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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a shock absorber with a check valve and a check valve for a shock absorber. The check valve, possibly even a shutoff valve or non-return valve, is between two segments of a fluid connection, which connects two fluid chambers of a shock absorber with one another, whereby the check valve device with at least one check valve which separates a high-pressure segment and a low-pressure segment and has a checking body, can be adjusted between a closed and an open position by means of an external control via a magnet armature and a magnetic winding which is protected by means of a separator plate from the check valve, whereby a first side of the check valve pressurized by the high-pressure segment can be elastically pressed against a check valve seat which is a component of a pot-shaped insert, by means of a compression spring, also that a second side of the check valve body at some distance from this first side and adjacent to a control chamber is pressurized by the fluid pressure in this chamber, also that the control chamber is connected by means of a throttle section which bypasses the check valve body, also that the control chamber is connected by means of a control chamber discharge to the low-pressure segment, whereby there is a control chamber discharge valve with a control chamber discharge valve seat in the control chamber discharge, whereby the control chamber valve seat is configured on a supplemental discharge valve body, which together with a supplemental discharge valve seat on the check valve body forms a supplemental control chamber discharge of the control chamber, and that between the control chamber discharge valve body and the supplemental discharge valve body there is a coil compression spring which applies a prestress to the control chamber discharge valve body in the direction of lifting it from the control chamber discharge valve seat of the supplemental discharge valve body.
2. Background Information
Federal Republic of Germany Laid-Open Patent Application No. 41 14 305 discloses a check valve which, even after the magnet armature has been moved into the open position, only essentially switches from a hard damping force setting to a soft damping force setting when the pressure in the high-pressure section falls below a specified value. During tests on vehicles which have a particularly soft damping characteristic, unpleasant noises occurred which were caused by an unacceptable fluctuation of the damping force characteristic. In spite of the open position of the magnet armature, isolated damping force peaks were measured in the force-velocity diagram of a shock absorber equipped with such a check valve device.
OBJECT OF THE INVENTION
The object of the present invention is to eliminate the clicks and noises and the fluctuations of the damping force setting or damping force peaks of the check valve component which may occur when a particularly comfortable damping force has been set.
SUMMARY OF THE INVENTION
The invention teaches that this object can be achieved wherein the maximum magnet armature stroke length is greater than the maximum check body lifting stroke length, so that when there is a maximum magnet armature lifting stroke, the supplemental control chamber discharge between the control chamber discharge valve body and the supplemental discharge valve body is completely open.
As a result of the controlled coordination of the stroke lengths, the check valve body can open wide enough for the soft characteristic to be safely maintained. The damping force peaks which were previously detected can be eliminated, since the control chamber discharge is essentially completely opened, and thus the magnet armature also remains pressure-equalized. If the control chamber discharge is interrupted, even for only a brief period, for example by the sudden raising of the check valve device against the soft compression spring on account of the hydraulic forces in the high-pressure section, the magnet armature is essentially no longer hydraulically equalized and the magnet armature pushes the check valve body onto the check valve seat at high velocity.
To restrict the damping force characteristic tolerances, the invention teaches that the control chamber discharge preferably has a cross section which is sized so that an unthrottled discharge from the control chamber is allowed. As a result of this advantageous measure, the damping force characteristic is then determined essentially only by the compression spring and the lifting stroke length of the check valve body.
In one variant of the invention, a stop ring inside the check valve device can limit the check body stroke length. The stop ring represents a simple and economical part. Simultaneously, the ring wall of the check valve body can preferably be reduced or can be eliminated altogether, so that the part can be more easily manufactured using sintering technology.
Preferably, the stop ring is advantageously designed as a thrust collar. Thus, the geometry of the pot-shaped insert can preferably be simplified in the vicinity of the seal with the separator plate. In an alternative embodiment, the check valve body can have a ring wall, the height of which is preferably designed so that, when the ring wall reaches the maximum check valve body position, it comes in contact with the separator plate. This solution to the problem has the advantage that essentially no additional parts are required, and thus the influence of the individual tolerances is reduced.
In an additional advantageous variant, a compression spring can be used, the spring range of which is preferably smaller than the stroke length of the magnet armature.
In summary, one aspect of the invention resides broadly in a shock absorber comprising: a cylinder defining a chamber therein, said cylinder containing a damping fluid; a piston rod sealingly projecting into said cylinder and being axially displaceable with respect to said cylinder; a piston being attached to said piston rod, said piston being slidably disposed within said cylinder to sealingly divide said chamber into first and second chambers; means for permitting fluid communication between said first and second chambers; said means for permitting fluid communication comprising check valve means, said check valve means having first aperture means and second aperture means, said check valve means being configured for transmitting fluid between said first aperture means and said second aperture means; said check valve means comprising: an element comprising a first body portion and a second body portion; spring means for biasing said first body portion and said second body portion apart from one another; a seat; said element being selectively disposable against said seat; means for permitting displacement of said element away from said seat to promote fluid communication between said first aperture means and said second aperture means; said means for permitting displacement of said element away from said seat comprising: armature means; and electromagnetic means for activating said armature means to permit displacement of said element away from said seat; said means for permitting displacement of said element away from said seat permitting said first body portion and said second body portion to move with respect to one another upon action of said biasing means; means for maintaining separation of at least a portion of said first body portion and at least a portion of said second body portion from one another, upon displacement of said element away from said seat; said means for maintaining separation comprising: a first mechanical stop for limiting the displacement of said first body portion, upon displacement of said element away from said seat, to a first maximum displacement; a second mechanical stop for limiting the displacement of said second body portion, upon displacement of said element away from said seat, to a second maximum displacement; and said first and second mechanical stops being configured such that said first maximum displacement is greater than said second maximum displacement.
Another aspect of the invention resides broadly in a shock absorber comprising: a cylinder defining a chamber therein, said cylinder containing a damping fluid; a piston rod sealingly projecting into said cylinder and being axially displaceable with respect to said cylinder; a piston being attached to said piston rod, said piston being slidably disposed within said cylinder to sealingly divide said chamber into first and second chambers; means for permitting fluid communication between said first and second chambers; said means for permitting fluid communication comprising check valve means, said check valve means having first aperture means and second aperture means, said check valve means being configured for transmitting fluid between said first aperture means and said second aperture means; said check valve means comprising: an element comprising a first body portion and a second body portion; means for biasing said first body portion and said second body portion apart from one another; a seat; said element being selectively disposable against said seat; means for permitting displacement of said element away from said seat to promote fluid communication between said first aperture means and said second aperture means; and said means for permitting displacement of said element away from said seat permitting said first body portion and said second body portion to move with respect to one another upon action of said biasing means; and means for maintaining separation of at least a portion of said first body portion and at least a portion of said second body portion from one another, upon displacement of said element away from said seat.
Yet another aspect of the invention comprises, in a shock absorber, which shock absorber comprises: a cylinder defining a chamber therein, the cylinder containing a damping fluid; a piston rod sealingly projecting into the cylinder and being axially displaceable with respect to the cylinder; a piston being attached to the piston rod, the piston being slidably disposed within the cylinder to sealingly divide the chamber into first and second chambers, a check valve comprising means for permitting fluid communication between the first and second chambers; said check valve having first aperture means and second aperture means, said check valve being configured for transmitting fluid between the first aperture means and the second aperture means; said check valve further comprising: an element comprising a first body portion and a second body portion; spring means for biasing said first body portion and said second body portion apart from one another; a seat; said element being selectively disposable against said seat; means for permitting displacement of said element away from said seat to promote fluid communication between said first aperture means and said second aperture means; said means for permitting displacement of said element away from said seat comprising: armature means; and electromagnetic means for activating said armature means to permit displacement of said element away from said seat; said means for permitting displacement of said element away from said seat permitting said first body portion and said second body portion to move with respect to one another upon action of said biasing means; means for maintaining separation of at least a portion of said first body portion and at least a portion of said second body portion from one another, upon displacement of said element away from said seat; said means for maintaining separation comprising: a first mechanical stop for limiting the displacement of said first body portion, upon displacement of said element away from said seat, to a first maximum displacement; a second mechanical stop for limiting the displacement of said second body portion, upon displacement of said element away from said seat, to a second maximum displacement; and said first and second mechanical stops being configured such that said first maximum displacement is greater than said second maximum displacement.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention is explained in greater detail below, with reference to the accompanying figures, wherein:
FIG. 1 shows a shock absorber with a bypass and a check valve in the bypass;
FIGS. 2-4 show embodiments of the check valve according to the present invention;
FIG. 5 shows an overall view of a check valve which may be utilized in accordance with the embodiments of the present invention;
FIG. 6 is substantially the same view as FIG. 5, but more detailed;
FIG. 7 shows a spring with a force fit connection;
FIG. 8 shows a spring with a form fit connection;
FIG. 9 shows a check valve module with a connection between pot and plate;
FIG. 10 is substantially the same view as FIG. 9, but more detailed; and
FIGS. 11 and 12 illustrate a vibration damper, and components thereof, including a check valve, which may be utilized in accordance with the embodiments of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, the cylinder of a shock absorber is designated 1, and the piston rod is designated 3. On the bottom, the cylinder is closed by a base 5. The piston rod 3 preferably extends out of the upper end of the cylinder by means of a guide and sealing unit 7. Inside the cylinder 1, a piston unit 9 with a plunger valve system 11 is preferably fastened to the piston rod 3. The lower end of the cylinder 1 is preferably closed by means of a base plate 13 with a base valve system 15. The cylinder 1 is preferably enclosed by a container tube 17. Between the container tube 17 and the cylinder 1, a toroidal space 19 is preferably formed, which preferably represents an equalization chamber. The space inside the cylinder 1 is preferably divided by the piston unit 9 into a first work chamber 21a and a second work chamber 21b. The work chambers 21a and 21b are preferably filled with hydraulic fluid. The equalization chamber 19 is preferably filled up to the level 19a with fluid, and above that with gas. Inside the equalization chamber 19, there is preferably a first segment of a line or conduit, namely a high-pressure line segment 23, which is preferably connected by means of a hole 25 in the cylinder 1 to the second work chamber 21b. Connected to this high-pressure segment there is preferably a check valve device 27 connected laterally to the container tube 17. From the check valve 27, a second line segment (not shown), namely a low-pressure line segment, preferably leads to the equalization chamber 19.
When the piston rod 3 is extended upward out of the cylinder 1, the upper work chamber 21b essentially becomes smaller. An overpressure can accumulate in the upper work chamber 21b, which can preferably be relieved by the piston valve system 11 into the lower work chamber 21a, as long as the check valve device 27 is closed. Preferably, when the check valve device 27 is opened, fluid simultaneously flows from the upper work chamber 21b through the high-pressure line 23 and the check valve 27 into the equalization chamber 19. The damping characteristic of the shock absorber during the extension of the piston rod 3 can therefore essentially be a function of whether the check valve 27 is open or closed.
When the piston rod 3 is retracted into the cylinder 1, i.e. downwardly, an overpressure can accumulate in the lower work chamber 21a. Liquid can then preferably flow from the lower work chamber 21a through the plunger valve system 11 upward into the upper work chamber 21b. The fluid displaced by the increasing piston rod volume inside the cylinder 1 is preferably expelled by the base valve 15 into the equalization chamber 19. An increasing pressure can also accumulate in the upper work chamber 21b, since the flow resistance of the plunger valve system 11 is essentially less than the flow resistance of the base valve 15. When the check valve 27 is open, this increasing pressure can flow through the high-pressure line segment 23 into the equalization chamber 19. That means that when the check valve device 27 is open, the shock absorber essentially has a softer characteristic even during retraction. Also, the shock absorber essentially has a harder characteristic when the check valve device is closed, just as during the extension of the piston rod. It should be noted that, in at least one preferred embodiment of the present invention, the direction of flow through the high-pressure segment 23 of the bypass is essentially always the same, regardless of whether the piston rod is moving in or out.
FIG. 2 represents a cross section of the cylinder 1, and shows the high-pressure segment 23 of the bypass and the equalization chamber 19. Preferably, connected to the high-pressure segment 23 there is a central channel 29 belonging to the check valve device 27. In the upper end of the central channel 29, there is preferably a check valve seat 31. A rigid check valve plate 33 preferably lies on the check valve seat 31 in the manner of a check valve body. In FIG. 2, the check valve plate is shown in its checking position. Also, in FIG. 2, the connection between the central channel 29 and the equalization chamber 19 via holes 35 is essentially closed. The check valve plate 33 is preferably prestressed by a coil compression spring 37 in the direction of the check valve seat 31, wherein coil compression spring 37 is preferably supported on a separator plate 39.
In the check valve device 27, a magnet armature 41 is preferably oriented concentric to the central channel 29. This magnet armature 41 is preferably prestressed downward by a magnet armature prestress spring 43, and can preferably be pulled upward by means of a magnet winding 44, when this magnet winding 44 is charged with current. Such magnetic windings, and their operation in conjunction with a valve, are generally well-known to those of ordinary skill in the art, and will not be discussed in further detail here.
Between the magnet armature and the check valve plate 33, there is preferably an intermediate body component 45, 47. The intermediate body component 45, 47 preferably comprises a control chamber discharge valve body 45 and a supplemental discharge valve body 47.
A hole 41a in the magnet armature 41 preferably connects a spring chamber 41, which houses the magnet armature prestress spring 43, to the chamber 49 formed between the supplemental discharge valve body 47 and the check valve plate 33. A control chamber 50 is preferably formed collectively by: a hole 47a in the supplemental discharge valve body 47; hole 45a in the control chamber discharge valve body 45; hole 41a in the magnet armature 41; the spring chamber 41b; and chamber 41c located above the magnet armature.
The underside of the check valve plate 33 is designated 33a, and the upper side is designated 33b. As illustrated, the check valve plate 33 is preferably exposed on the bottom to the pressure P in the central channel 29, i.e. to the pressure in the upper work chamber 21 (see FIG. 1) and the high-pressure segment 23.
The check valve plate 33 is preferably installed in a pot-shaped, or cup-shaped, insert 51, which insert preferably has a hole 35 and a pipe socket 51a on the bottom. This pipe socket 51a preferably forms the central passage 29 and is preferably connected in a sealed manner by a gasket 53 to the first segment 23 of the bypass. The pot 51 is preferably inserted in a pipe socket 51a which is welded to the container 17. The space between the pot 51 and the pipe socket 51a preferably forms a low-pressure segment 23a of the bypass. The high-pressure segment 23 and the low-pressure segment 23a together preferably form the bypass. Preferably, placed on the pot 51 is the separator plate 39, which can form a single component, together with the iron parts and housing parts belonging to the magnet winding 44.
When the magnet winding 44 is not carrying a current, the control chamber discharge valve body 45 preferably lies in the illustrated check position with its cone 45b on a ring zone 47b of the supplemental discharge valve body 47 forming the control chamber discharge valve seat. A coil compression spring 57 preferably pushes the control chamber discharge valve body 45 in the direction of lifting off the control chamber discharge seat 47b. The control chamber discharge valve body 45 is preferably guided in a sealed manner in a tubular extension 41d of the magnet armature 41. As a result of the supplemental closing force generated by the magnet armature prestress spring 43, the magnet armature 41 essentially lies in the illustrated checking position of the control chamber discharge valve 45, 47b on the control chamber discharge valve body 45, and holds the control chamber discharge valve body 45 against the force of the spring 57 in its checking position. The pressure prevailing in the control chamber 50 is essentially forwarded via the passages formed in the magnet armature 41 to the entire back side 45c of the control chamber discharge valve body 45. Since the control chamber discharge valve body 45 offers a larger pressurization surface 45c to the pressure P in the control chamber 50 than does the supplemental discharge valve body 47 in the vicinity of the chamber 49, the pressure P in the control chamber 50 essentially exerts a hydraulic closing force directed downward on the intermediate body component 45, 47. In this position, the maximum stroke length hs is available for the magnet armature 41. Likewise, the distance a is the greatest between the check valve body 33 and a thrust collar 59a, which forms a stop by means of its end surface 61.
If the magnetic winding 44 is charged with current as a result of an opening command from the external signal source, and consequently the magnet armature 41 is lifted off the control chamber discharge valve body 45, so that the magnet armature 41 has travelled the entire stroke distance hs, then the control chamber discharge valve body 45 remains in its checking position, if the pressure P prevailing in the control chamber 50 is greater than a predetermined limit value PG of the pressure, since the hydraulic closing force exerted by the pressure P on the reverse side 45c of the control chamber discharge valve body 45 is essentially greater than the opening force exerted by the spring 57 on the control chamber discharge valve body 45. If the pressure P in the control chamber 50 drops below the limit value PG as a result of a reduction of the pressure in the central passage 29, then the control chamber discharge valve body 45 is essentially lifted from the control chamber discharge valve seat 47b on account of the now-dominant spring force exerted by the spring 47. At this point, damping fluid can flow between the control chamber discharge valve body 45 and the control chamber discharge valve seat 47b to the equalization chamber 19. The pressure P acting on the rear side 45c thereby breaks down, so that the control chamber discharge valve body 45, as a result of the force of the spring 57, is lifted completely off the control chamber discharge valve seat 47 and the hole 45a is essentially completely opened. At high flow rates, as a result of the pressure drop which occurs at the hole 45a, a force directed toward the opening of a supplemental discharge valve 47, 63 is exerted on the supplemental discharge valve body 47, so that the supplemental discharge valve 47, 63 opens. The check valve 33, 31 now acts in connection with the spring 37 as a standard, spring-loaded damping valve.
During the lifting motion of the check valve body 33, the latter cannot "open" against spring 37, in spite of the sudden pressure drop in the control chamber 50, but the thrust collar 59a essentially restricts the length of the lifting stroke to the distance a. In accordance with at least one preferred embodiment of the present invention, the spring 37 may essentially be considered to be "soft". The stroke length hs of the magnet armature 41 is always preferably greater by a defined amount, so that the control chamber discharge valve 45, 47b is always opened sufficiently wide by the spring 57 such that the control chamber valve body 45 is in contact with the magnet armature 41 and the control chamber discharge of the control chamber discharge valve 45, 47b is essentially at a maximum.
The discharge of the supplemental discharge valve 47, 63 essentially does not apply any additional damping forces to the check valve 33, 31, so that a series variance of the damping force is reduced to tolerances which may essentially be considered to be customary.
In the embodiment shown in FIG. 3, the distance a can preferably be determined by the height of the ring wall 33c of the check valve body 33 to the separator plate 39. In this configuration, the thrust collar 59a (see FIG. 2) can essentially be eliminated, and the small tolerance influence resulting from the height of the intermediate ring can essentially be eliminated.
FIG. 4 shows an embodiment which has a slotted clamping ring 59b as the stop ring. The clamping ring 59b is preferably lightly pressure-fitted to the pot-shaped insert 51, and is thereby essentially fixed in place. Otherwise, the function of the clamping ring 59b is essentially the same as that of the thrust collar 59a illustrated in FIG. 2.
An additional possibility for determining distance a is to specify the block length, or conversely the range of spring travel, of the spring 37, so that the distance a is determined by the spring 37.
FIG. 5 shows a check valve module 1' (see FIG. 6), the basic design and function of which are generally well-known. Preferably welded onto a container tube 3' is a pipe 5', which pipe 5' preferably holds the essential part of the valve. A pot, or cup, 7' is preferably engaged by means of its pipe sockets 9' in an adapter tube 11'. The pot 7' also preferably encloses a check valve seat 13' on which a check valve plate 15' is supported, which plate 15' is preferably prestressed by a coil spring 17', which spring 17' is preferably connected on the housing side to a plate 19'. Inside the plate 19', there is preferably a central opening for a magnet armature 21'. The magnet armature 21' can preferably have a ring flange 23' which projects downward, which holds and centers a control chamber discharge valve body 25'. The control chamber discharge valve body 25' preferably has a conical guide area, which in turn preferably guides a supplemental discharge body 27'. Between the control chamber discharge valve body 25' and the supplemental discharge body 27', there is preferably a spring 29' which prestresses the two valve parts 25' and 27' in relation to one another.
During the assembly of the check valve module 1', the shock absorber having the welded-on pipe sockets 5' is preferably equipped with the pot 7'. The valve plate 15' is preferably placed on the check valve seat 13'. Then the coil spring or springs 17' are preferably introduced. The magnet armature 21' is preferably introduced into the plate 19'. The magnet armature 21' can preferably have a completely-assembled field winding 31' (see FIG. 6), with a valve cover, on its reverse side. The control chamber discharge valve body 25' and the supplemental discharge body 27' are preferably in the ring flange 23' of the magnet armature 21'. The control chamber discharge valve body 25' and the supplemental discharge body 27' are preferably connected by means of the spring 29' and preferably form a single module. Once the plate 19' has been installed, the control chamber discharge body 25' and the supplemental discharge body 27' can essentially no longer fall apart.
FIG. 6 more particularly illustrates various features of a check valve according to the present invention.
FIG. 7 is restricted to an illustration of check valve module 11' in the area between the control chamber discharge valve body 25' and the supplemental discharge body 27', plus the spring 29'. The bodies 25'/27' are preferably connected by means of the spring 29'. This spring 29' is preferably fitted to the control chamber valve discharge body 25' at its outside diameter, and to the supplemental discharge body 27' at its inside diameter by means of a slight force fitting. Preferably, the connection is configured to be capable of absorbing axial tensile stresses which exceed the dead weight of one of the valve bodies 25'/27', so that the connection can be reliably maintained during the assembly process. The force-fitted seats 25a'/27a' of the valve bodies 25'/27' can generally very easily result from surfaces 25b'/27b', so that there can preferably be a ring-shaped gap formed between the spring 29' and the valve bodies 25'/27'. Therefore, essentially no friction will occur in the event of a relative movement between the control chamber discharge valve body 25' and the spring 29', or between the supplemental discharge body 27' and the spring 29'.
Thus, as shown in FIG. 7, in accordance with a preferred embodiment of the present invention, bodies 25' and 27' can preferably be connected by spring 29', as shown. Body 25' may generally be considered to be a generally cup-shaped receptacle for receiving a major portion of body 27'. In this respect, body 27' is preferably generally configured to protrude into the general cup shape of body 25'. The interior wall portion of body 25', that is, that wall portion of the general cup shape which faces generally towards the central axis of the check valve, preferably has a major portion, that is, the portion not constituted by seat 25a', which essentially does not come into contact with spring 29'. Surface 25b' is preferably frustoconical and preferably serves as a transition into seat 25a', wherein seat 25a', preferably a surface being parallel to the central axis of the check valve, preferably contacts a terminal coil of spring 29', at an outer diameter of the terminal coil, so as to provide a secure force-fit of that terminal coil of spring 29'.
Likewise, the exterior surface of body 27', that is, that surface facing generally away from the central axis of the check valve, preferably has a major portion, that is, that portion not constituted by seat 27a', which essentially does not come into contact with spring 29'. Surface 27b', like surface 25b', is preferably frustoconical and preferably serves as a transition into seat 27a', wherein seat 27a', preferably a surface being parallel to the central axis of the check valve, preferably contacts the other terminal coil of spring 29', at an inner diameter of the terminal coil, so as to provide a secure force-fit of that terminal coil of spring 29'.
In a variation of the arrangement illustrated in FIG. 7, the module illustrated in FIG. 8 has a form-fitted connection between the spring 29' and the control chamber discharge valve body 25' and the supplemental discharge body 27'. The form-fitted connection can preferably be achieved by means of a lock, or locking connection, between the spring 29' and the valve bodies 25'/27'. The lock can preferably be formed by the terminal coils 35' of spring 29' and corresponding locking grooves 25c'/27c'. For this type of connection, a spring 29' can preferably be used in which the terminal coils have different coil diameters.
Thus, as shown in FIG. 8, in accordance with a preferred embodiment of the present invention, the spring 29' connecting bodies 25' and 27' may preferably be form-fitted with bodies 25' and 27'. In this respect, body 25' preferably has a groove portion 25c' which is essentially constituted by a generally cylindrical area having a greater diameter than the rest of the inner wall portion of body 25'. This groove portion 25c' is thus preferably configured to accept a terminal coil 35' of spring 29' wherein such a terminal coil 35' preferably has a greater diameter than the other coils of spring 29'. Additionally, body 27' preferably has a groove portion 27c' indented into the outer surface of body 27', such a groove portion 27c' essentially being constituted by an indented cylindrical surface being parallel to the central axis of the check valve. This groove portion 27c' is thus preferably configured to accept the other terminal coil 35' of spring 29', wherein such a terminal coil 35' preferably has a smaller diameter than the other coils of spring 29'.
