectric filament 200. Conversely, by supplying an appropriately commutated voltage to the elements 216, the filament 200 canbe caused to rotate and thus operate as a motor.
FIGS. 8-10 show three different embodiments of a valve using the technologyof the present invention. In FIG. 8, a flexible tube 220 is shown attached at a closed end to a base 224, and having an open end 228 for receiving a fluid. A strip of shape memory alloy 232 is helically disposed about the exterior of the tube 220 and is coupled to a current source 236 which, by supplying current to the strip 232, selectively causes a change in shape of the strip to thereby cause a twisting of the tube 220 in the direction indicated by the arrow 240. When the tube 220 is twisted as indicated, a the slit 244 formed in the side of the tube is caused to open to allow theoutflow of fluid. When the tube 220 is untwisted, the slit 244 is closed toprevent the outflow of fluid. In this manner, the flow of fluid through andout the tube 220 can be controlled by controlling the twisting of the tube.The tube 220 could be made of a resilient ceramic or hard rubber.
FIG. 9 shows another embodiment of a valve utilizing the present invention.In this embodiment, two flexible tubes 250 and 254 are anchored respectively on bases 258 and 262. The free ends of the tubes are positioned to mate together in a colinear fashion to seal the inside of the tubes from the outside when the tubes are undeflected. An access port 266 is formed in the tube 250 to allow introduction of fluid to the insideof the tubes. Of course, such access could be provided through the other tube 254 or through the bases 258 or 262. Strips of shape memory alloy aredisposed on the upper sides of the tubes 250 and 254 and are selectively heated by a current source to cause the tubes to deflect or bend upwardly,as indicated by dotted lines in FIG. 9. When such deflection occurs, the ends of the tubes 250 and 254 are exposed to allow escape of fluid which has been introduced into the insides of the tubes. The flow of fluid through the valve of FIG. 9 is indicated by the arrows. When current to the strips of shape memory alloy is terminated so that the strips cool, the strips return to their original shape causing the tubes to deflect back to their original colinear position to again seal the inside of the tubes from the outside and prevent further outflow of fluid.
FIG. 10 shows a cross-sectional, elevational view of a third embodiment of a valve which, in this case, utilizes a selectively bendable rod 270 disposed to extend from a closed end of a housing 274 towards an open end 278. A conical cap 282 is disposed on the end of the bar 270 and is positioned in the open end 278 of the housing 274. The diameter of the conical cap 282 is greater than the opening in the open end 278 of the housing 274 so that if the cap is moved towards the closed end of the housing, it seats in the open end to seal off the inside of the housing from the outside. Fluid is introduced into the inside of the housing 274 through an inlet port 286. The bar 270 is made of a piezoelectric materialand conductive strips are disposed on the sides of the bar (not shown) so that when a voltage is supplied thereto, the bar is caused to selectively lengthen or shorten depending upon the polarity of the voltages. When the bar 270 is caused to shorten, the conical cap 282 is caused to seat on andclose off the opening at the open end 278 of the housing 274 to prevent theoutflow of fluid. When the bar 270 is caused to lengthen, the conical cap 278 is moved outwardly from the opening to allow the outflow of fluid frominside the housing 274, as indicated by the arrows.
FIGS. 11 and 12 show side, cross-sectional views of two embodiments of an accelerometer made in accordance with the present invention. In FIG. 11, the accelerometer is shown to include a housing 290 in which is disposed aflexible rod 294, one end of which is fixed at one end of the housing 290 to extend toward the other end of the housing as shown. Disposed on the free end of the rod 294 is a field emitter 298 for developing an electric field which emanates radially outwardly. Disposed on the interior of the housing 290 circumferentially about the field emitter 298, but spaced therefrom, are a plurality of field detectors 302. The field detectors 302are coupled to a signal processor 306 for determining which of the field detectors 302 is producing the strongest signal, indicating that the fieldemitter 298 is closest to that field detector. When the housing 290 is accelerated, the rod 294 is caused to deflect in the direction opposite the acceleration to move the field emitter 298 closest to one of the plurality of field detectors 302, and the signal processor 306 determines which field detector that is and therefore in which direction the acceleration is occurring. Also, the degree of deflection by the rod can be determined by the strength of the electric field detected and this provides an indication of the magnitude of the acceleration. The use of field emitters and field detectors for sensing movement is well known. SeeU.S. Pat. No. 4,767,973.
FIG. 12 shows a side, cross-sectional view of another embodiment of an accelerometer which also includes a housing 310 in which is disposed a piezoelectric rod 314 extending from one end of the housing toward the other end. Disposed about the sides of the rod 314 are a plurality of electrically conductive elements 318 for conducting to a signal processor 322 voltages developed in the rod 314 when it is deflected. Such voltages would be developed when the housing 310 were accelerated in a direction lateral of the housing 310 and the amount of voltage developed would provide an indication of the degree of deflection of the rod 313 and thus of the magnitude of the acceleration. Also, the polarity of the voltages developed at each of the electrically conductive elements 318 would provide an indication of the direction of the acceleration.
It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present invention. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the present invention and the appended claims are intended to cover such modifications and arrangements.