In the embodiment illustrated in FIG. 9, the housing-side plate 19' can preferably have a guide 41' which forms a connection with the pot 7'. The retention force of this connection 42' is preferably greater than the combined spring forces of the coil spring 17', the spring 29' and the spring 51' (see FIG. 10) for the armature 21'. The guide 41' preferably has at least one opening 43' for an O-ring, or gasket, 45' between the plate 19' and the pot 7'. The connection 42' can preferably be formed by a force fit 47', but can also preferably be formed by means of a weld 49'.
Thus, as illustrated in FIGS. 9 and 10, in accordance with a preferred embodiment of the present invention, housing-side plate 19' can preferably have a guide 41', essentially in the form of an annular extension, which extends so as to be able to make contact, in a radial direction of the check valve, with pot 7'. This radial contact is indicated as connection 42'. Connection 42' can preferably be formed by a force fit 47', a weld 49' or, conceivably, both.
If the housing of the check valve module is turned around, the housing can preferably form an assembly jig into which the individual parts of the check valve module can be inserted. The pot 7' thus essentially "closes" the check valve module to form a separate module, which can then be very easily and reliably installed on the shock absorber, without this module falling apart.
In other words, in accordance with a preferred embodiment of the present invention, the housing of the check valve module, if turned around so as to essentially be in the form of an upward-facing receptacle, individual parts of the check valve can essentially very easily be inserted into the "receptacle". In this manner, installation of the pot 7' would essentially "close" the check valve module by essentially capping the opening of the receptacle, which would then allow easy and reliable installation on a shock absorber. Between the spring 17' and the guide 41', and between the spring 17' and the check valve plate 15', a connection can preferably be achieved among components 17', 15a', 15c', 41a', 41c', in a manner analogous to that illustrated in FIGS. 7 and 8. In other words, in accordance with a preferred embodiment of the present invention, not only is it possible for bodies 25' and 27' to have the connections 25a/c' and 27a/c' with spring 29', as shown in FIGS. 7 and 8, but it is additionally possible for check valve plate 15' and guide 41' to have similar connections, in the form of force-fit connections 15a' and 41a' or form-fit connections 15c' and 41c', with spring 17'. Thus, there may conceivably be two sets of modular assemblies, one constituted by bodies 25' and 27' with spring 29', and the other constituted by check valve plate 15' and guide 41' with spring 17'.
It will be appreciated that, if the check valve module has to be disassembled, the pot can be removed without the row of components inside the check valve module falling apart. In this respect, it will be noted that the connection 15a', 15c', 41a', 41c' essentially holds all the individual parts together by means of the check valve plate 15'.
FIG. 11 shows a complete oscillation damper, shock absorber or vibration damper 1", which could incorporate the embodiments of present invention, a detailed illustration of the valve unit 3" being omitted for the sake of clarity. The embodiment shown in FIGS. 11 and 12 is not to be considered as restrictive. The oscillation damper 1" consists essentially of a pressure pipe 5" in which a piston 7" on a piston rod 9" divides a working space 11" into an upper or piston-rod-side working chamber 11b". A bottom valve unit 15" closes the pressure pipe 5" at the lower end thereof. A fluid path 19" is formed between the pressure pipe 5" and an intermediate pipe 81" said intermediate pipe 81" being arranged concentrically with respect to the pressure pipe 5". A connecting orifice 21" in the pressure pipe 5" connects the upper working chamber 11a" with the fluid path 19". A compensating chamber 25" is confined between the intermediate pipe 81" and a portion of the pressure pipe 5", on the one hand, and the container tube 10" on the other hand. This compensating chamber 25" is axially limited by a base member 12" and a piston rod guiding and sealing unit 83'. The working space 11" is separated by the piston 7" into the upper working chamber 11a" and the lower working chamber 11b". Both the upper and the lower working chamber are filled with a liquid. The compensating chamber 25" is also filled with damping liquid up to the level L" and contains a possibly pressurized gas above the level L". The bottom valve unit 15" provides communication between the working chamber 11b" and the compensating chamber 25". The piston 7" provides communication between the lower working chamber 11b" and the upper working chamber 11a". According to an illustrative example the oscillation damper works as follows: When the piston rod 9" moves upwards, a high flow resistance occurs across the piston 7" and a high pressure is generated in the upper working chamber 11a". Liquid from the upper working chamber 11a" flows through said high flow resistance into the lower working chamber 11b". As the piston rod 9" moves outward of the working space 11", the available volume within the working space 11" is increased. Therefore, liquid can flow from the compensating chamber 25" through the bottom valve unit 15" into the lower working chamber 11b". The flow resistance through the bottom valve unit 15" is small in this phase of operation. The movement of the piston rod 9" with respect to the pressure pipe 5" is damped.
On inward movement of the piston rod 9" fluid flows from the lower working chamber 11b" through the piston 7" into the upper working chamber 11a". The flow resistance across the piston 7" is relatively small and the flow resistance across the bottom valve unit 15" is relatively large. Therefore, a considerable pressure exists even within the upper working chamber 11a". The volume within the working space 11" is reduced by the piston rod 9' entering into the working space 11". Thus, damping liquid must flow from the lower working chamber 11b" through the bottom valve unit 15" into the compensating chamber 25". In this phase of operation the flow resistance through the bottom valve unit 15" is high such that a high pressure occurs within the lower working chamber 11b" and also within the upper working chamber 11a".
By the connecting orifice 21" and the fluid path 19" the upper working chamber 11a" is connected with the compensating chamber 25" via the valve unit 3". As long as the valve unit 3" is closed, the bypass established by the connecting orifice 21", the fluid path 19" and the valve unit 3" is also closed. This is the hardest mode of operation of the oscillation damper. When, however, the valve unit 3" is more or less opened, the bypass is also open. As a result thereof the following behavior exists: On upward movement of the piston rod 9" liquid can flow from the highly pressurized upper working chamber 11a" not only across the piston 7" providing a high flow resistance but also from the working chamber 11a" through the bypass 21", 19", 3" to the compensating chamber 25". Such, the damping force is reduced.
When the piston rod 9" moves downwards, there exists again a high pressure within the upper working chamber 11a", as described above. Therefore, damping liquid can flow from the upper working chamber 11a" through the bypass 21", 19", 3" to the compensating chamber 25". This means that the damping liquid which must be expelled from the working space 11" as a result of the reduced volume therein does not only escape through the bottom valve unit 15" to the compensating chamber 25" but can also partially escape through the bypass 21", 19", 3" to the compensating chamber 25". Such, the damping force is again reduced by the open bypass 21", 19", 3". It is to be noted that the direction of flow of the damping liquid through the bypass 21", 19", 3" is the same, both on upward movement and downward movement of the piston rod 9" with respect to the pressure pipe 5". By increasing the flow resistance through the valve unit 3" the damping force can be increased both for upward and downward movement of the piston rod 9", and by increasingly opening the valve unit 3" the damping force can be reduced both for upward movement and downward movement of the piston rod 9". It is possible to selectively open and close the valve unit or to continuously vary the flow resistance through the valve unit 3".
In FIG. 12 one can again see the fluid path 19" and the compensating chamber 25", which are interconnectable through the valve unit 3". The fluid path 19" is connected to the upper working chamber 11a". The flow direction from the fluid path 19" to the compensating chamber 25" across the valve unit 3" is indicated by the dotted line D" provided with arrows indicating the flow direction both for inward movement and outward movement of the piston rod 9" with respect to the pressure pipe 5". One can see in FIG. 12 a valve member v" which can be lifted with respect to a valve seat S", such as to open the flow path D" from the fluid path 19" to the compensating chamber 25". Generally, it is sufficient to say that the valve member V" is urged downward in the closing sense towards the valve seat S" by a helical compression spring H" and that the valve member V" can be lifted in response to upward movement of an electromagnetic armature member A". This armature member A" is biased in downward direction by a helical compression spring G" and can be lifted by energization of a magnetic coil 39" which is energized through a current supply cable 39b".
The valve unit 3" comprises a housing 70". This housing 70" is composed by the side tube 18' and a cover unit 71". The side tube 18" is welded at 22" to the container tube 10". The cover unit 71" is fastened to the side tube 18".
A pot-shaped valve components housing 33" is inserted into the side tube 18" and is axially located on a shoulder face 51" inside the side tube 18". Various valve components are located inside the valve components housing 33". The lower end of the valve components housing 33" is shaped as a tube section 33a", which provides the valve seat S" and is sealingly connected to the fluid path 19".
The cover unit 71" comprises an iron jacket 43" integral with an iron end wall 43a". The iron jacket 43" and the iron end wall 43a" are coated with a plastic layer 41". An annular electromagnetic coil 39" is housed within the iron jacket 43". This electromagnetic coil 39" is carried by a coil carrier 39a", which is annular about the axis B x " and is open in radial outward direction. The coil carrier 39a" is closed in radially outward direction by a plastics material 41a" integral with the plastic layer 41" through openings 43b" of the iron jacket 43". The plastics layer 41" and the plastics material 41a" are integrally moulded by injection moulding with the iron jacket 43", the iron end wall 43a" integral therewith and the electromagnetic coil 39" carrier 39a" being inserted into the injection mould.
A ferromagnetic core 44" is inserted into a central opening of the iron end wall 43a" and covered by the plastics layer 41". An iron flange portion 37" is provided at the lower side of the electromagnetic coil 38" and is engaged with a shoulder face 47" of the iron jacket 43". A pole tube 42" is seated within an annular recess 42a" of the iron flange portion 37". The pole tube 42" is sealingly connected to the iron flange portion 37" and to the ferromagnetic core 44". The armature A" is guided within the pole tube 42". The pole tube 42" is made of nonmagnetic material so that the magnetic field lines are deflected by the lower end of the pole tube 42". The iron jacket 43", the iron end wall 43a", the ferromagnetic core 44" and the iron flange portion 37" form a ferromagnetic core arrangement which toroidally surrounds the electromagnetic coil 39".
The cover unit 71" is fastened to the side tube 18" by a sleeve-shaped extension 43c" of the iron jacket 43". This sleeve-shaped extension 43c" axially overlaps the side tube 18" by a circumferential bead 55" being embossed into a circumferential groove 49" on the radially outer face of the side tube 18". The iron jacket 43" is provided with a pretensioning flange 45". The pretensioning flange 45" offers a pretension face 53". The cover unit 71" can be pretensioned in downward direction as shown in FIG. 17 toward the container tube 10" by a pretensioning tool engaging the container tube 10", on the one hand, and the pretensioning face 53", on the other hand. Such, the iron flange portion 37" is pressed against the upper end of the valve components housing 33", the valve components housing 33" is engaged with the shoulder face 51" of the side tube 18", and the iron flange portion 37" is engaged with the shoulder face 47" of the iron jacket 43". The helical compression spring H" is compressed between the iron flange portion 37" and the valve member V", which is seated on the valve seat S".
While maintaining this pretension of the cover unit 71" against the side tube 18", the bead 55" is rolled or caulked into the circumferential groove 49" of the side tube 18" so that after removing the pretensioning tool an internal pretension is maintained. A sealing ring 76" is, therefore, maintained in sealing engagement with the valve components housing 33", the iron flange portion 37" and the side tube 18". Such, the compartment C" confined by the side tube 18" and the cover unit 71" is sealed against atmosphere. All components of the valve unit 3" are positioned with respect to each other, and the helical compression spring H" as well as the helical compression spring G" and further springs are biased to the desired degree.
It is to be noted that the upper end of the side tube 18" is radially engaged at 77" with the iron flange portion 37" such that when rolling or caulking the bead 55" into the groove 49", no deformation of the side tube 18" and of the iron jacket 43" can occur.
The electromagnetic coil 39" is completely separated from the liquid within the compartment C" by the iron flange portion 37". The pretension during connecting the cover unit 71" and the side tube 18" is selected such that no play can occur.
It should be understood that the various components described and referenced hereinabove with reference to FIGS. 5-10, as well as FIGS. 11 and 12, may essentially be considered to be interchangeable with similar components described and referenced hereinabove with relation to FIGS. 1-4.
One feature of the invention resides broadly in the check valve device between two segments of a fluid connection, which connects two fluid chambers of a shock absorber with one another, whereby the check valve device with at least one check valve which separates a high-pressure segment and a low-pressure segment and has a checking body, can be adjusted between a closed and an open position by means of an external control via a magnet armature and a magnetic winding which is protected by means of a separator plate from the check valve, whereby a first side of the check valve pressurized by the high-pressure segment can be elastically pressed against a check valve seat which is a component of a pot-shaped insert, by means of a compression spring, also that a second side of the check valve body at some distance from this first side and adjacent to a control chamber is pressurized by the fluid pressure in this chamber, also that the control chamber is connected by means of a throttle section which bypasses the check valve body, also that the control chamber is connected by means of a control chamber discharge to the low-pressure segment, whereby there is a control chamber discharge valve with a control chamber discharge valve seat in the control chamber discharge, whereby the control chamber valve seat is configured on a supplemental discharge valve body, which together with a supplemental discharge valve seat on the check valve body forms a supplemental control chamber discharge of the control chamber, and that between the control chamber discharge valve body and the supplemental discharge valve body there is a coil compression spring which applies a prestress to the control chamber discharge valve body in the direction of lifting it from the control chamber discharge valve seat of the supplemental discharge valve body, characterized by the fact that the maximum magnet armature stroke length (hs) is greater than the maximum check body lifting stroke length (a), so that when there is a maximum magnet armature lifting stroke, the supplemental control chamber discharge 47b between the control chamber discharge valve body 45 and the supplemental discharge valve body 47 is completely open.
Another feature of the invention resides broadly in the check valve characterized by the fact that the control chamber discharge 37b has a cross section which is sized so that it makes possible an unthrottled discharge from the control chamber 50.
Yet another feature of the invention resides broadly in the check valve characterized by the fact that a stop ring 59a/b inside the check valve 27 restricts the lifting stroke of the checking body (a).
Still another feature of the invention resides broadly in the check valve characterized by the fact that the stop ring is designed as a thrust collar 59a which is braced between the pot-shaped insert 51 and the separator plate 39.
Another feature of the invention resides broadly in the check valve characterized by the fact that the check valve body 33 has a ring wall, the height of which is designed so that when the maximum check valve body stroke position is reached, the ring wall comes into contact with the separator plate 39.
Yet another feature of the invention resides broadly in the check valve characterized by the fact that the compression spring 37 has a smaller spring range than the magnet armature stroke length (hs).
Examples of check valve arrangements, and components associated therewith, which may be utilized in accordance with the embodiments of the present invention, may be found in the following U.S. Pat. No. 5,078,240, which issued to Ackermann et al. on Jan. 7, 1992; No. 4,482,036, which issued to Wossner et al. on Nov. 13, 1984; No. 4,287,970, which issued to Eusemann et al. on Sep. 8, 1981; and No. 4,105,041, which issued to Axthammer on Aug. 8, 1978.
Examples of electromagnetic valve arrangements with armatures, and associated components, which may be utilized in accordance with the embodiments of the present invention, may be found in the following U.S. Pat. No. 5,265,703, which issued to Ackermann on Nov. 30, 1993; No. 5,180,039, which issued to Axthammer et al. on Jan. 19, 1993; No. 4,899,996, which issued to Maassen et al. on Feb. 13, 1990; No. 4,850,460, which issued to Knecht et al. on Jul. 25, 1989; and No. 4,785,920, which issued to Knecht et al. on Nov. 22, 1988.
Examples of shock absorbers, and components associated therewith, which may be utilized in accordance with the embodiments of the present invention, may be found in the U.S. Patents listed above.
The corresponding foreign patent publication applications, namely, Federal Republic of Germany Patent Application No. P 43 14 519.1, filed on May 3, 1993, having inventors Gunther Handke, Otto Samonil and Andreas Zietsch, and DE-OS P 43 14 519.1 and DE-PS P 43 14 519.1, as well as their published equivalents, and other equivalents or corresponding applications, if any, in corresponding cases in the Federal Republic of Germany and elsewhere, and the references cited in any of the documents cited herein, are hereby incorporated by reference as if set forth in their entirety herein.
The following other foreign patent publication applications are also hereby incorporated by reference as if set forth in their entirety herein: Federal Republic of Germany Patent Application No. P 42 40 837.7, filed on Dec. 4, 1992, having inventor Gunther Handke, as well as DE-OS P 42 40 837.7 and DE-PS P 42 40 837.7, as well as their published equivalents, and other equivalents or corresponding applications, if any, in corresponding cases in the Federal Republic of Germany and elsewhere; and Federal Republic of Germany Patent Application No. P 43 08 328.5, filed on Mar. 16, 1993, and No. P 43 31 584.4, filed on Sep. 17, 1993, both having inventors Gunther Handke, Lars Rossberg and Andreas Zietsch, as well as DE-OS P 43 08 328.5, DE-PS P 43 08 328.5, DE-OS P 43 31 584.4 and DE-PS P 43 31 584.4, as well as their published equivalents, and other equivalents or corresponding applications, if any, in corresponding cases in the Federal Republic of Germany and elsewhere.
The invention as described hereinabove in the context of the preferred embodiments is not to be taken as limited to all of the provided details thereof, since modifications and variations thereof may be made without departing from the spirit and scope of the invention.
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A shock absorber with a check valve device and a check valve device for a shock absorber is disclosed. The check valve device located in the bypass of a shock absorber between a high-pressure segment and a low-pressure segment has a check valve which can be moved by an external control into a standby opening status, in which the actual opening can be performed as a function of the pressure prevailing in the high-pressure segment, when the pressure falls below a predetermined value. By coordinating the stroke distance of a check valve body with a magnet armature, and taking into consideration a control chamber discharge cross section, noises and fluctuations of the damping force characteristic can be eliminated even with a very soft comfort setting of the check valve device.
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BACKGROUND OF THE INVENTION
[0001] Compounds of formula
[0002] wherein R 1 is hydrogen or a lower alkyl radical and n is 4, 5, or 6 are known in U.S. Pat. No. 4,024,175 and its divisional U.S. Pat. No. 4,087,544. The uses disclosed are: protective effect against cramp induced by thiosemicarbazide; protective action against cardiazole cramp; the cerebral diseases, epilepsy, faintness attacks, hypokinesia, and cranial traumas; and improvement in cerebral functions. The compounds are useful in geriatric patients. The patents are hereby incorporated by reference.
[0003] Compounds of formula
[0004] or a pharmaceutically acceptable salt thereof wherein R 1 is a straight or branched alkyl group having from 1 to 6 carbon atoms, phenyl or cycloalkyl having from 3 to 6 carbon atoms; R 2 is hydrogen or methyl; and R 3 is hydrogen, or carboxyl are known in U.S. Pat. No. 5,563,175 and its various divisionals. These patents are hereby incorporated by reference.
SUMMARY OF THE INVENTION
[0005] The compounds of the instant invention are those of Formula I
[0006] or a pharmaceutically acceptable salt thereof wherein:
[0007] R 1 is hydrogen, straight or branched alkyl of from 1 to 6 carbon atoms or phenyl;
[0008] R 2 is straight or branched alkyl of from 1 to 8 carbon atoms,
[0009] straight or branched alkenyl of from 2 to 8 carbon atoms,
[0010] cycloalkyl of from 3 to 7 carbon atoms,
[0011] alkoxy of from 1 to 6 carbon atoms,
[0012] alkylcycloalkyl,
[0013] alkylalkoxy,
[0014] alkyl OH
[0015] alkylphenyl,
[0016] alkylphenoxy,
[0017] phenyl or substituted phenyl; and
[0018] R 1 is straight or branched alkyl of from 1 to 6 carbon atoms or phenyl when R 2 is methyl.
[0019] Preferred compounds are those of Formula I wherein R 1 is hydrogen, and R 2 is alkyl.
[0020] Other preferred compounds are those of Formula I wherein R 1 is methyl, and R 2 is alkyl.
[0021] Still other preferred compounds are those of Formula I wherein R 1 is methyl, and R 2 is methyl or ethyl.
[0022] Especially preferred compounds are selected from:
[0023] 3-Aminomethyl-5-methylheptanoic acid;
[0024] 3-Aminomethyl-5-methyl-octanoic acid;
[0025] 3-Aminomethyl-5-methyl-nonanoic acid;
[0026] 3-Aminomethyl-5-methyl-decanoic acid;
[0027] 3-Aminomethyl-5-methyl-undecanoic acid;
[0028] 3-Aminomethyl-5-methyl-dodecanoic acid;
[0029] 3-Aminomethyl-5-methyl-tridecanoic acid;
[0030] 3-Aminomethyl-5-cyclopropyl-hexanoic acid;
[0031] 3-Aminomethyl-5-cyclobutyl-hexanoic acid;
[0032] 3-Aminomethyl-5-cyclopentyl-hexanoic acid;
[0033] 3-Aminomethyl-5-cyclohexyl-hexanoic acid;
[0034] 3-Aminomethyl-5-trifluoromethyl-hexanoic acid;
[0035] 3-Aminomethyl-5-phenyl-hexanoic acid;
[0036] 3-Aminomethyl-5-(2-chlorophenyl)-hexanoic acid;
[0037] 3-Aminomethyl-5-(3-chlorophenyl)-hexanoic acid;
[0038] 3-Aminomethyl-5-(4-chlorophenyl)-hexanoic acid;
[0039] 3-Aminomethyl-5-(2-methoxyphenyl)-hexanoic acid;
[0040] 3-Aminomethyl-5-(3-methoxyphenyl)-hexanoic acid;
[0041] 3-Aminomethyl-5-(4-methoxyphenyl)-hexanoic acid; and
[0042] 3-Aminomethyl-5-(phenylmethyl)-hexanoic acid.
[0043] Other especially preferred compounds are selected from:
[0044] (3R,4S)-3-Aminomethyl-4,5-dimethyl-hexanoic acid;
[0045] 3-Aminomethyl-4,5-dimethyl-hexanoic acid;
[0046] (3R,4S)-3-Aminomethyl-4,5-dimethyl-hexanoic acid MP;
[0047] (3S,4S)-3-Aminomethyl-4,5-dimethyl-hexanoic acid;
[0048] (3R,4R)-3-Aminomethyl-4,5-dimethyl-hexanoic acid MP;
[0049] 3-Aminomethyl-4-isopropyl-hexanoic acid;
[0050] 3-Aminomethyl-4-isopropyl-heptanoic acid;
[0051] 3-Aminomethyl-4-isopropyl-octanoic acid;
[0052] 3-Aminomethyl-4-isopropyl-nonanoic acid;
[0053] 3-Aminomethyl-4-isopropyl-decanoic acid; and
[0054] 3-Aminomethyl-4-phenyl-5-methyl-hexanoic acid.
[0055] Other preferred compounds are selected from
[0056] (3S,5S)-3-Aminomethyl-5-methoxy-hexanoic acid;
[0057] (3S,5S)-3-Aminomethyl-5-ethoxy-hexanoic acid;
[0058] (3S,5S)-3-Aminomethyl-5-propoxy-hexanoic acid;
[0059] (3S,5S)-3-Aminomethyl-5-isopropoxy-hexanoic acid;
[0060] (3S,5S)-3-Aminomethyl-5-tert-butoxy-hexanoic acid;
[0061] (3S,5S)-3-Aminomethyl-5-fluoromethoxy-hexanoic acid;
[0062] (3S,5S)-3-Aminomethyl-5-(2-fluoro-ethoxy)-hexanoic acid;
[0063] (3S,5S)-3-Aminomethyl-5-(3,3,3-trifluoro-propoxy)-hexanoic acid;
[0064] (3S,5S)-3-Aminomethyl-5-phenoxy-hexanoic acid;
[0065] (3S,5S)-3-Aminomethyl-5-(4-chloro-phenoxy)-hexanoic acid;
[0066] (3S,5S)-3-Aminomethyl-5-(3-chloro-phenoxy)-hexanoic acid;
[0067] (3S,5S)-3-Aminomethyl-5-(2-chloro-phenoxy)-hexanoic acid;
[0068] (3S,5S)-3-Aminomethyl-5-(4-fluoro-phenoxy)-hexanoic acid;
[0069] (3S,5S)-3-Aminomethyl-5-(3-fluoro-phenoxy)-hexanoic acid;
[0070] (3S,5S)-3-Aminomethyl-5-(2-fluoro-phenoxy)-hexanoic acid;
[0071] (3S,5S)-3-Aminomethyl-5-(4-methoxy-phenoxy)-hexanoic acid;
[0072] (3S,5S)-3-Aminomethyl-5-(3-methoxy-phenoxy)-hexanoic acid;
[0073] (3S,5S)-3-Aminomethyl-5-(2-methoxy-phenoxy)-hexanoic acid;
[0074] (3S,5S)-3-Aminomethyl-5-(4-nitro-phenoxy)-hexanoic acid;
[0075] (3S,5S)-3-Aminomethyl-5-(3-nitro-phenoxy)-hexanoic acid;
[0076] (3S,5S)-3-Aminomethyl-5-(2-nitro-phenoxy)-hexanoic acid;
[0077] (3S,5S)-3-Aminomethyl-6-hydroxy-5-methyl-hexanoic acid;
[0078] (3S,5S)-3-Aminomethyl-6-methoxy-5-methyl-hexanoic acid;
[0079] (3S,5S)-3-Aminomethyl-6-ethoxy-5-methyl-hexanoic acid;
[0080] (3S,5S)-3-Aminomethyl-5-methyl-6-propoxy-hexanoic acid;
[0081] (3S,5S)-3-Aminomethyl-6-isopropoxy-5-methyl-hexanoic acid;
[0082] (3S,5S)-3-Aminomethyl-6-tert-butoxy-5-methyl-hexanoic acid;
[0083] (3S,5S)-3-Aminomethyl-6-fluoromethoxy-5-methyl-hexanoic acid;
[0084] (3S,5S)-3-Aminomethyl-6-(2-fluoro-ethoxy)-5-methyl-hexanoic acid;
[0085] (3S,5S)-3-Aminomethyl-5-methyl-6-(3,3,3-trifluoro-propoxy)-hexanoic acid;
[0086] (3S,5S)-3-Aminomethyl-5-methyl-6-phenoxy-hexanoic acid;
[0087] (3S,5S)-3-Aminomethyl-6-(4-chloro-phenoxy)-5-methyl-hexanoic acid;
[0088] (3S,5S)-3-Aminomethyl-6-(3-chloro-phenoxy)-5-methyl-hexanoic acid;
[0089] (3S,5S)-3-Aminomethyl-6-(2-chloro-phenoxy)-5-methyl-hexanoic acid;
[0090] (3S,5S)-3-Aminomethyl-6-(4-fluoro-phenoxy)-5-methyl-hexanoic acid;
[0091] (3S,5S)-3-Aminomethyl-6-(3-fluoro-phenoxy)-5-methyl-hexanoic acid;
[0092] (3S,5S)-3-Aminomethyl-6-(2-fluoro-phenoxy)-5-methyl-hexanoic acid;
[0093] (3S,5S)-3-Aminomethyl-6-(4-methoxy-phenoxy)-5-methyl-hexanoic acid;
[0094] (3S,5S)-3-Aminomethyl-6-(3-methoxy-phenoxy)-5-methyl-hexanoic acid;
[0095] (3S,5S)-3-Aminomethyl-6-(2-methoxy-phenoxy)-5-methyl-hexanoic acid;
[0096] (3S,5S)-3-Aminomethyl-5-methyl 6-(4-trifluoromethyl-phenoxy)-hexanoic acid;
[0097] (3S,5S)-3-Aminomethyl-5-methyl 6-(3-trifluoromethyl-phenoxy)-hexanoic acid;
[0098] (3S,5S)-3-Aminomethyl-5-methyl 6-(2-trifluoromethyl-phenoxy)-hexanoic acid;
[0099] (3S,5S)-3-Aminomethyl-5-methyl 6-(4-nitro-phenoxy)-hexanoic acid;
[0100] (3S,5S)-3-Aminomethyl-5-methyl 6-(3-nitro-phenoxy)-hexanoic acid;
[0101] (3S,5S)-3-Aminomethyl-5-methyl 6-(2-nitro-phenoxy)-hexanoic acid;
[0102] (3S,5S)-3-Aminomethyl-6-benzyloxy-5-methyl-hexanoic acid;
[0103] (3S,5S)-3-Aminomethyl-7-hydroxy-5-methyl-heptanoic acid;
[0104] (3S,5S)-3-Aminomethyl-7-methoxy-5-methyl-heptanoic acid;
[0105] (3S,5S)-3-Aminomethyl-7-ethoxy-5-methyl-heptanoic acid;
[0106] (3S,5S)-3-Aminomethyl-5-methyl-7-propoxy-heptanoic acid;
[0107] (3S,5S)-3-Aminomethyl-7-isopropoxy-5-methyl-heptanoic acid;
[0108] (3S,5S)-3-Aminomethyl-7-tert-butoxy-5-methyl-heptanoic acid;
[0109] (3S,5S)-3-Aminomethyl-7-fluoromethoxy-5-methyl-heptanoic acid;
[0110] (3S,5S)-3-Aminomethyl-7-(2-fluoro-ethoxy)-5-methyl-heptanoic acid;
[0111] (3S,5S)-3-Aminomethyl-5-methyl-7-(3,3,3-trifluoro-propoxy)-heptanoic acid;
[0112] (3S,5S)-3-Aminomethyl-7-benzyloxy-5-methyl-heptanoic acid;
[0113] (3S,5S)-3-Aminomethyl-5-methyl-7-phenoxy-heptanoic acid;
[0114] (3S,5S)-3-Aminomethyl-7-(4-chloro-phenoxy)-5-methyl-heptanoic acid;
[0115] (3S,5S)-3-Aminomethyl-7-(3-chloro-phenoxy)-5-methyl-heptanoic acid;
[0116] (3S,5S)-3-Aminomethyl-7-(2-chloro-phenoxy)-5-methyl-heptanoic acid;
[0117] (3S,5S)-3-Aminomethyl-7-(4-fluoro-phenoxy)-5-methyl-heptanoic acid;
[0118] (3S,5S)-3-Aminomethyl-7-(3-fluoro-phenoxy)-5-methyl-heptanoic acid;
[0119] (3S,5S)-3-Aminomethyl-7-(2-fluoro-phenoxy)-5-methyl-heptanoic acid;
[0120] (3S,5S)-3-Aminomethyl-7-(4-methoxy-phenoxy)-5-methyl-heptanoic acid;
[0121] (3S,5S)-3-Aminomethyl-7-(3-methoxy -phenoxy)-5-methyl-heptanoic acid;
[0122] (3S,5S)-3-Aminomethyl-7-(2-methoxy-phenoxy)-5-methyl-heptanoic acid;
[0123] (3S,5S)-3-Aminomethyl-5-methyl-7-(4-trifluoromethyl-phenoxy)-heptanoic acid;
[0124] (3S,5S)-3-Aminomethyl-5-methyl-7-(3-trifluoromethyl-phenoxy)-heptanoic acid;
[0125] (3S,5S)-3-Aminomethyl-5-methyl-7-(2-trifluoromethyl-phenoxy)-heptanoic acid;
[0126] (3S,5S)-3-Aminomethyl-5-methyl-7-(4-nitro-phenoxy)-heptanoic acid;
[0127] (3S,5S)-3-Aminomethyl-5-methyl-7-(3-nitro-phenoxy)-heptanoic acid;
[0128] (3S,5S)-3-Aminomethyl-5-methyl-7-(2-nitro-phenoxy)-heptanoic acid;
[0129] (3S,5S)-3-Aminomethyl-5-methyl-6-phenyl-hexanoic acid;
[0130] (3S,5S)-3-Aminomethyl-6-(4-chloro-phenyl)-5-methyl-hexanoic acid;
[0131] (3S,5S)-3-Aminomethyl-6-(3-chloro-phenyl)-5-methyl-hexanoic acid;
[0132] (3S,5S)-3-Aminomethyl-6-(2-chloro-phenyl)-5-methyl-hexanoic acid;
[0133] (3S,5S)-3-Aminomethyl-6-(4-methoxy-phenyl)-5-methyl-hexanoic acid;
[0134] (3S,5S)-3-Aminomethyl-6-(3-methoxy-phenyl)-5-methyl-hexanoic acid;
[0135] (3S,5S)-3-Aminomethyl-6-(2-methoxy-phenyl)-5-methyl-hexanoic acid;
[0136] (3S,5S)-3-Aminomethyl-6-(4-fluoro-phenyl)-5-methyl-hexanoic acid;
[0137] (3S,5S)-3-Aminomethyl-6-(3-fluoro-phenyl)-5-methyl-hexanoic acid;
[0138] (3S,5S)-3-Aminomethyl-6-(2-fluoro-phenyl)-5-methyl-hexanoic acid;
[0139] (3S,5R)-3-Aminomethyl-5-methyl-7-phenyl-heptanoic acid;
[0140] (3S,5R)-3-Aminomethyl-7-(4-chloro-phenyl)-5-methyl-heptanoic acid;
[0141] (3S,5R)-3-Aminomethyl-7-(3-chloro-phenyl)-5-methyl-heptanoic acid;
[0142] (3S,5R)-3-Aminomethyl-7-(2-chloro-phenyl)-5-methyl-heptanoic acid;
[0143] (3S,5R)-3-Aminomethyl-7-(4-methoxy-phenyl)-5-methyl-heptanoic acid;
[0144] (3S,5R)-3-Aminomethyl-7-(3-methoxy-phenyl)-5-methyl-heptanoic acid;
[0145] (3S,5R)-3-Aminomethyl-7-(2-methoxy-phenyl)-5-methyl-heptanoic acid;
[0146] (3S,5R)-3-Aminomethyl-7-(4-fluoro-phenyl)-5-methyl-heptanoic acid;
[0147] (3S,5R)-3-Aminomethyl-7-(3-fluoro-phenyl)-5-methyl-heptanoic acid;
[0148] (3S,5R)-3-Aminomethyl-7-(2-fluoro-phenyl)-5-methyl-heptanoic acid;
[0149] (3S,5R)-3-Aminomethyl-5-methyl-oct-7-enoic acid;
[0150] (3S,5R)-3-Aminomethyl-5-methyl-non-8-enoic acid;
[0151] (E)-(3S,5S)-3-Aminomethyl-5-methyl-oct-6-enoic acid;
[0152] (Z)-(3S,5S)-3-Aminomethyl-5-methyl-oct-6-enoic acid;
[0153] (Z)-(3S,5S)-3-Aminomethyl-5-methyl-non-6-enoic acid;
[0154] (E)-(3S,5S)-3-Aminomethyl-5-methyl-non-6-enoic acid;
[0155] (E)-(3S,5R)-3-Aminomethyl-5-methyl-non-7-enoic acid;
[0156] (Z)-(3S,5R)-3-Aminomethyl-5-methyl-non-7-enoic acid;
[0157] (Z)-(3S,5R)-3-Aminomethyl-5-methyl-dec-7-enoic acid;
[0158] (E)-(3S,5R)-3-Aminomethyl-5-methyl-undec-7-enoic acid;
[0159] (3S,5S)-3-Aminomethyl-5,6,6-trimethyl-heptanoic acid;
[0160] (3S,5S)-3-Aminomethyl-5,6-dimethyl-heptanoic acid;
[0161] (3S,5S)-3-Aminomethyl-5-cyclopropyl-hexanoic acid;
[0162] (3S,5S)-3-Aminomethyl-5-cyclobutyl-hexanoic acid;
[0163] (3S,5S)-3-Aminomethyl-5-cyclopentyl-hexanoic acid; and
[0164] (3S,5S)-3-Aminomethyl-5-cyclohexyl-hexanoic acid.
[0165] Still other more preferred compounds are:
[0166] (3S,5R)-3-Aminomethyl-5-methyl-heptanoic acid;
[0167] (3S,5R)-3-Aminomethyl-5-methyl-octanoic acid;
[0168] (3S,5R)-3-Aminomethyl-5-methyl-nonanoic acid;
[0169] (3S,5R)-3-Aminomethyl-5-methyl-decanoic acid;
[0170] (3S,5R)-3-Aminomethyl-5-methyl-undecanoic acid;
[0171] (3S,5R)-3-Aminomethyl-5-methyl-dodecanoic acid;
[0172] (3S,5R)-3-Aminomethyl-5,9-dimethyl-decanoic acid;
[0173] (3S,5R)-3-Aminomethyl-5,7-dimethyl-octanoic acid;
[0174] (3S,5R)-3-Aminomethyl-5,8-dimethyl-nonanoic acid;
[0175] (3S,5R)-3-Aminomethyl-6-cyclopropyl-5-methyl-hexanoic acid;
[0176] (3S,5R)-3-Aminomethyl-6-cyclobutyl-5-methyl-hexanoic acid;
[0177] (3S,5R)-3-Aminomethyl-6-cyclopentyl-5-methyl-hexanoic acid;
[0178] (3S,5R)-3-Aminomethyl-6-cyclohexyl-5-methyl-hexanoic acid;
[0179] (3S,5R)-3-Aminomethyl-7-cyclopropyl-5-methyl-heptanoic acid;
[0180] (3S,5R)-3-Aminomethyl-7-cyclobutyl-5-methyl-heptanoic acid;
[0181] (3S,5R)-3-Aminomethyl-7-cyclopentyl-5-methyl-heptanoic acid;
[0182] (3S,5R)-3-Aminomethyl-7-cyclohexyl-5-methyl-heptanoic acid;
[0183] (3S,5R)-3-Aminomethyl-8-cyclopropyl-5-methyl-octanoic acid;
[0184] (3S,5R)-3-Aminomethyl-8-cyclobutyl-5-methyl-octanoic acid;
[0185] (3S,5R)-3-Aminomethyl-8-cyclopentyl-5-methyl-octanoic acid;
[0186] (3S,5R)-3-Aminomethyl-8-cyclohexyl-5-methyl-octanoic acid;
[0187] (3S,5S)-3-Aminomethyl-6-fluoro-5-methyl-hexanoic acid;
[0188] (3S,5S)-3-Aminomethyl-7-fluoro-5-methyl-heptanoic acid;
[0189] (3S,5R)-3-Aminomethyl-8-fluoro-5-methyl-octanoic acid;
[0190] (3S,5R)-3-Aminomethyl-9-fluoro-5-methyl-nonanoic acid;
[0191] (3S,5S)-3-Aminomethyl-7,7,7-trifluoro-5-methyl-heptanoic acid;
[0192] (3S,5R)-3-Aminomethyl-8,8,8-trifluoro-5-methyl-octanoic acid;
[0193] (3S,5R)-3-Aminomethyl-5-methyl-8-phenyl-octanoic acid;
[0194] (3S,5S)-3-Aminomethyl-5-methyl-6-phenyl-hexanoic acid; and
[0195] (3S,5R)-3-Aminomethyl-5-methyl-7-phenyl-heptanoic acid.
[0196] The invention is also a pharmaceutical composition comprising a therapeutically effective amount of one or more compounds of Formula I and a pharmaceutically acceptable carrier.
[0197] The compounds of the invention are useful in the treatment of epilepsy, faintness attacks, hypokinesia, cranial disorders, neurodegenerative disorders, depression, anxiety, panic, pain, neuropathological disorders, arthritis, sleep disorders, irritable bowel syndrome (IBS), and gastric damage.
DETAILED DESCRIPTION OF THE INVENTION
[0198] The compounds of the instant invention are mono- and disubstituted 3-propyl gamma-aminobutyric acids as shown in Formula I above.
[0199] The terms are as described below or as they occur in the specification.
[0200] The term alkyl or alkenyl is a straight or branched group of from 1 to 8 carbon atoms or 2 to 8 carbon atoms including but not limited to methyl, ethyl, propyl, n-propyl, isopropyl, butyl, 2-butyl, tert-butyl, and octyl. Alkyl can be unsubstituted or substituted by from 1 to 3 fluorine atoms. Preferred groups are methyl and ethyl.
[0201] Cycloalkyl is a cyclic group of from 3 to 7 carbon atoms.
[0202] The benzyl and phenyl groups may be unsubstituted or substituted with from 1 to 3 groups each independents selected from halogen, especially fluoro, alkoxy, alkyl, and amino.
[0203] Halogen includes fluorine, chlorine, bromine, and iodine.
[0204] Alkoxy is as described above for alkyl.
[0205] Since amino acids are amphoteric, pharmacologically compatible salts when R is hydrogen can be salts of appropriate inorganic or organic acids, for example, hydrochloric, sulphuric, phosphoric, acetic, oxalic, lactic, citric, malic, salicylic, malonic, maleic, succinic, and ascorbic. Starting from corresponding hydroxides or carbonates, salts with alkali metals or alkaline earth metals, for example, sodium, potassium, magnesium, or calcium are formed. Salts with quaternary ammonium ions can also be prepared with, for example, the tetramethyl-ammonium ion.
[0206] Prodrugs of compounds I-VIII are included in the scope of the instant invention. Aminoacyl-glycolic and -lactic esters are known as prodrugs of amino acids (Wermuth C. G., Chemistry and Industry, 1980:433-435). The carbonyl group of the amino acids can be esterified by known means. Prodrugs and soft drugs are known in the art (Palomino E., Drugs of the Future, 1990;15(4):361-368). The last two citations are hereby incorporated by reference.
[0207] The effectiveness of an orally administered drug is dependent upon the drug's efficient transport across the mucosal epithelium and its stability in entero-hepatic circulation. Drugs that are effective after parenteral administration but less effective orally, or whose plasma half-life is considered too short, may be chemically modified into a prodrug form.
[0208] A prodrug is a drug which has been chemically modified and may be biologically inactive at its site of action, but which may be degraded or modified by one or more enzymatic or other in vivo processes to the parent bioactive form.
[0209] This chemically modified drug, or prodrug, should have a different pharmacokinetic profile to the parent, enabling easier absorption across the mucosal epithelium, better salt formulation and/or solubility, improved systemic stability (for an increase in plasma half-life, for example). These chemical modifications may be
[0210] 1) ester or amide derivatives which may be cleaved by, for example, esterases or lipases. For ester derivatives, the ester is derived from the carboxylic acid moiety of the drug molecule by known means. For amide derivatives, the amide may be derived from the carboxylic acid moiety or the amine moiety of the drug molecule by known means.
[0211] 2) peptides which may be recognized by specific or nonspecific proteinases. A peptide may be coupled to the drug molecule via amide bond formation with the amine or carboxylic acid moiety of the drug molecule by known means.
[0212] 3) derivatives that accumulate at a site of action through membrane selection of a prodrug form or modified prodrug form,
[0213] 4) any combination of 1 to 3.
[0214] Current research in animal experiments has shown that the oral absorption of certain drugs may be increased by the preparation of “soft” quaternary salts. The quaternary salt is termed a “soft” quaternary salt since, unlike normal quaternary salts, e.g., R—N + (CH 3 ) 3 , it can release the active drug on hydrolysis.
[0215] “Soft” quaternary salts have useful physical properties compared with the basic drug or its salts. Water solubility may be increased compared with other salts, such as the hydrochloride, but more important there may be an increased absorption of the drug from the intestine. Increased absorption is probably due to the fact that the “soft” quaternary salt has surfactant properties and is capable of forming micelles and unionized ion pairs with bile acids, etc., which are able to penetrate the intestinal epithelium more effectively. The prodrug, after absorption, is rapidly hydrolyzed with release of the active parent drug.
[0216] Certain of the compounds of the present invention can exist in unsolvated forms as well as solvated forms, including hydrated forms. In general, the solvated forms, including hydrated forms, are equivalent to unsolvated forms and are intended to be encompassed within the scope of the present invention.
[0217] The compounds of the present invention includes all enantiomeric and epimeric forms as well as the appropriate mixtures thereof. For example, the compound of Example 1 is a mixture of all four possible stereoisomers. The compound of Example 6 is one of the isomers. The configuration of the cyclohexane ring carbon centers may be R or S in these compounds where a configuration can be defined.
[0218] The radioligand binding assay using [ 3 H]gabapentin and the α 2 δ subunit derived from porcine brain tissue was used (Gee N. S., Brown J. P., Dissanayake V. U. K., Offord J., Thurlow R., Woodruff G. N., “The Novel Anti-convulsant Drug, Gabapentin, Binds to the α 2 δ Subunit of a Calcium Channel,” J. Biol. Chem., 1996;271:5879-5776).
TABLE 1 [ 3 H] GBP Anticonvulsant Binding % Protect Structure (IC 50 , nM) 1 hr 2 hr 0.218 100 1.8 0 0 0.04 80 100 0.206 0 20 On test 0 20 0.092 60 100
[0219] Table 1 above shows the binding affinity of the compounds of the invention to the α 2 δ subunit.
[0220] The compounds of the invention are compared to Neurontin®, a marketed drug effective in the treatment of such disorders as epilepsy. Neurontin® is 1-(aminomethyl)-cyclohexaneacetic acid of structural formula
[0221] Gabapentin (Neurontin®) is about 0.10 to 0.12 μM in this assay. The compounds of the instant invention are expected, therefore, to exhibit pharmacologic properties comparable to or better than gabapentin. For example, as agents for convulsions, anxiety, and pain.
[0222] The present invention also relates to therapeutic use of the compounds of the mimetic as agents for neurodegenerative disorders.
[0223] Such neurodegenerative disorders are, for example, Alzheimer's disease, Huntington's disease, Parkinson's disease, and Amyotrophic Lateral Sclerosis.
[0224] The present invention also covers treating neurodegenerative disorders termed acute brain injury. These include but are not limited to: stroke, head trauma, and asphyxia.
[0225] Stroke refers to a cerebral vascular disease and may also be referred to as a cerebral vascular incident (CVA) and includes acute thromboembolic stroke. Stroke includes both focal and global ischemia. Also, included are transient cerebral ischemic attacks and other cerebral vascular problems accompanied by cerebral ischemia. A patient undergoing carotid endarterectomy specifically or other cerebrovascular or vascular surgical procedures in general, or diagnostic vascular procedures including cerebral angiography and the like.
[0226] Other incidents are head trauma, spinal cord trauma, or injury from general anoxia, hypoxia, hypoglycemia, hypotension as well as similar injuries seen during procedures from embole, hyperfusion, and hypoxia.
[0227] The instant invention would be useful in a range of incidents, for example, during cardiac bypass surgery, in incidents of intracranial hemorrhage, in perinatal asphyxia, in cardiac arrest, and status epilepticus.
[0228] Pain refers to acute as well as chronic pain.
[0229] Acute pain is usually short-lived and is associated with hyperactivity of the sympathetic nervous system. Examples are postoperative pain and allodynia.
[0230] Chronic pain is usually defined as pain persisting from 3 to 6 months and includes somatogenic pains and psychogenic pains. Other pain is nociceptive.
[0231] Still other pain is caused by injury or infection of peripheral sensory nerves. It includes, but is not limited to pain from peripheral nerve trauma, herpes virus infection, diabetes mellitus, causalgia, plexus avulsion, neuroma, limb amputation, and vasculitis. Neuropathic pain is also caused by nerve damage from chronic alcoholism, human immunodeficiency virus infection, hypothyroidism, uremia, or vitamin deficiencies. Neuropathic pain includes, but is not limited to pain caused by nerve injury such as, for example, the pain diabetics suffer from.
[0232] Psychogenic pain is that which occurs without an organic origin such as low back pain, atypical facial pain, and chronic headache.
[0233] Other types of pain are: inflammatory pain, osteoarthritic pain, trigeminal neuralgia, cancer pain, diabetic neuropathy, restless leg syndrome, acute herpetic and postherpetic neuralgia, causalgia, brachial plexus avulsion, occipital neuralgia, gout, phantom limb, bum, and other forms of neuralgia, neuropathic and idiopathic pain syndrome.
[0234] A skilled physician will be able to determine the appropriate situation in which subjects are susceptible to or at risk of, for example, stroke as well as suffering from stroke for administration by methods of the present invention.
[0235] The compounds of the invention are also expected to be useful in the treatment of depression. Depression can be the result of organic disease, secondary to stress associated with personal loss, or idiopathic in origin. There is a strong tendency for familial occurrence of some forms of depression suggesting a mechanistic cause for at least some forms of depression. The diagnosis of depression is made primarily by quantification of alterations in patients' mood. These evaluations of mood are generally performed by a physician or quantified by a neuropsychologist using validated rating scales, such as the Hamilton Depression Rating Scale or the Brief Psychiatric Rating Scale. Numerous other scales have been developed to quantify and measure the degree of mood alterations in patients with depression, such as insomnia, difficulty with concentration, lack of energy, feelings of worthlessness, and guilt. The standards for diagnosis of depression as well as all psychiatric diagnoses are collected in the Diagnostic and Statistical Manual of Mental Disorders (Fourth Edition) referred to as the DSM-IV-R manual published by the American Psychiatric Association, 1994.
[0236] GABA is an inhibitory neurotransmitter with the central nervous system. Within the general context of inhibition, it seems likely that GABA-mimetics might decrease or inhibit cerebral function and might therefore slow function and decrease mood leading to depression.