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A movement actuator includes an elongate filament made of a flexible material, and a strip of shape memory alloy disposed on the surface of one side of the filament. The shape memory alloy is responsive to actuation signals, heat or electrical signals, for changing its shape and when its shape changes, it causes the filament to move, i.e., bend, to accommodate the change in shape of the alloy. Also included is a signal supply device for selectively applying heat signals or electrical current to the strip of shape memory alloy to cause the alloy to change its shape and cause the filament to bend. Other patterns for the shape memory alloy could be disposed on the filament to cause other kinds of movements. For example, a helical pattern of the shape memory alloy about the filament would cause the filament to twist when the helical pattern were caused to shorten or lengthen.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation of pending patent application Ser. No. 12/582,446, filed Oct. 20, 2009, the contents of which are incorporated herein by reference, which is a continuation of U.S. application Ser. No. 11/002,583, filed Dec. 3, 2004, (U.S. Pat. No. 7,631,043) the contents of which are incorporated herein by reference.
BACKGROUND
1. Technical Field
This invention relates to apparatus, method and stored computer program media for managing “messages sent” files and/or resending of messages from mobile wireless communication devices.
2. Related Art
Various email systems are now well known and utilized by millions on a daily basis. Email systems typically maintain a stored file or folder containing current opened and unopened mail, previously sent mail, messages that have been “deleted” (e.g., in a “trash” file until also deleted therefrom), email address files for various categories of parties with whom communications have been made or may be made in the future (e.g., an “address book”) and the like. Sometimes email systems also incorporate calendar, personal contact data, documents, check lists and the like as well.
Besides composing new email messages and sending them, most systems also include features for forwarding received emails onward to other recipients and for resending previously sent messages (e.g., possibly retracting the earlier message in favour of a later version or possibly sending the same message on to additional recipients or possibly resending a message which for some reason went astray and was never acknowledged or actually received by the intended recipient.
Such email systems become considerably more complicated when they include mobile wireless communication devices as well as a user's base PC or enterprise message server or the like. In this more complex email system, a given email message may have originated at the user's desktop PC (or at somebody else's PC or otherwise) or may have originated in the first instance from the mobile wireless communication device itself. It is thus possible that the file of previously sent messages maintained in the mobile wireless communication device is not always synchronized (i.e., identical in content) with the file of previously sent messages for that particular user (in either the user's desktop PC base unit or a message server associated therewith for an entire enterprise). While synchronization of address books and the like between a user's PC base unit and a mobile FDA or the like has been known for some time, many if not all prior email systems incorporating mobile wireless communication devices have apparently not maintained well synchronized “message sent” files. Perhaps at least partially for such reasons, when a message is being resent from a user's mobile wireless communication device, it has heretofore typically involved resending of the entire message (e.g., the message header and message body text in full) from the mobile wireless communication device to an enterprise message server or the like (from which that particular message was then re-iterated to the same or new message recipients).
At the same time, typically such prior email systems incorporating mobile wireless communication devices have for a long time used a shortcut technique for effecting replies to received messages and/or forwarding of received messages from the mobile wireless communication device. In particular, since in such instances the received message must already be resident at the enterprise message server which sent it to the mobile wireless communication device, rather than including the entire received message text in a reply to or forwarding of that message, an abbreviated unique reference ID was instead transmitted back to the enterprise message server. This reference ID was then treated as a request to find the appropriate uniquely associated message and then to add the reply text thereto and send it onward and/or to forward the message (possibly also with additional added message text).
However, in spite of the fact that such shortcut techniques/protocols have been in existence for many years in this context for replying to and/or forwarding incoming messages from a mobile wireless communication device, it does not appear that an analogous shortcut technique has previously been used for resending previously sent messages. In the past, when a message was resent from the mobile device, the entire contents of the message was sent from the device to the server. In some cases, particularly if there is not complete 100% current message syncing of the sent message files), not all previously sent message information (e.g., message body text) may be available at the mobile wireless communication device. However (particularly if synchronization of sent files is well maintained), then full message information for each previously sent message is likely to be already available at the server. Nevertheless, the prior art practice effectively has ignored this situation and required redundant message information to be sent across the wireless network which has been a waste of network- bandwidth and device battery.
BRIEF SUMMARY
We have now recognized that it is possible to avoid such needless waste of wireless bandwidth and/or device battery.
In exemplary embodiments an abbreviated (but unique) reference ID of the message is initially sent to the server to be resent, similar to what has previously been done for “replies” and “forwards”. If the server recognizes the reference ID (i.e., has the message already stored) it simply resends that particular message. If not, the server informs the device that the received reference ID is unknown, and the device then sends the entire message (as it knows it) back to the server for resending.
This saves network bandwidth because in most cases the server already will have the original sent message available. When the server does not (hopefully a rare occurrence if the “sent message” files are frequently synchronized), the prior mechanism of requesting the device's version of the complete message is still available, so there is no downgrade of service from the user's perspective.
As may be noted, this is related to the previous protocol used when replying and forwarding from the device. It has now become apparent that this needs to be extended to resends, particularly with the introduction of syncing of sent items, - but wherein the syncing may also be abbreviated such that only message headers and reference ID's are regularly maintained at the device (i.e., for messages originating elsewhere). In this case, the device typically does not have the entire message on the device (just the message header) and typical prior implementations would require the device to request the entire message to be delivered to the device before the user could then resend that same message back from the device.