[0237] The compounds of the instant invention may produce an anticonvulsant effect through the increase of newly created GABA at the synaptic junction. If gabapentin does indeed increase GABA levels or the effectiveness of GABA at the synaptic junction, then it could be classified as a GABA-mimetic and might decrease or inhibit cerebral finction and might, therefore, slow function and decrease mood leading to depression.
[0238] The fact that a GABA agonist or GABA-mimetic might work just the opposite way by increasing mood and thus, be an antidepressant, is a new concept, different from the prevailing opinion of GABA activity heretofore.
[0239] The compounds of the instant invention are also expected to be useful in the treatment of anxiety and of panic as demonstrated by means of standard pharmacological procedures.
[0240] The compounds of the invention are also expected to be useful in the treatment of sleep disorders. Sleep disorders are disturbances that affect the ability to fall and/or stay asleep, that involves sleeping to much, or that result in abnormal behavior associated with sleep. The disorders include, for example, insomnia, drug-associated sleeplessness, hypersomnia, narcolepsy, sleep apnea syndromes, and parasomnias.
[0241] The compounds of the invention are also useful in the treatment of arthritis.
[0242] Biological Activity
TABLE 2 [ 3 H] GBP Anxiolytic Anticonvulsant Binding Activity* % Protect* Example (IC 50 , μM) % Preg. Act. 1 h 2 h Pregabalin 0.218 100 100 (3S,4R)3-Aminomethyl- 2.2 12 20 20 4,5-dimethyl-hexanoic acid (3R,4S)3-Aminomethyl- 1.7 58 20 0 4,5-dimethyl-hexanoic acid (3R,4R)3-Aminomethyl- 0.022 204 100 100 4,5-dimethyl-hexanoic acid 3-Aminomethyl-5- 0.092 79 60 100 methylheptanoic acid 3-Aminomethyl-5- 0.019 NT 40 100 methyloctanoic acid 3-Aminomethyl-5- 0.150 NT 0 0 methyldecanoic acid 3-Aminomethyl-5- 0.178 NT 40 80 methylnonanoic acid 3-Aminomethyl-5- 0.163 NT NT methylundecanoic acid (3S,5R)-3-Aminomethyl- On test On test 80 100 5-methyl-heptanoic acid (3S,5R)-3-Aminomethyl- 0.012 160 100 100 5-methyl-octanoic acid hydrochloride (3S,5R)-3-Aminomethyl- 0.026 125.94 100 100 5-methyl-nonanoic acid hydrochloride (3S,5R)-3-Aminomethyl- 0.0297 105.59 100 100 5-methyl-decanoic acid (3S,5S)-3-Aminomethyl- On test On test 0 0 5-methyl-heptanoic acid (3S,5S)-3-Aminomethyl- 1.2 15.6 0 20 5-methyl-octanoic acid (3S,5S)-3-Aminomethyl- On test On test 0 0 5-methyl-nonanoic acid 3-Aminomethyl-5- 9.08 NT 0 0 methyl-6-phenyl- hexanoic acid 3-Aminomethyl-5,7,7- >10 NT NT trimethyl-octanoic acid (S)-3-Aminomethyl-5- 0.0126 135.38 100 100 methyl-octanoic acid 3-Aminomethyl-5,7- 0.359 NT NT dimethyl-octanoic acid 3-Aminomethyl-6,6,6- 4.69 NT 0 0 trifluoro-5-methyl- hexanoic acid 3-Aminomethyl-5- >10 NT 0 0 methyl-oct-7-enoic acid (S)-3-Aminomethyl-6- On test On test 0 0 methoxy-5-methyl- hexanoic acid 3-aminomethyl-4- 0.671 NT NT isopropyl-heptanoic acid 3-aminomethyl-4- 5.4 NT 0 0 isopropyl-octanoic acid 3-aminomethyl-4- 0.49 NT 0 0 isopropyl-hexanoic acid 3-Aminomethyl-5- NT 0 0 methyl-4-phenyl- hexanoic acid (S)-3-Aminomethyl-6- 0.605 NT NT fluoro-5-methyl- hexanoic acid 3-Aminomethyl-5- 7.3 NT NT cyclohexyl-hexanoic acid 3-Aminomethyl-5- >10 cyclopentyl-hexanoic acid 3-Aminomethyl-5- 10.1 NT NT phenyl-hexanoic acid (3S,5S)-3-Aminomethyl- On test On test 0 20 5-methyl-decanoic acid
[0243] The compounds of the instant invention are useful as anxiolytics and anticonvulsants as shown in Table 2 above. They are compared to pregabalin which is isobutylgaba or (S)-3-(Aminomethyl)-5-methylhexanoic acid of formula
Materials and Methods
[0244] Carrageenin-Induced Hyperalgesia
[0245] Nociceptive pressure thresholds were measured in the rat paw pressure test using an analgesimeter (Randall-Selitto method: Randall L. O. and Selitto J. J., “A method for measurement of analgesic activity on inflamed tissue,” Arch. Int. Pharmacodyn., 1957;4:409-419). Male Sprague-Dawley rats (70-90 g) were trained on this apparatus before the test day. Pressure was gradually applied to the hind paw of each rat and nociceptive thresholds were determined as the pressure (g) required to elicit paw withdrawal. A cutoff point of 250 g was used to prevent any tissue damage to the paw. On the test day, two to three baseline measurements were taken before animals were administered 100 μL of 2% carrageenin by intraplantar injection into the right hind paw. Nociceptive thresholds were taken again 3 hours after carrageenin to establish that animals were exhibiting hyperalgesia. Animals were dosed with either gabapentin (3-300 mg, s.c.), morphine (3 mg/kg, s.c.) or saline at 3.5 hours after carrageenin and nociceptive thresholds were examined at 4, 4.5, and 5 hours postcarrageenin.
[0246] (R)-2-Aza-spiro[4.5]decane-4-carboxylic acid hydrochloride was tested in the above carrageenan-induced hyperalgesia model. The compound was dosed orally at 30 mg/kg, and 1 hour postdose gave a percent of maximum possible effect (MPE) of 53%. At 2 hours postdose, it gave only 4.6% of MPE.
[0247] Semicarbazide-Induced Tonic Seizures
[0248] Tonic seizures in mice are induced by subcutaneous administration of semicarbazide (750 mg/kg). The latency to the tonic extension of forepaws is noted. Any mice not convulsing within 2 hours after semicarbazide are considered protected and given a maximum latency score of 120 minutes.
[0249] Animals
[0250] Male Hooded Lister rats (200-250 g) are obtained from Interfauna (Huntingdon, UK) and male TO mice (20-25 g) are obtained from Bantin and Kingman (Hull, UK). Both rodent species are housed in groups of six. Ten Common Marmosets (Callithrix Jacchus) weighing between 280 and 360 g, bred at Manchester University Medical School (Manchester, UK) are housed in pairs. All animals are housed under a 12-hour light/dark cycle (lights on at 07.00 hour) and with food and water ad libitum.
[0251] Drug Administration
[0252] Drugs are administered either intraperitoneally (IP) or subcutaneously (SC) 40 minutes before the test in a volume of 1 mL/kg for rats and marmosets and 10 mL/kg for mice.
[0253] Mouse Light/Dark Box
[0254] The apparatus is an open-topped box, 45 cm long, 27 cm wide, and 27 cm high, divided into a small (2/5) and a large (3/5) area by a partition that extended 20 cm above the walls (Costall B., et al., “Exploration of mice in a black and white box: validation as a model of anxiety,” Pharmacol. Biochem. Behav., 1989;32:777-785).
[0255] There is a 7.5×7.5 cm opening in the center of the partition at floor level. The small compartment is painted black and the large compartment white. The white compartment is illuminated by a 60-W tungsten bulb. The laboratory is illuminated by red light. Each mouse is tested by placing it in the center of the white area and allowing it to explore the novel environment for 5 minutes. The time spent in the illuminated side is measured (Kilfoil T., et al., “Effects of anxiolytic and anxiogenic drugs on exploratory activity in a simple model of anxiety in mice,” Neuropharmacol., 1989;28:901-905).
[0256] Rat Elevated X-Maze
[0257] A standard elevated X-maze (Handley S. L., et al., “Effects of alpha-adrenoceptor agonists and antagonists in a maze-exploration model of ‘fear’-motivated behavior,” Naunyn - Schiedeberg's Arch. Pharmacol., 1984;327:1-5), was automated as previously described (Field, et al., “Automation of the rat elevated X-maze test of anxiety,” Br. J. PharmacoL, 1991;102(Suppl.):304P). The animals are placed on the center of the X-maze facing one of the open arms. For determining anxiolytic effects the entries and time spent on the end half sections of the open arms is measured during the 5-minute test period (Costall, et al., “Use of the elevated plus maze to assess anxiolytic potential in the rat,” Br. J. Pharmacol., 1989;96(Suppl.):312p).
[0258] Marmoset Human Threat Test
[0259] The total number of body postures exhibited by the animal towards the threat stimulus (a human standing approximately 0.5 m away from the marmoset cage and staring into the eyes of the marmoset) is recorded during the 2-minute test period. The body postures scored are slit stares, tail postures, scent marking of the cage/perches, piloerection, retreats, and arching of the back. Each animal is exposed to the threat stimulus twice on the test day before and after drug treatment. The difference between the two scores is analyzed using one-way analysis of variance followed by Dunnett's t-test. All drug treatments are carried out SC at least 2 hours after the first (control) threat. The pretreatment time for each compound is 40 minutes.
[0260] Rat Conflict Test
[0261] Rats are trained to press levers for food reward in operant chambers. The schedule consists of alternations of four 4-minute unpunished periods on variable interval of 30 seconds signaled by chamber lights on and three 3-minute punished periods on fixed ratio 5 (by footshock concomitant to food delivery) signaled by chamber lights off. The degree of footshock is adjusted for each rat to obtain approximately 80% to 90% suppression of responding in comparison with unpunished responding. Rats receive saline vehicle on training days.
[0262] DBA2 Mouse Model of Anticonvulsant Efficacy
[0263] All procedures were carried out in compliance with the NIH Guide for the Care and Use of Laboratory Animals under a protocol approved by the Parke-Davis Animal Use Committee. Male DBA/2 mice, 3 to 4 weeks old were obtained from Jackson Laboratories, Bar Harbour, Me. Immediately before anticonvulsant testing, mice were placed upon a wire mesh, 4 inches square, suspended from a steel rod. The square was slowly inverted through 180° and mice observed for 30 seconds. Any mouse falling from the wire mesh was scored as ataxic (Coughenour L. L., McLean J. R., Parker R. B., “A new device for the rapid measurement of impaired motor function in mice,” Pharm. Biochem. Behav., 1977;6(3):351-3). Mice were placed into an enclosed acrylic plastic chamber (21 cm height, approximately 30 cm diameter) with a high-frequency speaker (4 cm diameter) in the center of the top lid. An audio signal generator (Protek model B-810) was used to produce a continuous sinusoidal tone that was swept linearly in frequency between 8 kHz and 16 kHz once each 10 msec. The average sound pressure level (SPL) during stimulation was approximately 100 dB at the floor of the chamber. Mice were placed within the chamber and allowed to acclimatize for one minute. DBA/2 mice in the vehicle-treated group responded to the sound stimulus (applied until tonic extension occurred, or for a maximum of 60 sec) with a characteristic seizure sequence consisting of wild running followed by clonic seizures, and later by tonic extension, and finally by respiratory arrest and death in 80% or more of the mice. In vehicle-treated mice, the entire sequence of seizures to respiratory arrest lasts approximately 15 to 20 seconds. The incidence of all the seizure phases in the drug-treated and vehicle-treated mice was recorded, and the occurrence of tonic seizures were used for calculating anticonvulsant ED 50 values by probit analysis (Litchfield J. T., Wilcoxon F. “A simplified method for evaluating dose-effect experiments,” J. Pharmacol., 1949;96:99-113). Mice were used only once for testing at each dose point. Groups of DBA/2 mice (n=5-10 per dose) were tested for sound-induced seizure responses 2 hours (previously determined time of peak effect) after given drug orally. All drugs in the present study were dissolved in distilled water and given by oral gavage in a volume of 10 mL/kg of body weight. Compounds that are insoluble will be suspended in 1% carboxymethocellulose. Doses are expressed as weight of the active drug moiety.
[0264] The compounds of the instant invention are also expected to be useful in the treatment of pain and phobic disorders ( Am. J. Pain Manag., 1995;5:7-9).
[0265] The compounds of the instant invention are also expected to be useful in treating the symptoms of manic, acute or chronic, single upside, or recurring depression. They are also expected to be useful in treating and/or preventing bipolar disorder (U.S. Pat. No. 5,510,381).
[0266] The compounds of the invention are also expected to be useful in sleep disorders. The assessment is as described in Drug Dev Res 1988;14:151-159.
[0267] The compounds of the present invention can be prepared and administered in a wide variety of oral and parenteral dosage forms. Thus, the compounds of the present invention can be administered by injection, that is, intravenously, intramuscularly, intracutaneously, subcutaneously, intraduodenally, or intraperitoneally. Also, the compounds of the present invention can be administered by inhalation, for example, intranasally. Additionally, the compounds of the present invention can be administered transdermally. It will be obvious to those skilled in the art that the following dosage forms may comprise as the active component, either a compound of Formula I or a corresponding pharmaceutically acceptable salt of a compound of Formula I.
[0268] For preparing pharmaceutical compositions from the compounds of the present invention, pharmaceutically acceptable carriers can be either solid or liquid. Solid form preparations include powders, tablets, pills, capsules, cachets, suppositories, and dispersible granules. A solid carrier can be one or more substances which may also act as diluents, flavoring agents, binders, preservatives, tablet disintegrating agents, or an encapsulating material.
[0269] In powders, the carrier is a finely divided solid which is in a mixture with the finely divided active component.
[0270] In tablets, the active component is mixed with the carrier having the necessary binding properties in suitable proportions and compacted in the shape and size desired.
[0271] The powders and tablets preferably contain from five or ten to about seventy percent of the active compound. Suitable carriers are magnesium carbonate, magnesium stearate, talc, sugar, lactose, pectin, dextrin, starch, gelatin, tragacanth, methylcellulose, sodium carboxymethylcellulose, a low melting wax, cocoa butter, and the like. The term “preparation” is intended to include the formulation of the active compound with encapsulating material as a carrier providing a capsule in which the active component with or without other carriers, is surrounded by a carrier, which is thus in association with it. Similarly, cachets and lozenges are included. Tablets, powders, capsules, pills, cachets, and lozenges can be used as solid dosage forms suitable for oral administration.
[0272] For preparing suppositories, a low melting wax, such as a mixture of fatty acid glycerides or cocoa butter, is first melted and the active component is dispersed homogeneously therein, as by stirring. The molten homogenous mixture is then poured into convenient sized molds, allowed to cool, and thereby to solidify.
[0273] Liquid form preparations include solutions, suspensions, and emulsions, for example, water or water propylene glycol solutions. For parenteral injection liquid preparations can be formulated in solution in aqueous polyethylene glycol solution.
[0274] Aqueous solutions suitable for oral use can be prepared by dissolving the active component in water and adding suitable colorants, flavors, stabilizing and thickening agents as desired.
[0275] Aqueous suspensions suitable for oral use can be made by dispersing the finely divided active component in water with viscous material, such as natural or synthetic gums, resins, methylcellulose, sodium carboxymethylcellulose, and other well-known suspending agents.
[0276] Also included are solid form preparations which are intended to be converted, shortly before use, to liquid form preparations for oral administration. Such liquid forms include solutions, suspensions, and emulsions. These preparations may contain, in addition to the active component, colorants, flavors, stabilizers, buffers, artificial and natural sweeteners, dispersants, thickeners, solubilizing agents, and the like.
[0277] The pharmaceutical preparation is preferably in unit dosage form. In such form the preparation is subdivided into unit doses containing appropriate quantities of the active component. The unit dosage form can be a packaged preparation, the package containing discrete quantities of preparation, such as packeted tablets, capsules, and powders in vials or ampoules. Also, the unit dosage form can be a capsules, tablet, cachet, or lozenge itself, or it can be the appropriate number of any of these in packaged form.
[0278] The quantity of active component in a unit dose preparation may be varied or adjusted from 0.1 mg to 1 g according to the particular application and the potency of the active component. In medical use the drug may be administered three times daily as, for example, capsules of 100 or 300 mg. The composition can, if desired, also contain other compatible therapeutic agents.
[0279] In therapeutic use, the compounds utilized in the pharmaceutical method of this invention are administered at the initial dosage of about 0.01 mg to about 100 mg/kg daily. A daily dose range of about 0.01 mg to about 100 mg/kg is preferred. The dosages, however, may be varied depending upon the requirements of the patient, the severity of the condition being treated, and the compound being employed. Determination of the proper dosage for a particular situation is within the skill of the art. Generally, treatment is initiated with smaller dosages which are less than the optimum dose of the compound. Thereafter, the dosage is increased by small increments until the optimum effect under the circumstances is reached. For convenience, the total daily dosage may be divided and administered in portions during the day, if desired.
[0280] The following examples are illustrative of the instant invention; they are not intended to limit the scope.
[0281] General Synthetic Schemes
[0282] Generic Description
[0283] Method 1
[0284] a) LiAlH 4 ;
[0285] b) pyridinium dichormate;
[0286] c) triethylphosphonoacetate, NaH;
[0287] d) Nitromethane DBU;
[0288] e) i. H2 Pd/C; ii. HCl; iii ion exchange chromatography.
[0289] Method 2
[0290] X=OEt or chiral oxazolidine auxiliary.
[0291] a) Triethylphosphonoacetate, NaH;
[0292] b) i. NaOH, ii. Pivaloyl chloride, Et 3 N, XH;
[0293] c) R 1 MgBr, CuBr 2 DMS;
[0294] d) NaHMDS, BrCH 2 CO 2 tBu;
[0295] e) R=tBu i. LiOH, H 2 O 2 ; ii. BH 3 , iii. TsCl, ET 3 N, iv. NaN 3 , DMSO;
[0296] f) R=Et i. LiOH, H2O 2; ii. BH 3 , iii. PTSA, THF; iv HBr EtOH, v. NaN 3 DMSO;
[0297] g) i. H 2 Pd/C; ii. HCl, iii. Ion exchange chromatography.
SPECIFIC EXAMPLES
Synthesis of Example 1
3-Aminomethyl-5-methylheptanoic acid
[0298] [0298]
[0299] a) PDC, CH 2 Cl 2 ;
[0300] b) NaH, triethylphosphonoacetate;
[0301] c) DBU, CH 3 NO 2 ;
[0302] d) H 2 , 10% Pd/C;
[0303] e) 6N HCl, reflux, ion exchange resin (Dowex 50WX8, strongly acidic).
[0304] 3-Methyl-1-pentanal 11
[0305] To a stirred suspension of pyridinum dichromate (112.17 g, 298.1 mmol) in dichloromethane 500 mL was added 3-methyl-1-pentanol 10 (15 g, 146.79 mmol). After stirring for 2.5 hours, ether 400 mL was added, and stirring was continued for another 5 minutes. The filtrate from the mixture was concentrated to a small volume and applied to a column of Florisil. The compound was eluted with petroleum ether, and further chromatographed on silica gel column using 10% ether in petroleum ether as eluent gave 11 (6.5 g, 44%). 1 H-NMR (CDCl 3 ) δ9.72, (d, C H O), 2.38 (dd, 1H, —C H 2 CHO), 2.19 (dd, 1H, —C H 2 CHO), 1.95 (m, 1H, C 2 H 5 (CH 3 )C H CH 2 —), 1.4-1.0 (m), 0.9-0.8 (m).
[0306] Ethyl 5-methyl-2-heptenoate 12
[0307] Sodium hydride (60% dispersion, 2.4 g, 65 mmol) was washed with hexane and suspended in dimethoxyethane 60 mL. While cooling in ice water bath triethyl phosphonoacetate was slowly added, calcd. 5 minutes. The reaction was stirred for 15 minutes at 0° C. and a solution of 3-methyl-i-pentanal 11 (6.5 g, 65 mmol) in imethoxyethane 20 mL was added. After refluxing overnight, it was concentrated, water and hexane were added, the organic phase was separated, and the aqueous portion discarded. The solution was washed twice with brine and dried on magnesium sulfate. The solvent was evaporated to give 12 (6.75 g, 61%). 1 H-NMR (CDCl 3 ) δ6.89 (m, 1H, —CH 2 C H :CHCOOEt), 5.77 (d, 1H, —CH 2 CH:C H COOEt), 4.16 (q, 2H, —COOC H 2 CH 3 ), 2.15 and 1.98 (1H each and a multiplet, —C H 2 CH:CHCOOEt), 1.48 (m, 1H, C 2 H 5 (CH 3 )C H CH 2 ), 1.30-1.10 (m), and 0.83.
[0308] Ethyl 5-methyl-3-nitromethylheptanoate 13
[0309] Ethyl 5-methyl-2-heptanoate 12 (6.75 g, 39.70 mmol), DBU (6.0 g, 39.7 mmol), nitromethane (21.97 g, 359.9 mmol) in acetonitrile 80 mL was stirred at room temperature under nitrogen atmosphere overnight. The mixture was concentrated to an oil. A solution of the oil in ether was washed with 1N HCl, brine and dried. It was evaporated to give a light oil which was chromatographed on silica gel, eluting with 5% to 10% ether in Pet. ether to give 13 (3.6 g, 42%). 1 H-NMR (CDCl 3 ) δ4.49-4.39 (m), 4.12-4.07 (m), 3.61 (m), 2.36 (m), 1.36-1.18 (m), 0.86-0.79.
[0310] 3-Aminomethyl-5-methylheptanoic acid (Example 1)
[0311] Ethyl 5-methyl-3-nitromethylheptanoate 13 (3.6 g) was hydrogenated in ethanol in the presence of 20% Pd/C and evaporated to give 14. Six normal hydrochloric acid 30 mL was added and refluxed overnight. The solvent was evaporated at reduced pressure, and the residue was azeotroped with toluene. Aqueous solution of the residue was applied to Dowex 50Wx 8-100 ion exchange resin that had been washed to neutral pH with HPLC grade water. The column was eluted with water until eluent was neutral pH, and then with 0.5N. NH 4 OH solution to give factions containing 3-aminomethyl-5-methylheptanoic acid. The fractions were combined and further chromatographed on a C 18 column. The compound was eluted with 40% water in methanol and crystallized from methanol-ether to give Example 1 630 mg. 1 H-NMR (CD 3 OD) δ2.83 (m, 1H), 2.75 (m, 1H), 2.35 (m, 1H), 2.15 (m, 1H), 1.95 (1H, bs), 1.38 (1H, m), 1.3-1.15 (m, 2H), 1.14-0.95 (m, 2H). 0.80 (m, 2CH 3 ). MS found molecular ion at (M+1) 174 and other ions at 156, 139, and 102: Anal, Calcd, for C 9 H 19 NO 2 : C, 62.39; H 11.05; N 8.08. Found C, 62.00; H, 10.83; N, 7.98.
[0312] In a similar way the following examples can be prepared.
[0313] 3-Aminomethyl-5-methyl-heptanoic acid;
[0314] 3-Aminomethyl-5-methyl-octanoic acid;
[0315] 3-Aminomethyl-5-methyl-nonanoic acid;
[0316] 3-Aminomethyl-5-methyl-decanoic acid;
[0317] 3-Aminomethyl-5-methyl-undecanoic acid;
[0318] 3-Aminomethyl-5-methyl-dodecanoic acid;
[0319] 3-Aminomethyl-5-methyl-tridecanoic acid;
[0320] 3-Aminomethyl-5-cyclopropyl-hexanoic acid;
[0321] 3-Aminomethyl-5-cyclobutyl-hexanoic acid;
[0322] 3-Aminomethyl-5-cyclopentyl-hexanoic acid;
[0323] 3-Aminomethyl-5-cyclohexyl-hexanoic acid;
[0324] 3-Aminomethyl-5-trifluoromethyl-hexanoic acid;
[0325] 3-Aminomethyl-5-phenyl-hexanoic acid;
[0326] 3-Aminomethyl-5-(2-chlorophenyl)-hexanoic acid;
[0327] 3-Aminomethyl-5-(3-chlorophenyl)-hexanoic acid;
[0328] 3-Aminomethyl-5-(4-chlorophenyl)-hexanoic acid;
[0329] 3-Aminomethyl-5-(2-methoxyphenyl)-hexanoic acid;
[0330] 3-Aminomethyl-5-(3-methoxyphenyl)-hexanoic acid;
[0331] 3-Aminomethyl-5-(4-methoxyphenyl)-hexanoic acid; and
[0332] 3-Aminomethyl-5-(phenylmethyl)-hexanoic acid.
Synthesis of Example 2
(3R,4S)3-Aminomethyl-4,5-dimethyl-hexanoic acid
[0333] [0333]
[0334] Reagents and Conditions:
[0335] a) (R)−(−)-4-phenyl-2-oxazolidinone, (CH 3 ) 3 CCOCl, Et 3 N, LiCl, THF, −20 to 23° C.;
[0336] b) MeMgCl, CuBrSMe 2 , THF, −35° C.;
[0337] c) NaHMDS, BrCH 2 CO 2 tBu, THF, −78° C. to −40° C.;
[0338] d) LiOH, H 2 O 2 , THF, H 2 O, 25° C.;
[0339] e) BH 3 SMe 2 , THF, 0 to 25° C.;
[0340] f) pTsCl, pyridine, 25° C.;
[0341] g) NaN 3 , DMSO, 60° C.;
[0342] h) Raney nickel, MeOH, H 2 ; i) 3M HCl, reflux, ion exchange resin (Dowex 50WX8, strongly acidic).
[0343] [R-(E)]3-(4-Methyl-pent-2-enoyl)-4-phenyl-oxazolidin-2-one 16
[0344] Trimethylacetyl chloride (7.8 g, 0.065 mol) was added to acid 14 (6.9 g, 0.06 mol) and triethylamine (18 g, 0.187 mol) in THF (200 mL) at −20° C. After 1 hour, lithium chloride (2.35 g, 0.55 mol) and (R)−(−)-4-phenyl-2-oxazolidinone (8.15 g, 0.05 mol) were added and the thick suspension warmed to room temperature. After 20 hours, the suspension was filtered and the filtrate concentrated. The resultant solid was recrystallized from hexane/ethyl acetate (5:1) to give the oxazolidinone 16 as a white solid (8.83 g, 68%). 1 H NMR (CDCl 3 ) δ7.35 (m, 5H), 7.18 (dd, 1H, J=15.4 and 1.2 Hz), 7.02 (dd, 1H, J=15.4 and 6.8 Hz), 5.45 (dd, 1H, J=8.8 and 3.9 Hz), 4.68 (t, 1H, J=8.8 Hz), 4.22 (dd, 1H, J=8.8 and 3.9 Hz), 2.50 (m, 1H), 1.04 (d, 1H, J=1.4 Hz), 1.02 (d, 1H, J=1.4 Hz). MS, m/z (relative intensity): 260 [M+H, 100%].
[0345] (3R,3R*)3-(3,4-Dimethyl-pentanoyl)-4-phenyl-oxazolidin-2-one 17
[0346] To copper(I) bromide-dimethyl sulphide complex in THF (45 mL) at −20° C. was added methylmagnesium chloride (as a 3 M solution in THF). After 20 minutes, the oxazolidinone 16 (3.69 g, 0.014 mol) in THF (20 mL) was added dropwise over 10 minutes. After 2.5 hours, the reaction was quenched through the addition of a saturated aqueous solution of ammonium chloride. The resultant two layers were separated and the aqueous phase extracted with ether. The combined organic phases were washed with 1 M hydrochloric acid, then with 5% aqueous ammonium hydroxide. The organic phases were dried (MgSO 4 ) and concentrated to give the oxazolidinone 17 as a white solid (3.39 g, 88%). 1 H NMR (CDCl 3 )δ7.30 (m, 1H), 5.40 (dd, 1H, J=8.8 and 3.7 Hz), 4.63 (t, 1H, J=8.8 Hz), 4.21 (dd, 1H, J=8.8 and 3.7 Hz), 2.85 (dd, 1H, J=16.1 and 5.6 Hz), 2.8 (dd, 1H, J=16.1 and 8.5 Hz), 1.90 (m, 1H), 1.56 (m, 2H), 0.83 (d, 3H, J=6.8 Hz), 0.78 (d, 3H, J=6.8 Hz), 0.75 (d, 3H, J=6.8 Hz). MS, m/z (relative intensity): 276 [M+H, 100%].
[0347] [3R-(3R*(R*),4S*]-4,5-Dimethyl-3-(2-oxo-4-phenyl-oxazolidine-3-carbonyl)-hexanoic acid tert-butyl ester 18
[0348] Sodium bis(trimethylsilyl)amide (14.4 mL, 0.014 mol of a 1 M solution in THF) was added to a solution of the oxazolidinone 17 (3.37 g, 0.012 mol) in THF (35 mL) at −78° C. After 35 minutes, tert-butyl bromoacetate (3.5 g, 0.018 mol) was added and the solution immediately warmed to −40° C. After 3 hours, the reaction was quenched through the addition of a saturated aqueous solution of ammonium chloride. The resultant two layers were separated and the aqueous phase extracted with ether. The combined organic phases were dried (MgSO 4 ) and concentrated. Flash chromatography (9:1 to 5:1 hexane/ethyl acetate gradient) gave the ester 18 (3.81 g, 82%) as a white solid. 1 H NMR (CDCl 3 ) δ6 7.35 (m, 5H), 5.37 (dd, 1H, J=8.4 and 3.1 Hz), 4.67 (t, 1H, J=8.7 Hz), 4.41 (dt, 1H, J=12.0 and 3.5 Hz), 4.25 (dd, 1H, J=8.68 and 3.1 Hz), 2.65 (dd, 1H, J=16.9 and 12.0 Hz), 2.25 (dd, 1H, J=16.9 and 3.5 Hz), 1.6 (m, 1H), 1.45 (m, 1H), 1.23 (s, 9H), 1.02 (d, 1H, J=6.5 Hz), 0.93 (d, 1H, J=6.7 Hz), 0.80 (d, 1H, J=7.0 Hz). MS, m/z (relative intensity): 429 [M−H+CH 3 CN, 100%], 388 [M−H, 20%].
[0349] (3R,4S)-2-(1,2-Dimethyl-propyl)-succinic acid 4-tert-butyl ester 19
[0350] To the oxazolidinone 18 (3.62 g, 9.3 mmol) in THF (54 mL)/water (15 mL) was added a premixed solution of lithium hydroxide (20 mL of a 0.8 M aqueous solution, 0.016 mol)/H 2 O 2 (5.76 mL of a 30% aqueous solution). After 7 hours, the solution was diluted with water and sodium bisulfite added (˜10 g). After stirring for a further 0.5 hours, the two layers were separated and the aqueous phase extracted with ether. The aqueous phase was then rendered acidic (pH 2) with 1 M hydrochloric acid and extracted with ether. The combined organic phases were dried (MgSO 4 ) and concentrated. Flash chromatography (5:1 hexane/ethyl acetate) gave the acid 19 (2.1 g, 95%) as a colorless oil. 1 H NMR (CDCl 3 ) δ3.0 (m, 1H), 2.55 (dd, 1H, J=16.6 and 11.2 Hz), 2.27 (dd, 1H, J=16.6 and 3.4 Hz), 1.70 (m, 1H), 1.53 (m, 1H), 1.45 (m, 1H), 1.43 (s, 9H), 0.95 (d, 1H, J=6.8 Hz), 0.90 (d, 1H, J=6.6 Hz), 0.83 (d, 1H, J=6.8 Hz). MS, m/z (relative intensity): 243 [M−H, 100%].
[0351] (3R,4S)-3-Hydroxymethyl-4,5-dimethyl-hexanoic acid tert-butyl ester 20
[0352] Borane-methyl sulfide complex (16 mL, 0.032 mol of a 2 M solution in THF) was added to a stirred solution of the acid 19 (1.96 g, 8 mmol) in THF (20 mL) at 0° C. After 20 hours, methanol was added until effervescence ceased and the solution concentrated. Flash chromatography (5:1 hexane/ethyl acetate gradient) gave the alcohol 20 (1.29 g, 70%) as a colorless oil. 1 H NMR (CDCl 3 ) δ3.62 (m, 1H), 2.32 (m, 1H), 2.14 (m, 1H), 1.6 (m, 1H), 1.45 (s, 9H), 1.35 (m, 1H), 0.93 (d, 1H, J=6.8 Hz), 0.86 (d, 1H, J=6.8 Hz), 0.77 (d, 1H, J=6.9 Hz). MS, m/z (relative intensity): 175 [M-tBu, 100%].
[0353] (3R,4S)-4,5-Dimethyl-3-(toluene-4-sulfonyloxymethyl)-hexanoic acid tert-butyl ester 21
[0354] p-Toluenesulfonyl chloride (847 mg, 4.4 mmol) was added to a stirred solution of the alcohol 6 (850 mg, 3.7 mmol), DMAP (10 mg, 0.08 mmol) and triethylamine (1.23 mL, 8.88 mmol) in CH 2 Cl 2 (20 mL) at 0° C. and the solution warmed to room temperature. After 15 hours, the solution was washed with 1N hydrochloric acid then with brine. The combined organic phases were dried (MgSO 4 ) and concentrated. Flash chromatography (100 to 92% hexane/ethyl acetate gradient) gave the tosylate 7 (1.22 g, 86%) as a thick gum. 1 H NMR (CDCl 3 ) δ7.80 (d, 2H, J=8.2 Hz), 7.25 (d, 2H, J=8.2 Hz), 3.92 (m, 1H), 2.38 (s, 3H), 2.20 (m, 2H), 1.95 (m, 1H), 1.40 (m, 1H), 1.32 (s, 9H), 1.27 (m, 1H), 0.78 (d, 1H, J=6.6 Hz), 0.73 (d, 1H, J=6.6 Hz), 0.63 (d, 1H, J=7.1 Hz). MS, m/z (relative intensity): 311 [85%], 198[100%], 157[95%].
[0355] (3R,4S)-3-Azidomethyl-4,5-dimethyl-hexanoic acid tert-butyl ester 22
[0356] A solution of the tosylate 21 (1.19 g, 3.1 mmol) and sodium azide (402 mg, 6.2 mmol) in DMSO (15 mL) was warmed to 60° C. for 2.5 hours. Water (100 mL) was added and the solution extracted with ether. The combined organic phases were dried (MgSO 4 ) and concentrated. Flash chromatography (9:1 hexane/ethyl acetate) gave the azide 22 (628 mg, 80%) as a colorless oil. 1 H NMR (CDCl 3 ) δ3.4 (dd, 1H, J=12.21 and 6.11 Hz), 3.3 (dd, 1H, J=21.11 and 6.59 Hz), 2.30 (dd, 1H, J=15.14 and 3.66 Hz), 2.25 (m, 1H), 2.05 (dd, 1H, J=15.14 and 9.04 Hz), 1.55 (m, 1H), 1.45 (s, 9H), 1.35 (m, 1H), 0.95 (d, 1H, J=6.59 Hz), 0.90 (d, 1H, J=6.83 Hz), 0.80 (d, 1H, J=7.08 Hz). MS (m/z): (relative intensity): 228[M−N 2 , 35%], 172[M−N 2 -tBu, 100%].
[0357] (3R,4S)-3-Aminomethyl-4,5-dimethyl-hexanoic acid tert-butyl ester 23 and [4R-[4R*(S*)]]-4-(1,2-Dimethyl-propyl)-pyrrolidin-2-one 24
[0358] The azide 8 (640 mg, 2.5 mmol) and Raney nickel (1 g) in methanol (50 mL) were shaken under an atmosphere of hydrogen for 4 hours. The solution was filtered and the filtrate concentrated to give a mixture of the amine 23 and lactam 24 which was used without further purification in the next step.
[0359] (3R,4S)-3-Aminomethyl-4,5-dimethyl-hexanoic Acid (Example 2)
[0360] A solution of the amine 23 and lactam 24 (500 mg) in 3 M hydrochloric acid were heated to reflux for 9 hours, then stirred at room temperature for 15 hours. The solution was concentrated and the resultant solid subjected to a sequential purification which involved ion exchange chromatography (Dowex 50WX8, strongly acidic), oxalate salt formation then further purification by ion exchange chromatography (Dowex 50WX8, strongly acidic) to give the Example 2 (343 mg) as a white solid. 1 H NMR (D 2 O) δ2.87 (m, 2H), 2.22 (dd, 1H, J=15.4 and 3.4 Hz), 2.12 (m, 1H), 1.93 (dd, 1H, J=15.4 and 9.5 Hz), 1.38 (m, 1H), 1.12 (m, 1H), 0.77 (d, 1H, J=6.6 Hz), 0.74 (d, 1H, J=6.6 Hz), 0.70 (d, 1H, J=6.8 Hz). MS, m/z (relative intensity): 174 [M+H, 100%].
[0361] In a similar way, the following examples can be prepared:
[0362] 3-Aminomethyl-4,5-dimethyl-hexanoic acid;
[0363] (3R,4S)-3-Aminomethyl-4,5-dimethyl-hexanoic acid MP;
[0364] (3S,4S)-3-Aminomethyl-4,5-dimethyl-hexanoic acid;
[0365] (3R,4R)-3-Aminomethyl-4,5-dimethyl-hexanoic acid MP:
[0366] 3-Aminomethyl-4-isopropyl-hexanoic acid;
[0367] 3-Aminomethyl-4-isopropyl-heptanoic acid;
[0368] 3-Aminomethyl-4-isopropyl-octanoic acid;
[0369] 3-Aminomethyl-4-isopropyl-nonanoic acid;
[0370] 3-Aminomethyl-4-isopropyl-decanoic acid; and
[0371] 3-Aminomethyl-4-phenyl-5-methyl-hexanoic acid.
[0372] Method 3
[0373] A compound of structure 30 could be prepared from a compound of structure 29 by treatment with an aqueous acid such as hydrochloric acid and alike at a temperature between room temperature and reflux. As an alternative, a compound of structure 30 can be prepared from a compound of structure 32 by treatment with trifluoroacetic acid in a solvent such as CH 2 Cl 2 or EtOAc and alike. Compound 32 could be prepared by base mediate hydrolysis of a Boc protected lactam such as compound 31 which itself could be prepared from a compound of structure 29 by treatment with di-tert-butyl dicarbonate in a solvent such as THF and alike. The treatment of the Boc-lactam 31 with aqueous sodium hydroxide for example would give rise to the acid 32.
[0374] A compound of structure 29 could be prepared from compound of structure 28 (n=0) by treatment with sodium or lithium metal in ammonia. Preferably, the reaction is carried out with sodium metal in ammonia. Alternatively, a compound of structure 29 could be prepared from compound of structure 28 (n=1 or 2) by treatment with ceric ammonium nitrate in a mixture of acetonitrile and water. Other methods known in the literature for the removal of substituted alkoxy benzyl groups from nitrogen are described in Green, Protective Groups in Organic Synthesis, Wiley, 2 ed, 1991 and could be utilized.
[0375] A compound of structure 28 could be prepared from a compound of structure 27 (where LG is a suitable leaving group such as a halide or an alkyl sulphonate, preferably an iodide would be used) by carbon-carbon bond forming reactions known in the art. Several methods exist in the literature for the coupling of organohalides or organoalkyl sulphonates with organometallic reagents in the presence of various metal salts as summarized in Comprehensive Organic Synthesis, volume 3:413 which could be utilized. For example, a compound of structure 28 could be prepared from a compound of structure 27 (where LG is iodide) by treatment with a suitable secondary halide (chloride or iodide) in the presence of magnesium metal, iodine and copper bromide dimethylsulphide in a solvent such as tetrahydrofaran and alike. Alternatively the method according to El Marini, Synthesis, 1992:1104 could be used. Hence, a compound of structure 28 could be prepared from a compound of structure 27 (where LG is iodide) by treatment with suitable methyl-substituted secondary halide such as an iodide in the presence of magnesium, iodine and lithium tetrachlorocuprate in a solvent such as tetrahydrofuran and alike.
[0376] A compound of structure 27 incorporates a suitable leaving group, which would undergo nucleophilic substitution with suitable nucleophile. Examples of such leaving groups include halides such as chloride, bromide, or iodide, and sulphonic esters such as mesylate, tosylate, triflate, nosylate, and alike. A compound of structure 27 (where LG=iodide) could be prepared from a compound of structure 26 through treatment with iodine, triphenylphosphine, and imidazole in a solvent such as toluene and alike.
[0377] A compound of structure 26 could be prepared from compound of structure 25 by treatment with a metal borohydride, such as sodium borohydride in a solvent such as tetrahydrofuran or DME and alike.
[0378] Compound 25 could be prepared in a similar fashion to the procedures of Zoretic et al, J. Org. Chem., 1980;45:810-814 or Nielsen et al J. Med. Chem., 1990;33:71-77 using an appropriate benzylamine, such as but not limited to benzylamine, 4-methoxybenzylamine or 2,4-dimethoxybenzylamine.
[0379] As an alternative approach, a compound of structure 26 could be treated with sodium metal and ammonia to give 4-hydroxymethyl-pyrrolidinone which could be iodinated affording 4-iodomethyl-pyrrolidinone. 4-iodomethyl-pyrrolidinone could then be coupled with organometallic reagents according to the above procedures avoiding protection of the lactam nitrogen as below.
[0380] Analogous to the above methods a lactam of structure 33 (see Nielsen et. al., J. Med. Chem., 1990;33:71-77 for general method of preparation) could be employed thus establishing fixed stereochemistry at C3 of the final amino acids.
[0381] Compounds which could be prepared in this manner include:
[0382] 3-Aminomethyl-5-methyl-6-phenyl-hexanoic acid;
[0383] 3-Aminomethyl-6-(4-chloro-phenyl)-5-methyl-hexanoic acid;
[0384] 3-Aminomethyl-6-(3-chloro-phenyl)-5-methyl-hexanoic acid;
[0385] 3-Aminomethyl-6-(2-chloro-phenyl)-5-methyl-hexanoic acid;
[0386] 3-Aminomethyl-6-(4-fluoro-phenyl)-5-methyl-hexanoic acid;
[0387] 3-Aminomethyl-6-(3-fluoro-phenyl)-5-methyl-hexanoic acid;
[0388] 3-Aminomethyl-6-(2-fluoro-phenyl)-5-methyl-hexanoic acid;
[0389] 3-Aminomethyl-5-methyl-7-phenyl-heptanoic acid;
[0390] 3-Aminomethyl-7-(4-chloro-phenyl)-5-methyl-heptanoic acid;
[0391] 3-Aminomethyl-7-(3-chloro-phenyl)-5-methyl-heptanoic acid;
[0392] 3-Aminomethyl-7-(2-chloro-phenyl)-5-methyl-heptanoic acid;
[0393] 3-Aminomethyl-7-(4-fluoro-phenyl)-5-methyl-heptanoic acid;
[0394] 3-Aminomethyl-7-(3-fluoro-phenyl)-5-methyl-heptanoic acid;
[0395] 3-Aminomethyl-7-(2-fluoro-phenyl)-5-methyl-heptanoic acid;
[0396] (3S)-3-Aminomethyl-6-cyclopropyl-5-methyl-hexanoic acid;
[0397] (3S)-3-Aminomethyl-6-cyclobutyl-5-methyl-hexanoic acid;
[0398] (3S)-3-Aminomethyl-6-cyclopentyl-5-methyl-hexanoic acid;
[0399] (3S)-3-Aminomethyl-6-cyclohexyl-5-methyl-hexanoic acid;
[0400] (3S)-3-Aminomethyl-7-cyclopropyl-5-methyl-heptanoic acid;
[0401] (3S)-3-Aminomethyl-7-cyclobutyl-5-methyl-heptanoic acid;
[0402] (3S)-3-Aminomethyl-7-cyclopentyl-5-methyl-heptanoic acid;
[0403] (3S)-3-Aminomethyl-7-cyclohexyl-5-methyl-heptanoic acid;
[0404] (3S)-3-Aminomethyl-8-cyclopropyl-5-methyl-octanoic acid;
[0405] (3S)-3-Aminomethyl-8-cyclobutyl-5-methyl-octanoic acid;
[0406] (3S)-3-Aminomethyl-8-cyclopentyl-5-methyl-octanoic acid;
[0407] (3S)-3-Aminomethyl-8-cyclohexyl-5-methyl-octanoic acid;
[0408] (3S)-3-Aminomethyl-5-methyl-heptanoic acid;
[0409] (3S)-3-Aminomethyl-5-methyl-octanoic acid;
[0410] (3S)-3-Aminomethyl-5-methyl-nonanoic acid;
[0411] (3S)-3-Aminomethyl-5-methyl-decanoic acid;
[0412] (3S)-3-Aminomethyl-5-methyl-undecanoic acid;
[0413] (3S)-3-Aminomethyl-5,7-dimethyl-octanoic acid;
[0414] (3S)-3-Aminomethyl-5,8-dimethyl-nonanoic acid;
[0415] (3S)-3-Aminomethyl-5,9-dimethyl-decanoic acid;
[0416] (3S)-3-Aminomethyl-5,6-dimethyl-heptanoic acid;
[0417] (3S)-3-Aminomethyl-5,6, 6-trimethyl-heptanoic acid;
[0418] (3S)-3-Aminomethyl-5-cyclopropyl-hexanoic acid;
[0419] (3S)-3-Aminomethyl-6-fluoro-5-methyl-hexanoic acid;
[0420] (3S)-3-Aminomethyl-7-fluoro-5-methyl-heptanoic acid;
[0421] (3S)-3-Aminomethyl-8-fluoro-5-methyl-octanoic acid;
[0422] (3S)-3-Aminomethyl-7,7,7-trifluoro-5-methyl-heptanoic acid;
[0423] (3S)-3-Aminomethyl-8,8,8-trifluoro-5-methyl-octanoic acid;
[0424] (3S)-3-Aminomethyl-5-methyl-hept-6-enoic acid;
[0425] (3S)-3-Aminomethyl-5-methyl-oct-7-enoic acid;
[0426] (3S)-3-Aminomethyl-5-methyl-non-8-enoic acid;
[0427] (E)-(3S)-3-Aminomethyl-5-methyl-oct-6-enoic acid;
[0428] (Z)-(3S)-3-Aminomethyl-5-methyl-oct-6-enoic acid;
[0429] (E)-(3S)-3-Aminomethyl-5-methyl-non-6-enoic acid;
[0430] (Z)-(3S)-3-Aminomethyl-5-methyl-non-6-enoic acid;
[0431] (E)-(3S)-3-Aminomethyl-5-methyl-non-7-enoic acid;
[0432] (Z)-(3S)-3-Aminomethyl-5-methyl-non-7-enoic acid;
[0433] (E)-(3S)-3-Aminomethyl-5-methyl-dec-7-enoic acid;
[0434] (Z)-(3S)-3-Aminomethyl-5-methyl-dec-7-enoic acid;
[0435] 3-Aminomethyl-6-cyclopropyl-5-methyl-hexanoic acid;
[0436] 3-Aminomethyl-6-cyclobutyl-5-methyl-hexanoic acid;
[0437] 3-Aminomethyl-6-cyclopentyl-5-methyl-hexanoic acid;
[0438] 3-Aminomethyl-6-cyclohexyl-5-methyl-hexanoic acid;
[0439] 3-Aminomethyl-7-cyclopropyl-5-methyl-heptanoic acid;
[0440] 3-Aminomethyl-7-cyclobutyl-5-methyl-heptanoic acid;
[0441] 3-Aminomethyl-7-cyclopentyl-5-methyl-heptanoic acid;
[0442] 3-Aminomethyl-7-cyclohexyl-5-methyl-heptanoic acid;
[0443] 3-Aminomethyl-8-cyclopropyl-5-methyl-octanoic acid;
[0444] 3-Aminomethyl-8-cyclobutyl-5-methyl-octanoic acid;
[0445] 3-Aminomethyl-8-cyclopentyl-5-methyl-octanoic acid;
[0446] 3-Aminomethyl-8-cyclohexyl-5-methyl-octanoic acid;
[0447] 3-Aminomethyl-5-methyl-heptanoic acid;
[0448] 3-Aminomethyl-5-methyl-octanoic acid;
[0449] 3-Aminomethyl-5-methyl-nonanoic acid;
[0450] 3-Aminomethyl-5-methyl-decanoic acid;
[0451] 3-Aminomethyl-5-methyl-undecanoic acid;
[0452] 3-Aminomethyl-5,7-dimethyl-octanoic acid;
[0453] 3-Aminomethyl-5,8-dimethyl-nonanoic acid;
[0454] 3-Aminomethyl-5,9-dimethyl-decanoic acid;
[0455] 3-Aminomethyl-5,6-dimethyl-heptanoic acid;
[0456] 3-Aminomethyl-5,6,6-trimethyl-heptanoic acid;
[0457] 3-Aminomethyl-5-cyclopropyl-hexanoic acid;
[0458] 3-Aminomethyl-6-fluoro-5-methyl-hexanoic acid;
[0459] 3-Aminomethyl-7-fluoro-5-methyl-heptanoic acid;
[0460] 3-Aminomethyl-8-fluoro-5-methyl-octanoic acid;
[0461] 3-Aminomethyl-7,7,7-trifluoro-5-methyl-heptanoic acid;
[0462] 3-Aminomethyl-8,8,8-trifluoro-5-methyl-octanoic acid;
[0463] 3-Aminomethyl-5-methyl-hept-6-enoic acid;
[0464] 3-Aminomethyl-5-methyl-oct-7-enoic acid;
[0465] 3-Aminomethyl-5-methyl-non-8-enoic acid;
[0466] (E)-3-Aminomethyl-5-methyl-oct-6-enoic acid;
[0467] (Z)-3-Aminomethyl-5-methyl-oct-6-enoic acid;
[0468] (E)-3-Aminomethyl-5-methyl-non-6-enoic acid;
[0469] (Z)-3-Aminomethyl-5-methyl-non-6-enoic acid;
[0470] (E)-3-Aminomethyl-5-methyl-non-7-enoic acid;
[0471] (Z)-3-Aminomethyl-5-methyl-non-7-enoic acid;
[0472] (E)-3-Aminomethyl-5-methyl-dec-7-enoic acid; and
[0473] (Z)-3-Aminomethyl-5-methyl-dec-7-enoic acid.