The exemplary protocol now allows resend from the mobile device by using, in most cases, only the message reference ID. That is, to resend the server now resends the original message as is (using the reference ID supplied by the device to find it). The identified message is simply found by the server and resent. If the message cannot be found by the server, the server responds with a transaction error. The device then sends the data that it has for this message (forward, reply or resend). Benefits of sending a reference ID (versus actual full message text data) at least include significant reduction in required network bandwidth and reduced device battery load. For example, in most cases, only a relatively small-sized reference ID will be required for sending to the server—rather than the whole message itself (which could be thousands of bytes).
For various reasons (in general, to save memory space on the device), the original message body may be truncated on the device. This is certainly true for messages that were originally sent from the user's desktop, but may also be true for messages truncated due to low memory storage conditions on the device. It is clearly a preferred method to not have to always download the entire message body to the device just to resend the same message back to the server from the device.
The invention may be embedded in hardware, software or a combination of hardware and software. The invention provides a method for achieving enhanced management of “messages sent” files and/or the resending of messages from mobile wireless communication devices. The exemplary embodiment is realized, in part, by executable computer program code (i.e., logic) which may be embedded in physical program memory media.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of this invention will be more completely understood and appreciated by careful study of the following more detailed description of at least one exemplary embodiment in conjunction with the accompanying drawings, in which:
FIG. 1 is an overall system wide schematic view of an exemplary wireless email communication system incorporating a mobile wireless communication device having enhanced “messages sent” file maintenance (synchronization) and message resend capability in accordance with one exemplary embodiment of this invention;
FIG. 2 is an abbreviated schematic diagram of hardware included within an exemplary mobile wireless communication device of FIG. 1 ;
FIG. 3 is an exemplary abbreviated schematic flowchart of computer software (i.e., program logic) that may be utilized, in parallel, in the device of FIG. 2 and the message server of FIG. 1 to achieve an exemplary synchronization of “message sent” files at the device and server sides, respectively; and
FIG. 4 is an exemplary of abbreviated schematic flowchart of computer software (i.e., program logic) that may be utilized in the device of FIG. 2 and the message server of FIG. 1 to achieve a more efficient resend message, functionality in the device and server, respectively.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
FIG. 1 is an overview of an exemplary communication system in which a wireless communication device 100 (with an optional wired connection port 40 ) may be used in accordance with this invention. One skilled in the art will appreciate that there may be hundreds of different system topologies. There may also be many message senders and recipients. The simple exemplary system shown in FIG. 1 is for illustrative purposes only, and shows perhaps the currently most prevalent Internet e-mail environment.
FIG. 1 shows an e-mail sender 10 , the Internet 12 , a message server system 14 , a wireless gateway 16 , wireless infrastructure 18 , a wireless network 20 and a mobile communication device 100 .
An e-mail sender 10 may, for example, be connected to an ISP (Internet Service Provider) on which a user of the system has an account, located within a company, possibly connected to a local area network (LAN), and connected to the Internet 12 , or connected to the Internet 12 through a large ASP (application service provider) such as American Online™ (AOL). Those skilled in the art will appreciate that the systems shown in FIG. 1 may instead be connected to a wide area network (WAN) other than the Internet, although e-mail transfers are commonly accomplished through Internet-connected arrangements as shown in FIG. 1 .
The message server 14 may be implemented, for example, on a network computer within the firewall of a corporation, a computer within an ISP or ASP system or the like, and acts as the main interface for e-mail exchange over the Internet 12 . Although other messaging systems might not require a message server system 14 , a mobile device 100 configured for receiving and possibly sending e-mail will normally be associated with an account on a message server. Perhaps the two most common message servers are Microsoft Exchange™ and Lotus Domino™. These products are often used in conjunction with Internet mail routers that route and deliver mail. These intermediate components are not shown in FIG. 1 , as they do not directly play a role in the invention described below. Message servers such as server 14 typically extend beyond just e-mail sending and receiving; they also include dynamic database storage engines that have predefined database formats for data like calendars, to-do lists, task lists, e-mail and documentation.
The wireless gateway 16 and infrastructure 18 provide a link between the Internet 12 and wireless network 20 . The wireless infrastructure 18 determines the most likely network for locating a given user and tracks the users as they roam between countries or networks. A message is then delivered to the mobile device 100 via wireless transmission, typically at a radio frequency (RF), from a base station in the wireless network 20 to the mobile device 100 . The particular network 20 may be virtually any wireless network over which messages may be exchanged with a mobile communication device.
As shown in FIG. 1 , a composed e-mail message 22 is sent by the e-mail sender 10 , located somewhere on the Internet 12 . This message 22 typically uses traditional Simple Mail Transfer Protocol (SMTP), RFC 822 headers and multipurpose Internet Mail Extension (MIME) body parts to define the format of the mail message. These techniques are all well known to those skilled in the art. The message 22 arrives at the message server 14 and is normally stored in a message store. Most known messaging systems support a so-called “pull” message access scheme, wherein the mobile device 100 must request that stored messages be forwarded by the message server to the mobile device 100 . Some systems provide for automatic routing of such messages which are addressed using a specific e-mail address associated with the mobile device 100 . In a preferred embodiment, messages addressed to a message server account associated with a host system such as a home computer or office computer 30 which belongs to the user of a mobile device 100 are redirected from the message server 14 to the mobile device 100 as they are received.