[0474] Method 4
[0475] A compound of structure 40 could be prepared from compound of structure 39 through treatment with diethylaminosulphur trifluoride in a solvent such as methylene chloride at a temperature between −78° C. and room temperature. Other method for the fluorination of alcohols are known and could be utilized as exemplified in Wilkinson, Chem. Rev. 1992;92:505-519. Compounds of structure 40 can be converted to the requisite γ-amino acid as described in method 3 above.
[0476] A compound of structure 39 could be prepared from compound of structure 38 through treatment with osmium tetroxide and sodium periodate in a solvent such as THF and water and reduction of the resultant intermediate with sodium borohydride in a solvent such as ethanol.
[0477] Compounds of structures 38 and 34 could be prepared from compound of structure 33 according to the principles described in method 3.
[0478] An alternative procedure for the synthesis of alcohol 39 (n=0) involves the treatment of a compound of structure 36 with a metal borohydride, such as sodium borohydride in a solvent such as tetrahydrofuran or DME and alike to give a compound of structure 37, the fluorination of which could be achived in a similar manner to the preparation of a compound of strucutre 40. A compound of structure 36 could be prepared from compound of structure 35 through treatment with sodium or lithium chloride in aqueous DMSO at a temperature between room temperature and reflux. Preferably the reaction is carried out using sodium chloride in aqueous DMSO at reflux. A compound of structure 35 could be prepared from compound of structure 34 through treatment with a suitable methyl malonic acid diester, such as dimethyl methylmalonate and alike with sodium hydride in a solvent such as DMSO or THF and alike. Preferably the reaction is carried out by adding NaH to a solution of dimethyl methylmalonate in DMSO followed by the addition of the lactam 34 (where LG is preferably iodide or as defined in method 3) pre-dissolved in DMSO.
[0479] Compounds 39 and 37 can be converted to the free amino acids bearing a hydroxyl group by the methods described above.
[0480] The following compounds could be prepared in this manner:
[0481] (3S)-3-Aminomethyl-6-fluoro-5-methyl-hexanoic acid;
[0482] (3S)-3-Aminomethyl-6-fluoro-5-methyl-hexanoic acid;
[0483] (3S)-3-Aminomethyl-7-fluoro-5-methyl-heptanoic acid;
[0484] (3S)-3-Aminomethyl-8-fluoro-5-methyl-octanoic acid;
[0485] (3S)-3-Aminomethyl-9-fluoro-5-methyl-nonanoic acid;
[0486] (3S)-3-Aminomethyl-7-hydroxy-5-methyl-heptanoic acid; and
[0487] (3S)-3-Aminomethyl-6-hydroxy-5-methyl-hexanoic acid.
[0488] Method 5
[0489] A compound of structure 41 could be prepared from compound of structure 39 through treatment with a suitable alkyl iodide (or alkyl sulphonate), such as methyl iodide and alike, and a base such as n-butyl lithium or sodium hydride and alike, in a solvent such as DMSO or THF and alike. Preferably the reaction is carried out by adding NaH to a solution of the alcohol in DMSO followed by the addition of the alkyl iodide and heating of the reaction mixture at a temperature between room temperature and reflux. The conversion of compounds of structure 41 to the γ-amino acids has been described above.
[0490] Alternatively, compounds of structure 41 could be derived from compounds of structure 42 (where LG=iodide, bromide or an sulphonic acid ester, as exampled in method 3) by treatment of an appropriate alkoxy anion in a solvent such as DMSO or THF and alike. A compound of structure 42would also serve as a substrate for carbon-carbon bond forming procedures as outlined in method 3.
[0491] Compounds which could be prepared in this manner include:
[0492] (3S)-3-Aminomethyl-7-hydroxy-5-methyl-heptanoic acid;
[0493] (3S)-3-Aminomethyl-7-methoxy-5-methyl-heptanoic acid;
[0494] (3S)-3-Aminomethyl-7-ethoxy-5-methyl-heptanoic acid;
[0495] (3S)-3-Aminomethyl-5-methyl-7-propoxy-heptanoic acid;
[0496] (3S)-3-Aminomethyl-7-fluoromethoxy-5-methyl-heptanoic acid;
[0497] (3S)-3-Aminomethyl-7-(2-fluoro-ethoxy)-5-methyl-heptanoic acid;
[0498] (3S)-3-Aminomethyl-5-methyl-7-(3,3,3-trifluoro-propoxy)-heptanoic acid;
[0499] (3S)-3-Aminomethyl-6-hydroxy-5-methyl-hexanoic acid;
[0500] (3S)-3-Aminomethyl-6-methoxy-5-methyl-hexanoic acid;
[0501] (3S)-3-Aminomethyl-6-ethoxy-5-methyl-hexanoic acid;
[0502] (3S)-3-Aminomethyl-5-methyl-6-propoxy-hexanoic acid;
[0503] (3S)-3-Aminomethyl-6-fluoromethoxy-5-methyl-hexanoic acid;
[0504] (3S)-3-Aminomethyl-6-(2-fluoro-ethoxy)-5-methyl-hexanoic acid; and
[0505] (3S)-3-Aminomethyl-5-methyl-6-(3,3,3-trifluoro-propoxy)-hexanoic acid.
[0506] Method 6
[0507] Compounds of structure 53 could be prepared from a compound of structure 45 as shown above and by the general procedures described in 5 Hoekstra et. al., Organic Process Research and Development, 1997;1:26-38.
[0508] Compounds of structure 45 can be prepared from compounds of structure 44 by treatment with a solution of chromium trioxide in water/sulfuric acid. Alternative methods of cleaving the olefin in 44 could be utilized as detailed in Hudlicky, Oxidations in Organic Chemistry, ACS Monograph 186, ACS 10 1990:77.
[0509] Compounds of structure 44 (where R 2 =alkyl, branched alkyl, cycloalkyl, alkyl-cycloalkyl) could be prepared from (S)-citronellyl bromide by carbon-carbon bond forming reactions known in the art and as described in method 3. The substitution of the halide in (S)-citronellyl bromide with alkoxy anions could also be used to provide compounds of structure 44 where R=alkoxy or phenoxy ethers (and appropriate substitutions thereof as according to Formula 1). Alternatively (S)-citronellol could be utilized to afford compounds of structure 44 by treatment of (S)-citronellol with a base such as sodium hydride, and treatment of the resultant alkoxide with an appropriate alkyl halide to afford ethers. In another method (S)-citronellyl bromide (or an appropriate sulphonic ester such as, but not limited to, methanesulfonic acid (S)-3,7-dimethyl-oct-6-enyl ester) could be reduced with an appropriate metal borohydride or with an aluminum hydride species, such as LAH, to provide (R)-2,6-dimethyl-oct-2-ene.
[0510] To one skilled in the art it will be appreciated that rational choice of either R- or S-citronellol or R- or S-citronellyl bromide would give rise to the requisite isomer at C5 of the final amino acid.
[0511] Compounds which could be prepared in this manner include:
[0512] (3S,5S)-3-Aminomethyl-7-methoxy-5-methyl-heptanoic acid;
[0513] (3S,5S)-3-Aminomethyl-7-ethoxy-5-methyl-heptanoic acid;
[0514] (3S,5S)-3-Aminomethyl-5-methyl-7-propoxy-heptanoic acid;
[0515] (3S,5S)-3-Aminomethyl-7-isopropoxy-5-methyl-heptanoic acid;
[0516] (3S,5S)-3-Aminomethyl-7-tert-butoxy-5-methyl-heptanoic acid;
[0517] (3S,5S)-3-Aminomethyl-7-fluoromethoxy-5-methyl-heptanoic acid;
[0518] (3S,5S)-3-Aminomethyl-7-(2-fluoro-ethoxy)-5-methyl-heptanoic acid;
[0519] (3S,5S)-3-Aminomethyl-5-methyl-7-(3,3,3-trifluoro-propoxy)-heptanoic acid;
[0520] (3S,5S)-3-Aminomethyl-7-benzyloxy-5-methyl-heptanoic acid;
[0521] (3S,5S)-3-Aminomethyl-5-methyl-7-phenoxy-heptanoic acid;
[0522] (3S,5S)-3-Aminomethyl-7-(4-chloro-phenoxy)-5-methyl-heptanoic acid;
[0523] (3S,5S)-3-Aminomethyl-7-(3-chloro-phenoxy)-5-methyl-heptanoic acid;
[0524] (3S,5S)-3-Aminomethyl-7-(2-chloro-phenoxy)-5-methyl-heptanoic acid;
[0525] (3S,5S)-3-Aminomethyl-7-(4-fluoro-phenoxy)-5-methyl-heptanoic acid;
[0526] (3S,5S)-3-Aminomethyl-7-(3-fluoro-phenoxy)-5-methyl-heptanoic acid;
[0527] (3S,5 S)-3-Aminomethyl-7-(2-fluoro-phenoxy)-5-methyl-heptanoic acid;
[0528] (3S,5 S)-3-Aminomethyl-7-(4-methoxy-phenoxy)-5-methyl-heptanoic acid;
[0529] (3S,5 S)-3-Aminomethyl-7-(3-methoxy -phenoxy)-5-methyl-heptanoic acid;
[0530] (3S,5 S)-3-Aminomethyl-7-(2-methoxy -phenoxy)-5-methyl-heptanoic acid;
[0531] (3S,5 S)-3-Aminomethyl-5-methyl-7-(4-trifluoromethyl-phenoxy)-heptanoic acid;
[0532] (3S,5S)-3-Aminomethyl-5-methyl-7-(3-trifluoromethyl-phenoxy)-heptanoic acid;
[0533] (3S,5 S)-3-Aminomethyl-5-methyl-7-(2-trifluoromethyl-phenoxy)-heptanoic acid;
[0534] (3S,5S)-3-Aminomethyl-5-methyl-7-(4-nitro-phenoxy)-heptanoic acid;
[0535] (3S,5S)-3-Aminomethyl-5-methyl-7-(3-nitro-phenoxy)-heptanoic acid;
[0536] (3S,5S)-3-Aminomethyl-5-methyl-7-(2-nitro-phenoxy)-heptanoic acid;
[0537] (3S,5R)-3-Aminomethyl-7-cyclopropyl-5-methyl-heptanoic acid;
[0538] (3S,5R)-3-Aminomethyl-7-cyclobutyl-5-methyl-heptanoic acid;
[0539] (3S,5R)-3-Aminomethyl-7-cyclopentyl-5-methyl-heptanoic acid;
[0540] (3S,5R)-3-Aminomethyl-7-cyclohexyl-5-methyl-heptanoic acid;
[0541] (3S,5R)-3-Aminomethyl-8-cyclopropyl-5-methyl-octanoic acid;
[0542] (3S,5R)-3-Aminomethyl-8-cyclobutyl-5-methyl-octanoic acid;
[0543] (3S,5R)-3-Aminomethyl-8-cyclopentyl-5-methyl-octanoic acid;
[0544] (3S,5R)-3-Aminomethyl-8-cyclohexyl-5-methyl-octanoic acid;
[0545] (3S,5R)-3-Aminomethyl-5-methyl-heptanoic acid;
[0546] (3S,5R)-3-Aminomethyl-5-methyl-octanoic acid;
[0547] (3S,5R)-3-Aminomethyl-5-methyl-nonanoic acid;
[0548] (3S,5R)-3-Aminomethyl-5-methyl-decanoic acid;
[0549] (3S,5R)-3-Aminomethyl-5-methyl-undecanoic acid;
[0550] (3S,5R)-3-Aminomethyl-5 ,9-dimethyl-decanoic acid;
[0551] (3S,5R)-3-Aminomethyl-5,8-dimethyl-nonanoic acid;
[0552] (3S,5S)-3-Aminomethyl-7-fluoro-5-methyl-heptanoic acid;
[0553] (3S,5R)-3-Aminomethyl-8-fluoro-5-methyl-octanoic acid;
[0554] (3S,5R)-3-Aminomethyl-8,8,8-trifluoro-5-methyl-octanoic acid;
[0555] (3S,5R)-3-Aminomethyl-5-methyl-7-phenyl-heptanoic acid;
[0556] (3S,5R)-3-Aminomethyl-7-(4-chloro-phenyl)-5-methyl-heptanoic acid;
[0557] (3S,5R)-3-Aminomethyl-7-(3-chloro-phenyl)-5-methyl-heptanoic acid;
[0558] (3S,5R)-3-Aminomethyl-7-(2-chloro-phenyl)-5-methyl-heptanoic acid;
[0559] (3S,5R)-3-Aminomethyl-7-(4-methoxy-phenyl)-5-methyl-heptanoic acid;
[0560] (3S,5R)-3-Aminomethyl-7-(3-methoxy-phenyl)-5-methyl-heptanoic acid;
[0561] (3S,5R)-3-Aminomethyl-7-(2-methoxy-phenyl)-5-methyl-heptanoic acid;
[0562] (3S,5R)-3-Aminomethyl-7-(4-fluoro-phenyl)-5-methyl-heptanoic acid;
[0563] (3S,5R)-3-Aminomethyl-7-(3-fluoro-phenyl)-5-methyl-heptanoic acid;
[0564] (3S,5R)-3-Aminomethyl-7-(2-fluoro-phenyl)-5-methyl-heptanoic acid; and
[0565] (3S,5R)-3-Aminomethyl-5,10-dimethyl-undecanoic acid.
[0566] Method 7
[0567] A compound of structure 58 can be prepared from a compound of structure 57 by treatment with borontrifluoride diethyletherate and triethylsilane in a solvent such as CH 2 Cl 2 . Alternatively the method described in Meyers, J. Org. Chem., 1993;58:36-42, could be utilized thus treating a compound of structure 57 with sodium cyanoborohydride in a solvent such as THF/methanol with 3% HCl in methanol.
[0568] A compound of structure 57 can be prepared from a compound of structure 56 by treatment with dimethylamine in a solvent such as DMF and alike according to the procedure of Koot, Tetrahedron Lett., 1992;33:7969-7972.
[0569] A compound of structure 56 can be prepared from a compound of structure 54 by treatment of a suitable primary halide 55 (iodide, bromide, or chloride) under standard transmetallation conditions with tBuLi and treatment of the resultant organometallic reagent with suitable copper salt, such as but not limited to, copper bromide or copper iodide. The resultant organo-cuprate is added to lactam (see Koot et al, J. Org. Chem., 1992;57:1059-1061 for the preparation of the chiral lactam 54) in a solvent such as THF and alike. The procedure of Koot, Tetrahedron Lett., 1992;33:7969-7972 exemplifies this method.
[0570] To one skilled in the art it will be appreciated that rational choice of either R- or S-primary halides 55 would give rise to the requisite isomer at C5 of the final amino acid.
[0571] Compounds which could be prepared in this manner include:
[0572] (3S,5S)-3-Aminomethyl-5-methoxy-hexanoic acid;
[0573] (3S,5S)-3-Aminomethyl-5-ethoxy-hexanoic acid;
[0574] (3S,5S)-3-Aminomethyl-5-propoxy-hexanoic acid;
[0575] (3S,5S)-3-Aminomethyl-5-isopropoxy-hexanoic acid;
[0576] (3S,5S)-3-Aminomethyl-5-tert-butoxy-hexanoic acid;
[0577] (3S,5S)-3-Aminomethyl-5-fluoromethoxy-hexanoic acid;
[0578] (3S,5S)-3-Aminomethyl-5-(2-fluoro-ethoxy)-hexanoic acid;
[0579] (3S,5S)-3-Aminomethyl-5-(3,3,3-trifluoro-propoxy)-hexanoic acid;
[0580] (3S,5S)-3-Aminomethyl-5-phenoxy-hexanoic acid;
[0581] (3S,5S)-3-Aminomethyl-5-(4-chloro-phenoxy)-hexanoic acid;
[0582] (3S,5S)-3-Aminomethyl-5-(3-chloro-phenoxy)-hexanoic acid;
[0583] (3S,5S)-3-Aminomethyl-5-(2-chloro-phenoxy)-hexanoic acid;
[0584] (3S,5S)-3-Aminomethyl-5-(4-fluoro-phenoxy)-hexanoic acid;
[0585] (3S,5S)-3-Aminomethyl-5-(3-fluoro-phenoxy)-hexanoic acid;
[0586] (3S,5S)-3-Aminomethyl-5-(2-fluoro-phenoxy)-hexanoic acid;
[0587] (3S,5S)-3-Aminomethyl-5-(4-methoxy-phenoxy)-hexanoic acid;
[0588] (3S,5S)-3-Aminomethyl-5-(3-methoxy-phenoxy)-hexanoic acid;
[0589] (3S,5S)-3-Aminomethyl-5-(2-methoxy-phenoxy)-hexanoic acid;
[0590] (3S,5S)-3-Aminomethyl-5-(4-nitro-phenoxy)-hexanoic acid;
[0591] (3S,5S)-3-Aminomethyl-5-(3-nitro-phenoxy)-hexanoic acid;
[0592] (3S,5S)-3-Aminomethyl-5-(2-nitro-phenoxy)-hexanoic acid;
[0593] (3S,5S)-3-Aminomethyl-6-methoxy-5-methyl-hexanoic acid;
[0594] (3S,5S)-3-Aminomethyl-6-ethoxy-5-methyl-hexanoic acid;
[0595] (3S,5S)-3-Aminomethyl-5-methyl-6-propoxy-hexanoic acid;
[0596] (3S,5S)-3-Aminomethyl-6-isopropoxy-5-methyl-hexanoic acid;
[0597] (3S,5S)-3-Aminomethyl-6-tert-butoxy-5-methyl-hexanoic acid;
[0598] (3S,5S)-3-Aminomethyl-6-fluoromethoxy-5-methyl-hexanoic acid;
[0599] (3S,5S)-3-Aminomethyl-6-(2-fluoro-ethoxy)-5-methyl-hexanoic acid;
[0600] (3S,5S)-3-Aminomethyl-5-methyl-6-(3,3,3-trifluoro-propoxy)-hexanoic acid;
[0601] (3S,5S)-3-Aminomethyl-5-methyl-6-phenoxy-hexanoic acid;
[0602] (3S,5S)-3-Aminomethyl-6-(4-chloro-phenoxy)-5-methyl-hexanoic acid;
[0603] (3S,5S)-3-Aminomethyl-6-(3-chloro-phenoxy)-5-methyl-hexanoic acid;
[0604] (3S,5S)-3-Aminomethyl-6-(2-chloro-phenoxy)-5-methyl-hexanoic acid;
[0605] (3S,5S)-3-Aminomethyl-6-(4-fluoro-phenoxy)-5-methyl-hexanoic acid;
[0606] (3S,5S)-3-Aminomethyl-6-(3-fluoro-phenoxy)-5-methyl-hexanoic acid;
[0607] (3S,5S)-3-Aminomethyl-6-(2-fluoro-phenoxy)-5-methyl-hexanoic acid;
[0608] (3S,5S)-3-Aminomethyl-6-(4-methoxy-phenoxy)-5-methyl-hexanoic acid;
[0609] (3S,5S)-3-Aminomethyl-6-(3-methoxy-phenoxy)-5-methyl-hexanoic acid;
[0610] (3S ,5S)-3-Aminomethyl-6-(2-methoxy-phenoxy)-5-methyl-hexanoic acid;
[0611] (3S,5S)-3-Aminomethyl-5-methyl 6-(4-trifluoromethyl-phenoxy)-hexanoic acid;
[0612] (3S,5S)-3-Aminomethyl-5-methyl 6-(3-trifluoromethyl-phenoxy)-hexanoic acid;
[0613] (3S,5S)-3-Aminomethyl-5-methyl 6-(2-trifluoromethyl-phenoxy)-hexanoic acid;
[0614] (3S,5S)-3-Aminomethyl-5-methyl 6-(4-nitro-phenoxy)-hexanoic acid;
[0615] (3S,5S)-3-Aminomethyl-5-methyl 6-(3-nitro-phenoxy)-hexanoic acid;
[0616] (3S,5S)-3-Aminomethyl-5-methyl 6-(2-nitro-phenoxy)-hexanoic acid;
[0617] (3S,5S)-3-Aminomethyl-6-benzyloxy-5-methyl-hexanoic acid;
[0618] (3S,5R)-3-Aminomethyl-6-cyclopropyl-5-methyl-hexanoic acid;
[0619] (3S,5R)-3-Aminomethyl-6-cyclobutyl-5-methyl-hexanoic acid;
[0620] (3S,5R)-3-Aminomethyl-6-cyclopentyl-5-methyl-hexanoic acid;
[0621] (3S,5R)-3-Aminomethyl-6-cyclohexyl-5-methyl-hexanoic acid;
[0622] (3S,5R)-3-Aminomethyl-5-methyl-heptanoic acid;
[0623] (3S,5R)-3-Aminomethyl-5-methyl-octanoic acid;
[0624] (3S,5R)-3-Aminomethyl-5-methyl-nonanoic acid;
[0625] (3S,5R)-3-Aminomethyl-5-methyl-decanoic acid;
[0626] (3S,5R)-3-Aminomethyl-5-methyl-undecanoic acid;
[0627] (3S,5R)-3-Aminomethyl-5-methyl-dodecanoic acid;
[0628] (3S,5R)-3-Aminomethyl-5,7-dimethyl-octanoic acid;
[0629] (3S,5R)-3-Aminomethyl-5,8-dimethyl-nonanoic acid;
[0630] (3S,5R)-3-Aminomethyl-5,9-dimethyl-decanoic acid;
[0631] (3S,5R)-3-Aminomethyl-5,10-dimethyl-undecanoic acid;
[0632] (3S,5S)-3-Aminomethyl-5,6-dimethyl-heptanoic acid;
[0633] (3S,5S)-3-Aminomethyl-5,6,6-trimethyl-heptanoic acid;
[0634] (3S,5S)-3-Aminomethyl-5-cyclopropyl-hexanoic acid;
[0635] (3S,5S)-3-Aminomethyl-6-fluoro-5-methyl-hexanoic acid;
[0636] (3S,5S)-3-Aminomethyl-7-fluoro-5-methyl-heptanoic acid;
[0637] (3S,5R)-3-Aminomethyl-8-fluoro-5-methyl-octanoic acid;
[0638] (3S,5S)-3-Aminomethyl-7,7,7-trifluoro-5-methyl-heptanoic acid;
[0639] (3S,5R)-3-Aminomethyl-8,8,8-trifluoro-5-methyl-octanoic acid;
[0640] (3S,5S)-3-Aminomethyl-5-methyl-6-phenyl-hexanoic acid;
[0641] (3S,5S)-3-Aminomethyl-6-(4-chloro-phenyl)-5-methyl-hexanoic acid;
[0642] (3S,5S)-3-Aminomethyl-6-(3-chloro-phenyl)-5-methyl-hexanoic acid;
[0643] (3S,5S)-3-Aminomethyl-6-(2-chloro-phenyl)-5-methyl-hexanoic acid;
[0644] (3S,5S)-3-Aminomethyl-6-(4-methoxy-phenyl)-5-methyl-hexanoic acid;
[0645] (3S,5S)-3-Aminomethyl-6-(3-methoxy-phenyl)-5-methyl-hexanoic acid;
[0646] (3S,5S)-3-Aminomethyl-6-(2-methoxy-phenyl)-5-methyl-hexanoic acid;
[0647] (3S,5S)-3-Aminomethyl-6-(4-fluoro-phenyl)-5-methyl-hexanoic acid;
[0648] (3S,5S)-3-Aminomethyl-6-(3-fluoro-phenyl)-5-methyl-hexanoic acid;
[0649] (3S,5S)-3-Aminomethyl-6-(2-fluoro-phenyl)-5-methyl-hexanoic acid;
[0650] (3S,5R)-3-Aminomethyl-5-methyl-7-phenyl-heptanoic acid;
[0651] (3S,5R)-3-Aminomethyl-7-(4-chloro-phenyl)-5-methyl-heptanoic acid;
[0652] (3S,5R)-3-Aminomethyl-7-(3-chloro-phenyl)-5-methyl-heptanoic acid;
[0653] (3S,5R)-3-Aminomethyl-7-(2-chloro-phenyl)-5-methyl-heptanoic acid;
[0654] (3S,5R)-3-Aminomethyl-7-(4-methoxy-phenyl)-5-methyl-heptanoic acid;
[0655] (3S,5R)-3-Aminomethyl-7-(3-methoxy-phenyl)-5-methyl-heptanoic acid;
[0656] (3S,5R)-3-Aminomethyl-7-(2-methoxy-phenyl)-5-methyl-heptanoic acid;
[0657] (3S,5R)-3-Aminomethyl-7-(4-fluoro-phenyl)-5-methyl-heptanoic acid;
[0658] (3S,5R)-3-Aminomethyl-7-(3-fluoro-phenyl)-5-methyl-heptanoic acid;
[0659] (3S,5R)-3-Aminomethyl-7-(2-fluoro-phenyl)-5-methyl-heptanoic acid;
[0660] (3S,5S)-3-Aminomethyl-5-methyl-hept-6-enoic acid;
[0661] (3S,5R)-3-Aminomethyl-5-methyl-oct-7-enoic acid;
[0662] (3S,5R)-3-Aminomethyl-5-methyl-non-8-enoic acid;
[0663] (E)-(3S,5S)-3-Aminomethyl-5-methyl-oct-6-enoic acid;
[0664] (Z)-(3S,5S)-3-Aminomethyl-5-methyl-oct-6-enoic acid;
[0665] (Z)-(3S,5S)-3-Aminomethyl-5-methyl-non-6-enoic acid;
[0666] (E)-(3S,5S)-3-Aminomethyl-5-methyl-non-6-enoic acid;
[0667] (E)-(3S,5R)-3-Aminomethyl-5-methyl-non-7-enoic acid;
[0668] (Z)-(3S,5R)-3-Aminomethyl-5-methyl-non-7-enoic acid;
[0669] (Z)-(3S,5R)-3-Aminomethyl-5-methyl-dec-7-enoic acid; and
[0670] (E)-(3S,5R)-3-Aminomethyl-5-methyl-undec-7-enoic acid.
[0671] Method 8
[0672] A compound of structure 60 can be prepared from a compound of structure 59 through treatment with an appropriately substituted phenol (including phenol itself) under conditions described by Mitsunobu, Synthesis, 1981:1.
[0673] A compound of structure 59 could be prepared from compound of structure 39 by treatment with sodium or lithium metal and alike in ammonia. Preferably, the reaction is carried out with sodium metal in ammonia.
[0674] The direct hydrolysis of compound 60 would give rise to the desired amino acid or the approach via hydrolysis of the Boc protected lactam could be utilized.
[0675] Compounds which could be prepared in this manner include:
[0676] (3S)-3-Aminomethyl-5-methyl-7-phenoxy-heptanoic acid;
[0677] (3S)-3-Aminomethyl-7-(4-chloro-phenoxy)-5-methyl-heptanoic acid;
[0678] (3S)-3-Aminomethyl-7-(3-chloro-phenoxy)-5-methyl-heptanoic acid;
[0679] (3S)-3-Aminomethyl-7-(2-chloro-phenoxy)-5-methyl-heptanoic acid;
[0680] (3S)-3-Aminomethyl-7-(4-fluoro-phenoxy)-5-methyl-heptanoic acid;
[0681] (3S)-3-Aminomethyl-7-(3-fluoro-phenoxy)-5-methyl-heptanoic acid;
[0682] (3S)-3-Aminomethyl-7-(2-fluoro-phenoxy)-5-methyl-heptanoic acid;
[0683] (3S)-3-Aminomethyl-7-(4-methoxy-phenoxy)-5-methyl-heptanoic acid;
[0684] (3S)-3-Aminomethyl-7-(3-methoxy-phenoxy)-5-methyl-heptanoic acid;
[0685] (3S,)-3-Aminomethyl-7-(2-methoxy -phenoxy)-5-methyl-heptanoic acid;
[0686] (3S)-3-Aminomethyl-5-methyl-7-(4-trifluoromethyl-phenoxy)-heptanoic acid;
[0687] (3S)-3-Aminomethyl-5-methyl-7-(3-trifluoromethyl-phenoxy)-heptanoic acid;
[0688] (3S)-3-Aminomethyl-5-methyl-7-(2-trifluoromethyl-phenoxy)-heptanoic acid;
[0689] (3S)-3-Aminomethyl-5-methyl-7-(4-nitro-phenoxy)-heptanoic acid;
[0690] (3S)-3-Aminomethyl-5-methyl-7-(3-nitro-phenoxy)-heptanoic acid;
[0691] (3S)-3-Aminomethyl-5-methyl-7-(2-nitro-phenoxy)-heptanoic acid;
[0692] (3S)-3-Aminomethyl-6-(3-chloro-phenoxy)-5-methyl-hexanoic acid;
[0693] (3S)-3-Aminomethyl-6-(2-chloro-phenoxy)-5-methyl-hexanoic acid;
[0694] (3S)-3-Aminomethyl-6-(4-fluoro-phenoxy)-5-methyl-hexanoic acid;
[0695] (3S)-3-Aminomethyl-6-(3-fluoro-phenoxy)-5-methyl-hexanoic acid;
[0696] (3S)-3-Aminomethyl-6-(2-fluoro-phenoxy)-5-methyl-hexanoic acid;
[0697] (3S)-3-Aminomethyl-6-(4-methoxy-phenoxy)-5-methyl-hexanoic acid;
[0698] (3S)-3-Aminomethyl-6-(3-methoxy-phenoxy)-5-methyl-hexanoic acid;
[0699] (3S)-3-Aminomethyl-6-(2-methoxy-phenoxy)-5-methyl-hexanoic acid;
[0700] (3S)-3-Aminomethyl-5-methyl-6-(4-trifluoromethyl-phenoxy)-hexanoic acid;
[0701] (3S)-3-Aminomethyl-5-methyl-6-(3-trifluoromethyl-phenoxy)-hexanoic acid;
[0702] (3S)-3-Aminomethyl-5-methyl-6-(2-trifluoromethyl-phenoxy)-hexanoic acid;
[0703] (3S)-3-Aminomethyl-5-methyl-6-(4-nitro-phenoxy)-hexanoic acid;
[0704] (3S)-3-Aminomethyl-5-methyl-6-(3-nitro-phenoxy)-hexanoic acid;
[0705] (3S)-3-Aminomethyl-5-methyl-6-(2-nitro-phenoxy)-hexanoic acid;
[0706] (3S)-3-Aminomethyl-5-methyl-6-phenoxy-hexanoic acid; and
[0707] (3S)-3-Aminomethyl-6-(4-chloro-phenoxy)-5-methyl-hexanoic acid.
[0708] Method 9 Synthesis of C-4 Substituted Analogs
[0709] A compound of structure 64 could be prepared from compound of structure 63 by treatment of 63 with hydrogen at 50 psi in the presence of a catalyst such as such as Raney nickel in the presence of a base such as triethyl amine in an organic solvent for example methanol. The resulting product is then treated with an aqueous acid such as 6N HCl at a temperature between room temperature and reflux. The resulting mixture could be subjected to ion exchange chromatography to isolate the product 64.
[0710] A compound of structure 63 can be prepared from a compound of structure 62B by treatment with an appropriate base, such as but not limited too sodium hydride, n-butyl lithium and alike, and an alkylating reagent such as t-butylbromoacetate or benzylbromoacetate in a solvent such as DMSO or THF an alike. Preferably, the reaction is carried out by treating a solution of a compound of structure 62B in THF with sodium hydride and alkylation of the resultant anion with t-butylbromoaceate.
[0711] A compound of structure 62B can be prepared from a compound of structure 62A by treatment with sodium chloride in a solvent such as aqueous DMSO at a temperature between 50° C. and reflux.
[0712] A compound of structure 62A can be prepared from a compound of structure 61 by treatment with an appropriate alkylmetalhalide such as an alkyllithium reagent or an organomagnesium halide in a solvent such as THF or ether in the presence of a copper salt, such as but not limited to copper iodide, copper bromide dimethylsulphide. Alternatively, the reaction may be carried out by the treatment of the nitrile in a solvent such as ether at, or below, room temperature with an alkylmagenisum chloride.
[0713] A compound such as 61 can be prepared according to known literature procedures between the condensation of isobutylaldheyde and methylcyanoacetate.
[0714] Method 10: C-4 Substitution
[0715] Doubly branched 3-substituted GABA analogs 72 can be prepared in two steps from the azide 71 through hydrogenation of the azide 71 in the presence of a noble metal catalyst such as 5% palladium on carbon and hydrolysis of the resulting lactam with a strong acid such as 6 N HCl at reflux. The final product 72 can then be isolated using ion exchange chromatography.
[0716] Compound 71 can be prepared in two steps by treatment of a lactone such as 70 with HBr in a solvent such as ethanol at a temperature such as 0° C. and reacting the resulting bromide with sodium azide in a solvent such as dimethyl sulfoxide at a temperature between 10° C. and 80° C.
[0717] Lactone 70 can be prepared in two steps by oxidation of a compound such as 69 with an oxidant such as sodium periodate in the presence of a catalytic amount of ruthenium trichloride in a solvent such as acetonitrile at a temperature between 0° C. and 100° C. and treatment of the resulting compound with potassium carbonate in methanol followed at a temperature between 25° C. and 70° C. and then treatment with an acid such as p-toluene sulfonic acid in a solvent such as THF at reflux or an aqueous acid such as HCl in water at ambient temperature.
[0718] A compound such as 69 can be prepared by a by reduction of a compound such as 68 with a hydride reducing agent such as lithium aluminum hydride in a solvent such as ether or THF and reaction of the resulting alcohol with an acylating agent such as acetic anhydride in the presence of a base such as triethyl amine or pyridine or the like.
[0719] Compounds of structure 68 can be prepared by reaction of a compound such as 67 with hydrogen at approximately 50 psi in the presence of a noble metal catalyst such as 5% palladium on carbon in a solvent such as ethanol. A compound of the formula 67 can be prepared by reaction of a compound of structure 66 with a solution of ethanol saturated with hydrogen bromide gas. A compound such as 66 can be prepared from a compound such as 65 by treatment of a compound such as one with a strong base such as lithium diisopropyl amine in a solvent such as THF at a temperature such as −78° C. and reaction of the resulting anion with a compound such as benzyl bromide or benzyl iodide. Compounds of the structure 66 (R=H or loweralkyl) can be prepared in optical form from methods known in the literature (Davies, J. Org. Chem., 1999;64(23):8501-8508; Koch J. Org. Chem., 1993;58(10):2725-37; Afonso, Tetrahedron, 1993;49(20):4283-92; Bertus, Tetrahedron , Asymmetry 1999;10(7):1369-1380; Yamamoto, J. Am. Chem. Soc., 1992;1 14(20):7652-60).
Specific Examples
Example 3
Synthesis of 3-Aminomethyl-5-methyl-octanoic acid
[0720] [0720]
[0721] 1-Benzyl-4-hydroxymethyl-pyrrolidine-2-one 74
[0722] Sodium borohydride (8.0 g, 0.211 mol) was added to a solution of methyl-1-benzyl-5-oxo-3-pyrrolidnecarboxylate 73 (See Zoretic et al, J. Org. Chem., 1980;45:810-814 for general method of synthesis) (32.0 g, 0.137 mol) in 1,2-dimethoxyethane (600 mL) and refluxed for 19 hours. The reaction was cooled to room temperature and 200 mL of water was added. The reaction was quenched with 1 M citric acid and concentrated under reduced pressure. The residue was extracted with dichloromethane, dried over magnesium sulfate, and evaporated to dryness to give 17.47 g, 62% of the alcohol 74 as clear oil. 1 H NMR (CDCl 3 ) δ7.30 (m, 5H), 4.38 (d, 1H, J=14.7), 4.46 (d, 1H, J=14.7), 3.56 (m, 2H), 3.36 (m, 1H), 3.10 (m, 1H), 2.52 (m, 2H), 2.26 (m, 1H). MS, m/z (relative intensity): 207 [M+2H, 66%]. IR (KBr) 3345, 2946, 2866, 1651, 1445, 1025, 737, and 698 cm −1 .
[0723] 1-Benzyl-4-iodomethyl-pyrrolidin-2-one 75
[0724] To alcohol lactam 74 (11.18 g, 0.056 mol) in 210 mL toluene was added in turn, triphenylphosphine (20.0 g, 0.076 mol), imidazole (10.8 g, 0.159 mol), and iodine (19.0 g, 0.075 mol). After stirring the suspension for 1.5 hours, the supernatant was poured into another flask. The sticky yellow residue was washed twice with ether and the solutions were combined. The solvent was evaporated and the residue was chromatographed on silica, eluting with 1:1 acetone/hexane to give 7.92 g, 46% of the iodolactam 75 as yellow oil. 1 H NMR (CDCl 3 ) δ7.25 (m, 5H), 4.38 (d, 1H, J=14.6), 4.46 (d, 1H, J=14.6), 3.38 (dd, 1H, J=7.8 and 2.2) 3.20 (dd, 1H, J=5.6 and 4.4), 3.12 (dd, 1H, J=7.3 and 2.4), 2.96 (dd, 1H, J=5.8 and 4.4), 2.60 (m, 2H), 2.22 (dd, 1H, J=10.5 and 9.7). MS, m/z (relative intensity): 224 [M−H−Bn, 94%], 317 [M+2H, 64%]. IR 3027, 2917, 1688, 1438, 1267, and 701 cm −1 .
[0725] 1-Benzyl-4-(2-methyl-pentyl)-pyrrolidin-2-one 76
[0726] To a suspension of magnesium turnings (0.50 g, 0.021 mol) in 15 mL of dry THF under nitrogen, was added an iodine crystal and 2-bromopentane (2.88 g, 0.019 mol). After an exothermic reaction which was periodically cooled in an ice bath, the reaction was stirred at room temperature for 2 hours. Eight milliliters of Li 2 CuCl 4 (made from 84 mg LiCl and 134 mg CuCl 2 in 10 mL of dry THF) was added at 0° C. followed by dropwise addition of 1-Benzyl-4-iodomethyl-pyrolidine-2-one 75 in 15 mL dry THF, and the resulting suspension was let stir at 0° C. for 3 hours. Stirring was continued at room temperature for 1 hour before quenching with a saturated solution of ammonium chloride. Water was added to dissolve the precipitate formed, and the solution was then extracted with ether and dried over magnesium sulfate. The solvent was evaporated under vacuum and the residue chromatographed on silica eluting with 1:1 acetone/hexane to give 1.13 g, 69% of the 1-benzyl-4-(2-methyl-pentyl)-pyrrolidin-2-one 76. 1 H NMR (CDCl 3 ) δ7.30 (m, 5H), 4.44 (m, 2H), 3.32 (m, 1H), 2.86 (m, 1H), 2.56 (m, 1H), 2.40 (m, 1H), 2.10 (m, 1H), 1.30 (m, 6H), 1.10 (m, 1H), 0.90 (m, 6H). MS, m/z (relative intensity): 261 [M+2H, 100%], 301 [M−H+CH 3 CN, 82%], 260 [M+H, 72%].
[0727] 4-(2-Methyl-pentyl)-pyrrolidin-2-one 77
[0728] A 250 mL 3-neck flask equipped with a dry ice condenser was chilled to −78° C. Ammonia (80 mL) was condensed into the flask and 1-benzyl-4-(2-methyl-pentyl)-pyrrolidin-2-one 76 (1.67 g, 0.006 mol) in 15 mL THF was added. Freshly cut sodium beads were added until a deep blue color persisted. The cooling bath was removed and the reaction stirred at reflux (−33° C.) for 1 hour. The reaction was quenched with ammonium chloride and the excess ammonia was allowed to evaporate. The resulting residue was diluted with water, extracted with dichloromethane, and dried over magnesium sulfate. Evaporation of the solvent followed by chromatography on silica eluting with 1:1 acetone/hexane gave 0.94 g, 86% of the 4-(2-Methyl-pentyl)-pyrrolidin-2-one 77. 1 H NMR (CDCl 3 ) δ6.25 (br, 1H), 3.44 (m, 1H), 2.95 (m, 1H), 2.54 (m, 1H), 2.40 (m, 1H), 1.98 (m, 1H), 1.30 (m, 6H), 0.80 (m, 6H). MS, m/z (relative intensity): 212 [M+2H+CH 3 CN, 100%], 171 [M+2H, 72%], 170 [M+1H, 65%].
[0729] 3-Aminomethyl-5-methyl-octanoic Acid (Example 3)
[0730] The 4-(2-methyl-pentyl)-pyrrolidin-2-one 77 (0.94 g, 0.007 mol) was dissolved in 70 mL of 6N HCl and refluxed for 20 hours. The solution was evaporated under vacuum and an aqueous solution of the residue was applied to Dowex 50WX 8-100 (strongly acidic) ion exchange resin that had been washed with HPLC grade water. The column was eluted, first with water until the eluent was at constant pH, and then with 5% ammonium hydroxide solution. The ammonium hydroxide fractions were evaporated and azeotroped with toluene. The white solid was washed with acetone filtered and dried in a vacuum oven for 24 hours to give the amino acid 0.61 g, 59%. 1 H NMR (CD 3 OD) δ3.00 (m, 1H), 2.85 (m, 1H), 2.48 (m, 1H), 2.30 (m, 1H), 2.14 (brm, 1H), 1.60 (brm, 1H), 1.38 (m, 4H), 1.18 (m, 2H), 0.60 (m, 6H). MS, m/z (relative intensity): 188 [M+H, 100%].
Example 4
Synthesis of 3-Aminomethyl-5,7-dimethyl-octanoic acid
[0731] [0731]
[0732] 1-(4-Methoxy-benzyl)-5-oxo-pyrrolidine-3-carboxylic acid methyl ester 79
[0733] To 4-methoxybenzylamine (42 g, 0.306 mol) in methanol (40 mL) at 0° C. was added the dimethyl itaconate (48 g, 0.306 mol) in methanol (13 mL). The solution was stirred at room temperature for 4 days. 1N HCl was added to the solution followed by ether. The two layers were separated and the aqueous phase extracted with ether. The combined organic phases were dried (MgSO 4 ). Upon filtration of the drying agent the desired material 79 precipitated from solution that was collected and dried under vacuum. 23.26 g, 29%. MS, m/z (relative intensity): 264 [M+H, 100%]. Anal. Calcd for C 14 H 17 N 1 O 4 : C, 63.87; H, 6.51; N, 5.32. Found: C, 63.96; H, 6.55; N, 5.29.
[0734] 4-Hydroxymethyl-1-(4-methoxy-benzyl)-pyrrolidine-2-one 80
[0735] NaBH 4 (15 g, 0.081 mol) was added in portions to ester 79 in ethanol (600 mL) at room temperature. After 4.5 hours water (˜200 mL) was carefully added to the reaction and the solution stirred at room temperature overnight. The resultant solid was removed by filtration and the filtrate concentrated to give alcohol 80 as an oil. 15.33 g, 81%. MS, m/z (relative intensity): 235 [M+H, 100%].
[0736] 4-Iodomethyl-1-(4-methoxy-benzyl)-pyrrolidin-2-one 81
[0737] To alcohol 80 (12.9 g, 0.055 mol) in PhMe was added triphenylphosphine (20 g, 0.077 mol), imidazole (10.8 g, 0.16 mol), and iodine (19 g, 0.075 mol). The suspension was stirred at room temperature 5 hours. A saturated aqueous solution of sodium thiosulphate was added and the two layers separated. The aqueous phase was extracted with ether and the combined organic phases washed with brine, dried (MgSO 4 ) and concentrated. Flash chromatography (6:1 to 4:1 toluene/acetone) of the residue gave iodide 81 as an oil. 11.9 g, 63%. MS, m/z (relative intensity): 346 [M+H, 100%].
[0738] 4-(2,4-Dimethyl-pentyl)-1-(4-methoxy-benzyl)-pyrrolidin-2-one 82
[0739] A procedure similar to the preparation of 1-benzyl-4-(2-methyl-pentyl)-pyrrolidin-2-one 76 was utilized to give 4-(2,4-dimethyl-pentyl)-1-(4-methoxy-benzyl)-pyrrolidin-2-one as an oil. 1.22 g, 29%. MS, m/z (relative intensity): 304 [M+H, 100%].
[0740] 4-(2,4-Dimethyl-pentyl)-pyrrolidin-2-one 83
[0741] To the lactam (1.17 g, 3.86 mmol) in MeCN (20 mL) at 0° C. was added ceric ammonium nitrate (4.2 g, 7.7 mmol) in H 2 O (10 mL). After 50 minutes a further portion of ceric ammonium nitrate (2.1 g, 3.86 mmol) was added, and after 1 hour the mixture was absorbed onto silica and flash chromatographed to give an oil. MS, m/z (relative intensity): 183 [M+H, 100%].
[0742] 3-Aminomethyl-5,7-dimethyl-octanoic acid (Example 4)
[0743] A procedure similar to the preparation of 3-aminomethyl-5-methyl-octanoic acid (Example 3) was utilized to give the amino acid as a solid. MS, m/z (relative intensity): 202 [M+H, 100%].
Example 5
Synthesis of (S)-3-Aminomethyl-5-methyl-octanoic acid
[0744] [0744]
[0745] (S)-4-Hydroxymethyl-1-((S)-1-phenyl-ethyl)-pyrrolidin-2-one 84
[0746] To the ester 33 (49 g, 0.198 mol) in EtOH (600 mL) was added sodium borohydride (22 g, 0.595 mol). After 7 hours, 1 M citric acid was carefully added and, after effervescence had ceased, water was added to fully quench the reaction. The ethanol was removed under reduced pressure and ethyl acetate added. The resultant two layers were separated, the aqueous phase was extracted with EtOAc, and the combined organic phases dried (MgSO 4 ) and concentrated to give a heavy oil. MS, m/z (relative intensity): [M+H, 100%].
[0747] (S)-4-Iodomethyl-1-((S)-1-phenyl-ethyl)-pyrrolidin-2-one 85
[0748] A procedure similar to the iodination of compound 80 was utilized giving iodide 85 as an oil. 35.2 g, 56%. Anal. Calcd for C 13 H 16 I 1 N 1 O 1 : C, 47.43; H, 4.90; N, 4.25. Found: C, 47.41; H, 4.83; N, 4.17.
[0749] 4-(2-Methyl-pentyl)-1-((S)-1-phenyl-ethyl)-pyrrolidin-2-one 86
[0750] A procedure similar to the preparation of 1-benzyl-4-(2-methyl-pentyl)-pyrrolidin-2-one 76 was utilized to give 2.71 g, 81.0% of 86 as an oil. MS, m/z (relative intensity): 274 [M+1H, 100%], 315 [M+H+CH 3 CN, 65%].
[0751] (S)-4-(2-Methyl-pentyl)-pyrrolidin-2-one 87
[0752] A procedure similar to the preparation of 4-(2-methyl-pentyl)-pyrrolidin-2-one 77 was used to give 1.14 g, 72.8% of 87 as an oil. MS, m/z (relative intensity): 170 [M+1H, 10%], 211 [M+1H+CH 3 CN, 90%].