Regardless of the specific mechanism controlling forwarding of messages to mobile device 100 , the message 22 , or possibly a translated or reformatted version thereof, is sent to wireless gateway 16 . The wireless infrastructure 18 includes a series of connections to wireless network 20 . These connections could be Integrated Services Digital Network (ISDN), Frame Relay or T 1 connections using the TCP/IP protocol used throughout the Internet. As used herein, the term “wireless network” is intended to include three different types of networks, those being (1) data-centric wireless networks, (2) voice-centric wireless networks and (3) dual-mode networks that can support both voice and data communications over the same physical base stations. Combined dual-mode networks include, but are not limited to, (1) Code Division Multiple Access (CDMA) networks, (2) the Group Special Mobile or the Global System for Mobile Communications (GSM) and the General Packet Radio Service (GPRS) networks, and (3) future third-generation (3G) networks like Enhanced Data-rates for Global Evolution (EDGE) and Universal Mobile Telecommunications Systems (UMTS). Some older examples of data-centric network include the Mobitex™ Radio Network and the DataTAC™ Radio Network. Examples of older voice-centric data networks include Personal Communication Systems (PCS) networks like GSM, and TDMA systems.
The wireless RF communication port connection is made via antenna 102 as depicted in FIG. 1 . However, the mobile wireless/wired communication device 100 also typically has a wired (or perhaps wireless irda, Bluetooth, etc.) connection port 40 which mates with a connection in a wired cradle 42 to establish a wired digital communication link via a USB cable 44 to USB port of the user desktop computer 30 . As will be appreciated, the user's computer 30 is also connected to the user's wired office network 46 (as is the message server 14 ).
As depicted in FIG. 2 , mobile communication device 100 includes a suitable RF antenna 102 for wireless communication to/from wireless network 20 . Conventional RF, demodulation/modulation and decoding/coding circuits 104 are provided. As those in the art will appreciate, such circuits can involve possibly many digital signal processors (DSPs), microprocessors, filters, analog and digital circuits and the like. However, since such circuitry is well known in the art, it is not further described.
The mobile communication device 100 will also typically include a main control CPU 106 which operates under control of a stored program in program memory 108 (and which has access to data memory 110 and a message sent file 110 a ). CPU 106 also communicates with a conventional keyboard 112 , display 114 (e.g., an LCD) and audio transducer or speaker 116 . A portion of program memory 108 a is available for storing an enhanced messages sent file synchronization and message resending sub-routine (which may also interface with and use an IT Policy resident in data memory 110 ). Suitable computer program executable code is stored in portions of program memory 108 a to constitute the enhanced sub-routine logic described below. As also depicted in FIG. 2 , the CPU 106 is typically connected to a wired cradle USB connector 40 (which is, in effect, a USB port).
In the preferred exemplary embodiment, provisions are made for maintaining, at least partial synchronization of the messages sent files stored at the server 14 and the mobile wireless communication device 100 . The exemplary embodiment of synchronization is referred to as “partial” because the messages sent file at the device 100 may not include full text for each message but, instead, only an abbreviated reference ID (preferably with header data sufficient to be user-recognizable) or the like to identify uniquely a particular previously sent message. At the same time, the server 14 will generally have a copy of the complete text of all previously sent messages in its messages sent file. Of course, as those in the art will appreciate, there typically will be conventional file housekeeping features available to permit purging records from the message sent files as may be desired by the user (or as necessitated by maximum file capacity or the like to avoid an excessive number of entries in a message sent file for a particular user).
As depicted in FIG. 3 , the device synchronization messages sent file sub-routine 300 may be activated by a user at device 100 . This causes a suitable “begin sync” signal 302 to be sent to the server 14 so as to also initiate the server synchronization message sent file sub-routine at 304 . During most, if not all, of the synchronization process, both sub-routines 300 and 304 are active. The server may thereafter simply wait for an expected synchronization communication 316 to be received (e.g., in a timed wait loop 306 , 308 ). If the expected synchronization communication 316 is not timely received from the device, then an error message is displayed at 310 and the server sub-routine is exited at 312 .
However, if the device sub-routine is operating successfully, then suitable synchronization message 316 will be generated at 314 and sent to the server. In an elementary implementation, this synchronization communication might include a listing of all message reference ID's for all messages now listed in the “messages sent” file at the device. However, as those in the art will appreciate, there are known file synchronization protocols and techniques that can, at least some of the time, make it unnecessary to exchange complete file content lists.
When the synchronization message from the device 100 is timely received, then it is processed at 318 so as to, in effect, compare (a) the received list of message ID's from the sent messages file at the device to (b) the current messages sent file content at the server. As previously noted, those in the art will appreciate that a laborious comparison of each and every entry in both files at each sync session can be avoided if desired under some circumstances.
If discrepancies are discovered at 320 , then suitable discrepancy data is generated (e.g., identify messages missing in either the device and server) and sent back to the device at 334 —before the timed wait loop 324 , 326 is entered. If no discrepancies are noted at 320 , then a zero error (i.e., synchronized) signal will be sent back to the device at 322 and another timed wait loop 324 , 326 is then entered to await a successful synchronization signal (and message text for messages previously identified as missing at the server) back from the device. If this is not timely received from the device, then the received previously messages are stored and an error message may be displayed at 328 and the routine exited at 330 . Otherwise, if a successful synchronization signal from the device is timely received, then a successful synchronization message is displayed at 332 before exit is taken at 330 .
At the device 100 , after the initial synchronization data 316 is transmitted at 314 , a timed wait loop 336 , 338 is entered to see if any discrepancies have been noted by the server in a return communication 340 . If the expected discrepancy data message 340 is not timely received, then an error message is displayed at 342 and exit of the sub-routine is taken at 344 . On the other hand, if a timely return message 340 is received, then it is processed at 346 so as to store missing message headers and message reference ID's or the like as may be necessary so as to synchronize (but preferably only partially) the messages sent file at the device 100 . Upon completion of this processing, further processing is done at 348 so that any discovered missing messages at the server are sent to the server at 350 and/or a successive synchronization signal is generated and sent back to the server. A successful synchronization message is displayed at 352 before the device sub-routine is exited at 344 .
When synchronized messages sent files are frequently maintained at the device and server, as already explained with respect to FIG. 3 , then it is possible to more frequently than not save bandwidth and device battery by employing a resend message protocol such as depicted in FIG. 4 . Here, for example, if a user wishes to resend a message from the device 100 , then a resend message sub-routine is entered at 400 and, using user-recognizable message identifying data (e.g., all or part of the message header data) available in the local sent messages file, only an abbreviated message reference ID is accessed (e.g., also available from the local sent messages file) at 402 and transmitted at 404 to the server 14 . This causes the server 14 to enter its enhanced resend message sub-routine at 406 . At 408 , the server 14 looks for the incoming message reference ID in its own, more complete, sent messages file. If such a message is found to reside there in its entirety (which is most likely to happen in the exemplary embodiment), then the entire message is resent at 410 from the server and a confirmation of that event is sent at 412 back to device 100 before exit is taken at 414 . On the other hand, in the event (hopefully rare) that the server cannot find the message referenced by the incoming message reference ID at 408 , then, at 416 , a suitable request is sent from the server back to the device requesting more complete message details (e.g., the text of the message) as it may exist in the messages sent file of the device 100 .
After sending the initial message reference ID at 402 , the device 100 enters a timed wait loop 418 , 420 waiting for either confirmation of the resend or a request for more message data to come back to it from the server. If a timely return message is not received, then an error message is displayed at 422 and exit of the sub-routine is taken at 424 . On the other hand, if a timely returning message is received, then a test is made at 426 to see whether the returned signal indicates a need to send the entire message (if available) back to the server 14 . If not, then exit is immediately taken at 424 . On the other hand, if the server does not have enough information to resend the message from its own files, then the entire message text is sent from the device back to the server at 428 before the device re-enters the timed wait loop 418 , 420 (to again await a confirmation of the resend having been successfully accomplished at the server 14 ).
If the server 14 sends a request for the entire message at 416 , then it enters timed wait loop 430 , 432 awaiting the requested further message data 434 . If timely received, then control is passed back to 410 where the message is resent. If not timely received, then an error message is displayed at 436 and the sub-routine is exited at 438 .
As those in the art will appreciate, the above described exemplary embodiments may be modified or varied in many ways while yet retaining novel features and advantages of this invention. Accordingly, all such modifications and variations are intended to be included within the scope of the appended claims.
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An enhanced email system incorporating mobile wireless communication devices includes program logic for efficiently managing (i.e., at least partially synchronizing) “messages sent” files in the mobile device and in a related message server. The exemplary program logic also more efficiently handles resending of previously sent email messages from the mobile wireless communication device (especially in the context of synchronized messages sent files) by sending to the message server only abbreviated unique message ID in the first instance. In this way, wireless bandwidth is conserved as is the device battery.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2000-289314, filed Sep. 22, 2000, the entire 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 semiconductor memory device, and more particularly to a rewritable non-volatile semiconductor memory device using a rewritable non-volatile memory element as in a rewritable memory section for a user for storing data which is inhibited from rewriting such as individual information.
[0004] 2. Description of the Related Art
[0005] In conventional semiconductor memory devices, it may be desirable to inhibit rewriting of some stored data. For example, when copyrighted information such as music is stored in a large capacity semiconductor memory device, individual certification is required for each semiconductor chip to secure the copy right.
[0006] For individual certification, it is necessary to output unique data for individual certification written to each semiconductor chip. Thus, different rewrite-inhibited data must be stored in each semiconductor chip with certain means.
[0007] The simplest method to achieve the aforementioned object is to make use of the characteristic of nonvolatile memory elements constituting a memory region of a semiconductor memory device being a writable memory such that data is written to a non-volatile memory element formed as in a typical memory region after a wafer process. Such a non-volatile memory element disposed in a memory cell array similar to a typical memory area is preferable for a higher degree of integration since write circuits and read circuits can be shared.
[0008] When the non-volatile memory element is rewritable, however, rewriting must be possible before rewrite-inhibited data is stored and a problem occurs in that rewriting is permitted in a rewrite-inhibited memory region through input of an electrical signal unless certain physical changes are added to a semiconductor chip. To address this, conventionally, a circuit as shown in FIG. 1 has been used to disable alteration of written data after the writing of the data to a rewrite-inhibited region in a memory cell array.
[0009] The circuit shown in FIG. 1 comprises a row decoder 60 for selecting a word line in a rewrite-inhibited region, and a non-volatile data region (memory cell array) 100 including a rewrite-inhibited region comprising nonvolatile memory elements Q 10 , Q 11 and the like. In the conventional circuit shown in FIG. 1, the rewrite-inhibited region is disposed in the typical non-volatile data region 100 open to general users. A word line in the rewrite-inhibited region is selected by activating the row decoder 60 different from a typical row decoder selected with an address.
[0010] Next, the operation of the row decoder 60 will be described. As described above, the functions required for the rewrite-inhibited region for individual certification are to inhibit data rewriting after data for individual certification is written to each semiconductor chip and to allow reading of the written data for individual certification in a rewrite-inhibited state at the time of individual certification.
[0011] In the row decoder 60 shown in FIG. 1, a fixed high-level voltage V 0 is input to the gates of N-channel transistors Q 1 , Q 2 , and Q 3 , which would receive address signal in a typical row decoder, to turn on the N-channel transistors Q 1 , Q 2 , and Q 3 . A signal V 0 is an activation signal for the row decoder. The signal φ going high turns on an N-channel transistor Q 4 and turns off a P-channel transistor Q 6 to separate a power supply voltage at high level provided for the source of the P-channel transistor Q 6 .
[0012] If a fuse element is connected, a selection signal X at high level for rewrite-inhibited region is input to the gate of an N-channel transistor Q 5 to set the voltage at a node N 1 to low level (ground).
[0013] The low-level voltage at the node N 1 is applied as a voltage at high level to the gate of a pass-transistor Q 8 for selecting a word line in the rewrite-inhibited region through a latch circuit including an inverter 13 and a P-channel transistor Q 7 and a voltage conversion circuit 14 to turn on the pass-transistor Q 8 , thereby applying a word line selection voltage to the gates of the non-volatile memory elements Q 10 , Q 11 and the like in the rewrite-inhibited region included in the memory cell array to write data for individual certification. In this case, since an N-channel transistor Q 9 is short-circuited with the fuse element, it is not involved in the operation of the row decoder 60 .
[0014] To inhibit rewriting of the data thus written for individual certification, the fuse element formed on the wafer using a metal layer is blown through laser processing. At this point, since a read mode signal is at low level and thus the N-channel transistor Q 9 is off, and the node N 1 is released from the low level, a voltage at low level is applied to the gate of the pass-transistor Q 8 through the inverter 13 of the latch circuit and the voltage conversion circuit 14 to turn off the pass-transistor Q 8 , thereby inhibiting writing of data to the memory elements Q 10 , Q 11 and the like.
[0015] When the read mode signal is driven high level with the fuse element blown, the N-channel transistor Q 9 is turned on and the node N 1 goes low. A word line can be selected using the pass-transistor Q 8 to read the data for individual certification written to the non-volatile memory elements Q 10 , Q 11 and the like in the rewrite-inhibited region.
[0016] As described above, rewriting has conventionally been inhibited by blowing the fuse element in the row decoder 60 for selection in the rewrite-inhibited memory region. The use of the method, however, requires laser processing for accurately blowing the fuse with laser and takes a long time for a test step after the semiconductor chip fabrication to result in a problem of increased manufacturing cost.
[0017] As mentioned above, since a conventional semiconductor memory device capable of individual certification is provided with a rewrite-inhibited function using the blowing of a fuse element, a long time is required for a test step after the semiconductor chip fabrication to cause a problem of increased manufacturing cost.
BRIEF SUMMARY OF THE INVENTION
[0018] A semiconductor memory device according to an embodiment of the present invention employs non-volatile memory elements typically constituting a memory cell array to form a rewrite-inhibited region for individual certification instead of a conventionally used fuse element. Before a semiconductor chip is sealed in a package, a voltage at high level is applied to a pad on the semiconductor chip with a probe or the like to set the non-volatile memory elements in the rewrite-inhibited region to a writable state. After data for individual certification is written thereto, the chip is sealed in a package to disable electrical connection to the pad from outside, thereby inhibiting rewriting of the data.
[0019] Specifically, a semiconductor memory device according to an embodiment of the preset invention comprises a rewritable non-volatile memory element, an erase circuit configured to erase storage data written to the non-volatile memory element, a circuit configured to write storage data to the non-volatile memory element, a circuit configured to read storage data written to the non-volatile memory element, and a pad formed by opening a passivation film on a surface of a semiconductor chip, wherein erasing and writing of storage data in the non-volatile memory element are allowed by inputting a signal at a first voltage level to the pad, and erasing or writing of storage data in the non-volatile memory element are inhibited by inputting a signal at a second voltage level to the pad.
[0020] A semiconductor memory device according to another embodiment of the present invention comprises a memory cell array including non-volatile memory elements. The memory cell array includes a non-volatile memory element forming a rewritable data region for a user and a non-volatile memory element forming a rewrite-inhibited region for individual certification. Erasing or writing of storage data in the non-volatile memory element forming the rewrite-inhibited region are inhibited by setting one of a row selection circuit and a column selection circuit for the memory cell array to an unselected state.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0021] [0021]FIG. 1 shows the configuration of a conventional semiconductor memory device including a rewrite-inhibited region;
[0022] [0022]FIG. 2 shows the configuration of a semiconductor memory device according to a first embodiment of the present invention;
[0023] [0023]FIG. 3 shows the circuit configuration of a typical row decoder of the semiconductor memory device according to the first embodiment;
[0024] [0024]FIG. 4 shows the circuit configuration of a row decoder for rewrite-inhibited region of the semiconductor memory device according to the first embodiment;
[0025] [0025]FIG. 5 shows a circuit for producing a signal B according to a second embodiment;
[0026] [0026]FIG. 6 shows a control circuit for a write command according to the second embodiment; and
[0027] [0027]FIG. 7 shows a control circuit for write voltage according to a third embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Some embodiments of the present invention will be hereinafter described with reference to the drawings.
First Embodiment
[0029] [0029]FIG. 2 shows the configuration of a semiconductor memory device having an individual certification function according to a first embodiment. The semiconductor memory device shown in FIG. 2 comprises a non-volatile data region 1 for a user in which data is rewritable, a rewrite-inhibited region 2 for storing data for individual certification, formed of nonvolatile memory elements similar to those of the nonvolatile data region 1 , a sense amplifier and write circuit 3 , a row decoder 4 , an address buffer 5 , a row decoder 6 for rewrite-inhibited region for selecting a word line in the rewrite-inhibited region 2 , a pad 7 formed on a semiconductor chip, a circuit including NOR gates 8 , 10 , a resistor 9 , and an inverter 11 , and a signal line 12 for inactivating the row decoder 4 .
[0030] The non-volatile data region 1 and the rewrite-inhibited region 2 constitute an array including a series of memory cells such that bit lines for common columns in the memory cell array are shared between the non-volatile data region rewritable by a user and the rewrite-inhibited region 2 to which data for individual certification is written and are connected to the sense amplifier and write circuit 3 . The rewritable non-volatile data region 1 and the rewrite-inhibited region 2 are connected to different word lines and selected using the typical row decoder 4 and the row decoder 6 for rewrite-inhibited region, respectively.
[0031] The circuit configuration and the operation of the typical row decoder 4 will be hereinafter described with reference to FIGS. 2 and 3. Since the circuit configuration of the typical row decoder 4 shown in FIG. 3 is substantially similar to the circuit configuration of the conventional row decoder 60 described earlier with reference to FIG. 1, difference between the configuration in FIG. 3 and that in FIG. 1 will be described particularly in detail with the corresponding portions designated the same reference symbols and numerals.
[0032] The typical non-volatile data region 1 shown in FIG. 2 allows erasing, writing, and reading data through selection of one word line in response to output from the address buffer 5 . In FIG. 3, a signal φ activates the row decoder 4 . When the activation signal φ is at low level, a P-channel transistor Q 6 is turned on to provide a power supply voltage at high level for a node N 1 , and a voltage at low level is applied to the gate of a pass-transistor Q 8 through an inverter 13 of a latch circuit and a voltage conversion circuit 14 to set all row decoders 4 to an unselected state.
[0033] When all address signals Adda, Addb, and Addc input to the gates of N-channel transistors Q 1 , Q 2 , and Q 3 , respectively, are at high level and a rewrite-inhibited region selection signal X input to the gate of an N-channel transistor Q 5 is low (/X is high in FIG. 3), the activation signal φ changed high discharges and sets the node N 1 to low level, the row decoder 4 enters into a selected state.
[0034] The low-level voltage at the node N 1 is converted to a voltage at high level through the inverter 13 of the latch circuit and the voltage conversion circuit 14 and applied to the gate of the pass-transistor Q 8 to send a word line selection signal to a word line. Thus, depending on an operation mode, erasing, writing, and reading operations can be performed.
[0035] Next, the circuit configuration and the operation of the row decoder 6 for rewrite-inhibited region will be described with reference to FIGS. 2 and 4. While the row decoder 6 for rewrite-inhibited region shown in FIG. 4 has the same configuration as the typical row decoder 4 shown in FIG. 3, a fixed voltage V 0 is input to the gates of N-channel transistors Q 1 , Q 2 , and Q 3 instead of an address signal input thereto in the typical row decoder 4 , and the selected or unselected row decoder 6 for rewrite-inhibited region is determined only by input of a signal A to the N-channel transistor Q 5 .
[0036] As shown in FIG. 2, the signal A is output from a circuit comprising the pad 7 formed by opening a passivation film on the semiconductor chip, the NOR gates 8 , 10 , the resistor 9 , and the inverter 11 . The voltage level of the signal A is determined by a rewrite-inhibited region selection signal X generated in a control circuit (not shown), a read mode signal, and the level of voltage applied to the pad 7 .
[0037] In the first place, description will be made on writing of data for individual certification to the rewrite-inhibited region.
[0038] When the pad 7 shown in FIG. 2 is at high level and the control circuit is in a rewrite-inhibited region selection mode to transmit a rewrite-inhibited region selection signal X at high level, the signal A at high level is output from the NOR gate 10 to turn on an N-channel transistor Q 5 in FIG. 4 to set the node N 1 to low level. The low level of the node N 1 is converted to a voltage at high level through an inverter 13 of a latch circuit and a voltage conversion circuit 14 and applied to the gate of a pass-transistor Q 8 to transfer a word line selection voltage to a word line, thereby making it possible to perform operations for erasing, writing, and reading on the rewrite-inhibited region 2 as in the typical nonvolatile data region 1 .
[0039] Next, description will be made on rewriting inhibition of individual certification data and reading.
[0040] When the pad 7 is grounded through the resistor 9 , for example, as shown in FIG. 2, the pad 7 is at low level while it is open. When the control circuit is in a read mode to set the read mode signal input to the NOR gate 8 to high level, and the control circuit is in a rewrite-inhibited region selection mode to set the rewrite-inhibited region selection signal X to high level, the output A from the NOR gate 10 is at high level to permit only reading of the individual certification data stored in the rewrite-inhibited region 2 and thus data cannot be rewritten.
[0041] In the manufacturing process of a non-volatile semiconductor memory device, unique data for individual certification is written to each chip upon the end of test at a wafer level. At this point, for allowing writing to a rewrite-inhibited region, a probe is used to input a voltage at high level to the pad 7 shown in FIG. 2.
[0042] Thereafter, in an assembly step, the chip is sealed in a package with the pad open. As described above, since the pad 7 is grounded (pull down) through the resistor 9 , the open pad 7 sealed in the package is at low level. Thus, only reading is permitted for the individual certification data stored in the rewrite-inhibited region 2 , and writing thereof is permanently inhibited unless the package is opened.
Second Embodiment
[0043] Next, a non-volatile semiconductor memory device according to a second embodiment will be hereinafter described with reference to FIGS. 5 and 6. The second embodiment is characterized by using a signal B to control transmission of a write command for the non-volatile semiconductor memory device, unlike the first embodiment.
[0044] [0044]FIG. 5 shows a circuit for producing the signal B comprising a pad 7 formed on a semiconductor chip, a pull-down resistor 9 , inverters 15 , 17 , and a NAND gate 16 . The NAND gate 16 has one input terminal applied with a rewrite-inhibited region selection signal X. FIG. 6 shows a circuit for controlling the transmission of the write command, comprising a control circuit 18 for producing the write command in accordance with an external input signal and an AND gate 19 . The AND gate 19 has one input terminal applied with the signal B.
[0045] When the rewrite-inhibited region selection signal X is at high level to select the rewrite-inhibited region 2 shown in FIG. 2 and the pad 7 is at low level, the signal B at high level is output from the circuit in FIG. 5. Thus, the write command at high level produced in the control circuit 18 in FIG. 6 is changed to a write signal at high level through the AND gate 19 to allow writing of individual certification data to the rewrite-inhibited region 2 .
[0046] On the other hand, when the rewrite-inhibited region selection signal X is at high level to select the rewrite-inhibited region 2 shown in FIG. 2, and the pad 7 is at high level, the signal B at low level is output from the circuit in FIG. 5. The write command at high level produced in the control circuit 18 in FIG. 6 is blocked by the AND gate 19 and no write signal is transmitted. Thus, data writing to the rewrite-inhibited region 2 is inhibited.
[0047] Since similar control of an erase command for the semiconductor memory device can inhibit erasing of the individual certification data written to the rewrite-inhibited region 2 , the circuits shown in FIGS. 5 and 6 can be used to inhibit rewriting of the individual certification data written to the rewrite-inhibited region 2 .
Third Embodiment
[0048] Next, a non-volatile semiconductor memory device according to a third embodiment will be described with reference to FIG. 7. The third embodiment is characterized by using a signal B to control production of a high voltage required for writing and erasing in the non-volatile semiconductor memory device, unlike the second embodiment.
[0049] [0049]FIG. 7 shows the configuration of a charge pump circuit for producing a high voltage required for writing and erasing and a control circuit with the signal B. The charge pump circuit shown in FIG. 7 comprises diode-connected N-channel transistors Q 10 to QN, capacitors C 10 to CN for storing charge, inverters I 10 , I 11 , I 11 a, I 12 , . . . IN for phase inversion required for pumping, an oscillation circuit 20 , an inverter 21 and a NAND gate 22 for controlling the output from the oscillation circuit 20 using the signal B. The signal B is input to one terminal of the NAND gate 22 .
[0050] When the output from the oscillation circuit 20 shown in FIG. 7 is blocked using the circuit for producing the signal B shown in FIG. 5, a high voltage required for writing and erasing cannot be produced to inhibit rewriting of individual certification data written to the rewrite-inhibited region 2 .
[0051] The present invention is not limited to the aforementioned embodiments. For example, while the first embodiment uses the pull-down resistor for setting the pad to the low level state with the pad open before the chip is sealed in a package, a pull-up resistor can be used to achieve the same object with an inverted logical circuit for producing the signal A.
[0052] In addition, the aforementioned embodiments have been described for the unselected row selection circuit of the memory cell array forming the rewrite-inhibited region to erase and write the storage data in the nonvolatile memory element, erasing and writing of the storage data in the non-volatile memory elements constituting the rewrite-inhibited region can also be inhibited by setting a column selection circuit to an unselected state. The present invention can be embodied with various modifications added thereto without departing from the spirit and scope of the present invention.
[0053] As described above, according to the semiconductor device of the present invention, a rewrite-inhibited region for individual certification is formed using elements similar to typical non-volatile memory elements constituting a memory cell array, and a conventional means such as blowout of a fuse element is not required for providing a rewrite-inhibited function, thereby making it possible to provide a semiconductor memory device including a rewrite-inhibited region for individual certification without increasing manufacturing cost.
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A semiconductor memory device is provided which includes a rewrite-inhibited region for individual certification. Non-volatile memory elements constituting a memory cell array are used instead of a conventionally used fuse element to form the rewrite-inhibited region for individual certification. A voltage at high level is applied to a pad formed on a chip with a probe before the chip is sealed in a package to set the non-volatile memory elements in the rewrite-inhibited region to a writable state. After data for individual certification is written thereto, the chip is sealed in a package to disable electrical connection from outside to the pad set to a voltage at low level with a pull-down resistor.
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