Example 5
(S)-3-Aminomethyl-5-methyl-octanoic acid
[0753] A procedure similar to the preparation of 3-aminomethyl-5-methyl-octanoic acid (Example 3) was used to give the amino acid (example 5) 0.88 g, 74.3%. 1 H NMR (CD 3 OD) δ2.95 (m, 1H), 2.80 (m, 1H), 2.40 (m, 1H), 2.25 (m, 1H), 2.05 (brm, 1H), 1.50 (brm, 1H), 1.30 (m, 4H), 1.10 (m, 2H), 0.90 (m, 6H). MS, m/z (relative intensity): 188 [M+1H, 100%], 186 [M−1H, 100%], 229 [M+1H+CH 3 CN, 30%].
Example 6
Synthesis of (S)-3-Aminomethyl-7-methoxy-5-methyl-heptanoic acid
[0754] [0754]
[0755] (S)-4-(2-Methyl-pent-4-enyl)-1-((S)-1-phenyl-ethyl)-pyrrolidin-2-one 88
[0756] A procedure similar to the preparation of 1-benzyl-4-(2-methyl-pentyl)-pyrrolidin-2-one 76 was followed giving the adduct 88 as an oil. 6 g, 74%. MS, m/z (relative intensity): 272 [M+H, 100%].
[0757] (S)-4-(4-Hydroxy-2-methyl-butyl)-1-((S)-1-phenyl-ethyl)-pyrrolidin-2-one 89
[0758] OsO 4 (2 mL of a 4% wt solution in t-BuOH) was added to the alkene 88 (5.8 g, 0.021 mol) in THF/H 2 O (3:1, 100 mL). After 1 hour, sodium periodate (11.4 g, 0.053 mol) was added. After 2 hours, the suspension was filtered and the solids washed with dichloromethane. The filtrate was concentrated and the residue azeotroped with toluene. The residue was dissolved in ethanol and sodium borohydride (2.5 g) added. The suspension was stirred at room temperature overnight. 1N citric acid was added and the mixture diluted with ether. The resultant two layers were separated and the aqueous phase was extracted with ether and the combined organic dried (MgSO 4 ) and concentrated. Flash chromatography (1:1 hexane/EtOAc) of the residue gave an oil. 4.2 g, 73%. MS, m/z (relative intensity): 276 [M+H, 100%].
[0759] (S)-4-(4-Methoxy-2-methyl-butyl)-1-((S)-1-phenyl-ethyl)-pyrrolidin-2-one 90
[0760] To alcohol 89 (2 g, 7.66 mmol) in DMSO (60 mL) at room temperature was added NaH (368 mg, 60% in oil). After 30 minutes the methyl iodide (1.08 g, 7.66 mmol) was added and the solution stirred at room temperature overnight, upon which the reaction was diluted with water (500 mL). The solution was extracted with ether, and the combined organic extracts were dried (MgSO 4 ) and concentrated. Flash chromatography (90% to 50% hexane/acetone) of the residue gave the product 90 as an oil (1.1 g, 52%). MS m/z 290 (M+H, 100%).
[0761] (S)-4-(4-Methoxy-2-methyl-butyl)-pyrrolidin-2-one 91
[0762] A procedure similar to the synthesis of 4-(2-methyl-pentyl)-pyrrolidin-2-one 77 was utilized giving lactam 91 as an oil. MS m/z 186 (M+H, 100%).
Example 6
(S)-3-Aminomethyl-7-methoxy-5-methyl-heptanoic acid
[0763] A procedure similar to the synthesis of example 3 was followed. The resultant amino acid isolated from ion-exchange chromatography was recrystallized from methanol/ethyl acetate to give the example 6 as a white solid. MS m/z 204 (M+H, 100%). Anal. Calcd for C 10 H 21 N 1 O 3 : C, 59.09; H, 10.41; N, 6.89. Found: C, 58.71; H, 10.21; N, 6.67.
Example 7
Synthesis of (S)-3-Aminomethyl-6-fluoro-5-methyl-hexanoic acid
[0764] [0764]
[0765] 2-Methyl-2-[(S)-5-oxo-1-((S)-1-phenyl-ethyl)-pyrrolidin-3-ylmethyl]-malonic acid dimethyl ester 92
[0766] To dimethyl methylmalonate (1.06 g, 7.29 mmol) in DMSO (7 mL) at room temperature was added NaH (291 mg of a 60% dispersion in oil). After the effervescence had ceased the lactam 85 (2 g, 7.29 mol) in DMSO (5 mL) was added. After 1 hour water was added and the aqueous solution extracted with ether. The combined organic extracts were dried (MgSO 4 ) and concentrated. Flash chromatography (1:1 hexane/acetone) of the residue gave the product as an oil (1.7 g, 81%). MS m/z 348 (M+H, 100%).
[0767] 2-Methyl-3-[(S)-5-oxo-1-((S)-1-phenyl-ethyl)-pyrrolidin-3yl]-propionic acid methyl ester 93
[0768] The ester 92 (483 mg, 1.4 mmol), NaCl (104 mg, 1.8 mmol), water (105 μL) and DMSO (5 mL) were heated to reflux for 2 hours. The solution was cooled to room temperature water was added and the aqueous solution extracted with ether. The combined organic extracts were dried (MgSO 4 ) and concentrated. Flash chromatography (80% to 66% hexane/acetone) of the residue gave the product as an oil (160 mg, 40%). MS m/z 290 (M+H, 100%).
[0769] (S)-4-(3-Hydroxy-2-methyl-propyl)-1-((S)-1-phenyl-ethyl)-pyrrolidin-2-one 37
[0770] To the ester 93 (4.82 g, 0.017 mol) in EtOH (100 mL) was added NaBH 4 (3.7 g, 0.10 mol) and the mixture heated to reflux for 2.5 hours. The solution was cooled to 0° C. and 1 M citric acid carefully added followed by water. The solution was concentrated to half volume added and extracted with ether. The combined organic extracts were dried (MgSO 4 ) and concentrated. Flash chromatography (1:1 hexane/acetone) of the residue gave the product as an oil (2.6 g, 59%). MS m/z 262 (M+H, 100%).
[0771] (S)-4-(3-Fluoro-2-methyl-propyl)-1-((S)-1-phenyl-ethyl)-pyrrolidin-2-one 94
[0772] To DAST (1 g, 6.2 mmol) in CH 2 Cl 2 (20 mL) at −78° C. was added the alcohol 37 in CH 2 Cl 2 (10 mL). After 1 hour at −78° C. the solution was warmed to room temperature. After 7 hours the solution was carefully quenched with a saturated aqueous solution of sodium bicarbonate and the two layers separated. The organic phase was dried (MgSO 4 ) and concentrated. Flash chromatography (90% to 66% hexane/acetone) of the residue gave the product as an oil (600 mg, 37%). MS m/z 264 (M+H, 100%).
[0773] (S)-4-(3-Fluoro-2-methyl-propyl)-pyrrolidin-2-one 95
[0774] A procedure similar to the preparation of 4-(2-methyl-pentyl)-pyrrolidin-2-one 77 was utilized affording the lactam as an oil (242 mg, 68%). MS m/z 159 (M, 100%).
Example 7
(S)-3-Aminomethyl-6-fluoro-5-methyl-hexanoic acid
[0775] A procedure similar to the synthesis of example 3 was followed. The resultant amino acid isolated from ion-exchange chromatography was recrystallized from methanol/ethyl acetate to give example 7 as a white solid. MS m/z 177 (M, 100%). Anal. Calcd for C 8 H 16 F 1 N 1 O 2 :0.02 H 2 O: C, 54.11; H, 9.10; N, 7.89. Found: C, 53.75; H, 9.24; N, 7.72.
Example 8
Synthesis of (S)-3-Aminomethyl-6-methoxy-5-methyl-hexanoic acid
[0776] [0776]
[0777] (S)-4-(3-Methoxy-2-methyl-propyl)-1-((S)-1-phenyl-ethyl)-pyrrolidin-2-one 96
[0778] A procedure similar to the synthesis of (S)-4-(4-methoxy-2-methyl-butyl)-1-((S)-1-phenyl-ethyl)-pyrrolidin-2-one 90 was utilized giving ether 96 as an oil (90 mg, 37%). MS m/z 276 (M+H, 100%).
[0779] (S)-4-(3-Methoxy-2-methyl-propyl)-pyrrolidin-2-one 97
[0780] A procedure similar to the synthesis of 4-(2-methyl-pentyl)-pyrrolidin-2-one 77 was utilized giving 97 as an oil (760 mg, 93%). MS m/z 171 (M+H, 100%).
Example 8
(S)-3-Aminomethyl-6-methoxy-5-methyl-hexanoic acid
[0781] A procedure similar to the synthesis of example 3 was followed. The resultant amino acid isolated from ion-exchange chromatography was recrystallized from methanol/ethyl acetate to give Example 8 as a white solid. MS m/z 190 (M+H, 100%). Anal. Calcd for C 9 H 19 N 1 O 3 : C, 57.12; H, 10.12; N, 7.40. Found: C, 57.04; H, 10.37; N, 7.30. A second batch precipitated from the mother liquors (1:5 ratio of C5 isomers by 1 H NMR). MS m/z 190 (M+H, 100%).
Example 9
Synthesis of (3S,5R)-3-Aminomethyl-5-methyl-octanoic acid hydrochloride
[0782] [0782]
[0783] (R)-2,6-Dimethyl-non-2-ene 98
[0784] To (S)-citronellyl bromide (50 g, 0.228 mol) in THF (800 mL) at 0° C. was added LiCl (4.3 g) followed by CuCl 2 (6.8 g). After 30 minutes methylmagnesium chloride (152 mL of a 3 M solution in THF, Aldrich) was added and the solution warmed to room temperature. After 10 hours the solution was cooled to 0° C. and a saturated aqueous solution of ammonium chloride carefully added. The resultant two layers were separated and the aqueous phase extracted with ether. The combined organic phases were dried (MgSO 4 ) and concentrated to give an oil. 32.6 g; 93%. Used without further purification. 13 C NMR (100 MHz; CDCl 3 ) 131.13, 125.28, 39.50, 37.35, 32.35, 25.92, 25.77, 20.31, 19.74, 17.81, 14.60.
[0785] (R)-4-Methyl-heptanoic acid 99
[0786] To alkene 98 (20 g, 0.13 mol) in acetone (433 mL) was added a solution of CrO 3 (39 g, 0.39 mol) in H 2 SO 4 (33 mL)/H 2 O (146 mL) over 50 minutes. After 6 hours a further amount of CrO 3 (26 g, 0.26 mol) in H 2 SO 4 (22 mL)/H 2 O (100 mL) was added. After 12 hours the solution was diluted with brine and the solution extracted with ether. The combined organic phases were dried (MgSO 4 ) and concentrated. Flash chromatography (gradient of 6:1 to 2:1 hexane/EtOAc) gave the product 99 as an oil. 12.1 g; 65%. MS, m/z (relative intensity): 143 [M−H, 100%].
[0787] (4R,5S)-4-Methyl-3-((R)-4-methyl-heptanoyl)-5-phenyl-oxazolidin-2-one 100
[0788] To the acid 99 (19 g, 0.132 mol) and triethylamine (49.9 g, 0.494 mol) in THF (500 mL) at 0° C. was added trimethylacetylchloride (20 g, 0.17 mol). After 1 hour LiCl (7.1 g, 0.17 mol) was added followed by the oxazolidinone (30 g, 0.17 mol). The mixture was warmed to room temperature and after 16 hours the filtrate was removed by filtration and the solution concentrated under reduced pressure. Flash chromatography (7:1 hexane/EtOAc) gave the product 100 as an oil. 31.5 g; 79%. [α] D =5.5 (c 1 in CHCl 3 ). MS, m/z (relative intensity): 304 [M+H, 100%].
[0789] (3S,5R)-5-Methyl-3-((4R,5S)-4-methyl-2-oxo-5-phenyl-oxazolidine-3-carbonyl)-octanoic acid tert-butyl ester 101
[0790] To oxazolidinone 100 (12.1 g, 0.04 mol) in THF (200 ml) at −50° C. was added NaHMDS (48 mL of a 1 M solution in THF). After 30 t-butylbromoaceate (15.6 g, 0.08 mol) was added. The solution was stirred for 4 hours at −50° C. and then warmed to room temperature. After 16 hours a saturated aqueous solution of ammonium chloride was added and the two layers separated. The aqueous phase was extracted with ether and the combined organic phases dried (MgSO 4 ) and concentrated. Flash chromatography (9:1 hexane/EtOAc) gave the product 101 as a white solid 12 g; 72%. [α] D =30.2 (c 1 in CHCl 3 ). 13 C NMR (100 MHz; CDCl 3 ) 176.47, 171.24, 152.72, 133.63, 128.87, 125.86, 80.85, 78.88, 55.34, 39.98, 38.77, 38.15, 37.58, 30.60, 28.23, 20.38, 20.13, 14.50, 14.28.
[0791] (S)-2-((R)-2-Methyl-pentyl)-succinic acid 4-tert-butyl ester 102
[0792] To ester 101 (10.8 g, 0.025 mol) in H 2 O (73 mL) and THF (244 mL) at 0° C. was added a premixed solution of LiOH (51.2 mL of a 0.8 M solution) and H 2 O 2 (14.6 mL of a 30% solution). After 4 hours a further 12.8 mL LiOH (0.8 M solution) and 3.65 mL of H 2 O 2 (30% solution) was added. After 30 minutes sodium bisulfite (7 g), sodium sulfite (13 g), and water (60 mL) was added followed by hexane (100 mL) and ether (100 mL). The two layers were separated and the aqueous layer extracted with ether. The combined organic phases were concentrated to an oil that was dissolved in heptane (300 mL). The resultant solid was filtered off and the filtrate dried (MgSO 4 ) and concentrated to afford an oil (6 g, 93%) which was used without further purification. MS, m/z (relative intensity): 257 [M+H, 100%].
[0793] (3S,5R)-3-Hydroxymethyl-5-methyl-octanoic acid tert-butyl ester 103
[0794] To acid 102 (3.68 g, 0.014 mol) in THF (100 mL) at 0° C. was added BH 3 .Me 2 (36 mL of a 2 M solution in THF, Aldrich) upon which the solution was warmed to room temperature. After 15 hours ice was carefully added (in order to control the effervescence) to the solution followed by brine. The solution was extracted with ether and the combined organic phases dried (MgSO 4 ) and concentrated under reduced pressure. Flash chromatography (4:1 hexane/EtOAc) gave alcohol 103 as an oil (2.0 g, 59%). 13 C NMR (100 MHz; CDCl 3 ) 173.56, 80.85, 65.91, 39.74, 39.20, 38.90, 35.65, 29.99, 28.31, 20.18, 19.99, 14.56.
[0795] (3S,5R)-5-Methyl-3-(toluene-4-sulfonyloxymethyl)-octanoic acid tert-butyl ester 104
[0796] To alcohol 103 (1.98 g, 8.1 mmol) in CH 2 Cl 2 (40 mL) at room temperature was added triethylamine (2.4 g, 0.024 mol), DMAP (20 mg) and tosyl chloride (2.3 g, 0.012 mol). After 14 hours 1N HCl was added and the two layers separated. The aqueous phase was extracted with ether and the combined organic phases dried (MgSO 4 ) and concentrated. Flash chromatography (95% hexane/EtOAc) gave tosylate 104 as an oil (2.94 g, 91%). 13 C NMR (100 MHz; CDCl 3 ) 171.60, 144.92, 133.07, 130.02, 128.12, 80.80, 72.15, 39.73, 38.09, 37.89, 32.67, 29.71, 28.22, 21.83, 20.10, 19.54, 14.49.
[0797] (3S,5R)-3-Azidomethyl-5-methyl-octanoic acid tert-butyl ester 105
[0798] Tosylate 104 (2.92 g, 7.3 mmol) and sodium azide (1.43 g, 0.02 mol) were warmed to ˜50° C. in DMSO (30 mL). After 2 hours the solution was cooled to room temperature and diluted with water. The solution was extracted with ether and the combined organic phases dried (MgSO 4 ) and concentrated to give an oil 1.54 g, 79%. Further purification by flash chromatography (95% hexane/EtOAc) gave an oil. [α] D =−8.3 (c 1 in CHCl 3 ). 13 C NMR (100 MHz; CDCl 3 ) 172.01, 80.73, 54.89, 39.73, 39.46, 39.00, 33.40, 29.85, 28.30, 20.15, 19.82, 14.52.
[0799] (S)-4-((R)-2-Methyl-pentyl)-pyrrolidin-2-one 107 and (3S,5R)-3-aminomethyl-5-methyl-octanoic acid tert-butyl ester 106
[0800] Azide 105 was treated with 5% Pd/C and shaken under an atmosphere of hydrogen for 20 hours where upon a further 200 mg of 5% Pd/C added. After 6 hours the filtrate was concentrated to afford an oil which by 1 H NMR was found to be a mixture of primary amine 106 and lactam 107 (1.75 g) which was used without further purification.
Example 9
(3S,5R)-3-Aminomethyl-5-methyl-octanoic acid hydrochloride
[0801] The mixture of the amine 106 and the lactam 107 (1.74 g) was treated with 3N HCl (40 mL) and the solution warmed to 50° C. for 4 hours then cooled to room temperature. After 12 hours the solution was concentrated and the residue recrystallized from ethyl acetate to give the amino acid as a white solid 605 mg. MS, m/z (relative intensity): 188 [M+H, 100%]. Anal. Calcd for C 10 H 21 N 1 O 2 :H 1 Cl 1 C, 53.68; H, 9.91; N, 6.26. Found: C, 53.83; H, 10.12; N, 6.07.
Example 10
Synthesis of (3S,5R)-3-Aminomethyl-5-methyl-heptanoic acid
[0802] [0802]
[0803] Methanesulfonic acid (S)-3,7-dimethyl-oct-6-enyl ester 108
[0804] To S-(−)-citronellol (42.8 g, 0.274 mol) and triethylamine (91 mL, 0.657 mol) in CH 2 Cl 2 (800 mL) at 0° C. was added methanesulphonyl chloride (26 mL, 0.329 mol) in CH 2 Cl 2 (200 mL). After 2 hours at 0° C. the solution was washed with IN HCl then brine. The organic phase was dried (MgSO 4 ) and concentrated to afford an oil (60.5 g, 94%) which was used without further purification. 1 H NMR (400 MHz; CDCl 3 ) 5.05 (1H, m), 4.2 (2H, m), 2.95 (3H, s), 1.98 (2H, m), 1.75 (1H, m), 1.6 (3H,s), 1.5 (4H, m), 1.35 (2H, m), 1.2 (1H, m), 0.91 (3H, d, J=6.5 Hz).
[0805] (R)-2,6-Dimethyl-oct-2-ene 109
[0806] To alkene 108 (60 g, 0.256 mol) in THF (1 L) at 0° C. was added lithium aluminum hydride (3.8 g, 0.128 mol). After 7 hours, a further 3.8 g of lithium aluminum hydride was added and the solution warmed to room temperature. After 18 hours, a further 3.8 g of lithium aluminum hydride was added. After a further 21 hours, the reaction was carefully quenched with 1N citric acid and the solution diluted further with brine. The resultant two phases were separated and the organic phase was dried (MgSO 4 ) and concentrated to afford an oil which was used without further purification. MS, m/z (relative intensity): 139 [M−H, 100%].
[0807] (R)-4-Methyl-hexanoic acid 110
[0808] A procedure similar to the synthesis of (R)-4-methyl-heptanoic acid 99 was utilized giving the acid as an oil (9.3 g, 56%). MS, m/z (relative intensity): 129 [M−H, 100%].
[0809] (4R, 5S)-4-Methyl-3-((R)-4-methyl-hexanoyl)-5-phenyl-oxazolidin-2-one 111
[0810] A procedure similar to the synthesis of (4R,5S)-4-methyl-3-((R)-4-methyl-heptanoyl)-5-phenyl-oxazolidin-2-one 100 was utilized giving oxazolidinone 111 as an oil (35.7 g, 95%). MS, m/z (relative intensity): 290 [M+H, 100%].
[0811] (3S,5R)-5-Methyl-3-[1-((4R,5S)-4-methyl-2-oxo-5-phenyl-oxazolidin-3-yl)-methanoyl]-heptanoic acid tert-butyl ester 112
[0812] A procedure similar to the preparation of (3S,5R)-5-methyl-3-((4R,5S)-4-methyl-2-oxo-5-phenyl-oxazolidine-3-carbonyl)-octanoic acid tert-butyl ester 101 was followed giving 112 as an oil (7.48 g; 31%).
[0813] (S)-2-((R)-2-Methyl-butyl)-succinic acid 4-tert-butyl ester 113
[0814] To ester 112 (7.26 g, 0.018 mol) in H 2 O (53 mL) and THF (176 mL) at 0° C. was added a premixed solution of LiOH (37 mL of a 0.8 M solution) and H 2 O 2 (10.57 mL of a 30% solution) and the solution warmed to room temperature. After 2 hours sodium bisulfite (7 g), sodium sulfite (13 g), and water (60 mL) was added and the two layers were separated and the aqueous layer extracted with ether. The combined organic phases were concentrated to an oil that was dissolved in heptane (200 mL). The resultant solid was filtered off and the filtrate dried (MgSO 4 ) and concentrated to afford an oil (4.4 g) that was used without further purification.
[0815] (3S,5R)-3-Hydroxymethyl-5-methyl-heptanoic acid tert-butyl ester 114
[0816] A procedure similar to the preparation of (3S,5R)-3-hydroxymethyl-5-methyl-octanoic acid tert-butyl ester 103 was utilized giving alcohol 114 as an oil (2.68 g, 69%). MS, m/z (relative intensity): 216 [89%], 174 [M−(CH 3 ) 3 C, 100%].
[0817] (3S,5R)-5-Methyl-3-(toluene-4-sulfonyloxymethyl)-heptanoic acid tert-butyl ester 115
[0818] To 114 alcohol (2.53 g, 0.011 mmol) in CH 2 Cl 2 (140 mL) at 0° C. was added pyridine (2.6 g,0.033 mol), DMAP (100 mg), and tosyl chloride (3.15 g, 0.016 mol) and the solution warmed to room temperature for 3.5 hours whereupon more DMAP and TsCl (3.15 g) were added. After 14 hours 1N HCl was added and the two layers separated. The organic phase was washed with brine then or dried (MgSO 4 ) and concentrated. Flash chromatography (95% to 86% hexane/EtOAc) gave tosylate 115 as an oil (1.53 g, 36%). 13 C NMR (100 MHz; CDCl 3 ) 130.03, 128.12, 72.18, 37.89, 37.71, 32.67, 31.49, 29.88, 28.22, 21.83, 19.07, 11.37.
[0819] (3S,5R)-3-Azidomethyl-5-methyl-heptanoic acid tert-butyl ester 116
[0820] A procedure similar to the preparation of (3S,5R)-3-azidomethyl-5-methyl-octanoic acid tert-butyl ester 105 was utilized giving an oil 0.956 g, 97%. MS, m/z (relative intensity): 228 [M−N 2 , 80%].
[0821] (S)-4-((R)-2-Methyl-butyl)-pyrrolidin-2-one 118 and (3S,5R)-3-Aminomethyl-5-methyl-heptanoic acid tert-butyl ester 117
[0822] Azide 116 (689 mg) was treated with 20% Pd/C (90 mg) in THF (20 mL) and shaken under an atmosphere of hydrogen for 36 hours. The catalyst was removed by filtration and the resultant oil used without further purification.
Example 10
(3S,5R)-3-Aminomethyl-5-methyl-heptanoic acid
[0823] The mixture of amine 117 and lactam 118 was treated with 6N HCl and the solution warmed to 50° C. for 17 hours then cooled to room temperature and concentrated. The resultant oil was subjected to ion-exchange chromatography (Dowex, strongly acidic resin) using 5% ammonium hydroxide to give a cream solid which was recrystallized from methanol/ethyl acetate to give (3S, 5R)-3-aminomethyl-5-methyl-heptanoic acid, example 10. MS, m/z (relative intensity): 174 [M+H, 100%]. Anal. Calcd for C 19 H 19 N 1 O 2 . C, 62.39; H, 11.05; N, 8.08. Found: C, 62.23; H, 11.33; N, 7.89.
Example 11
Synthesis of (3S,5S)-3-Aminomethyl-5-methyl-octanoic acid
[0824] [0824]
[0825] (S)-2,6-Dimethyl-non-2-ene 119
[0826] CuCl 2 (5.36 g, 39.7 mmol) and LiCl (3.36, 80.0 mmol) were stirred together in dry THF (40 mL) for 15 minutes. The resulting solution was added to methylmagnesium chloride, 3.0 M in THF (168 mL) at 0° C. under nitrogen atmosphere and stirred at that temperature for 15 minutes. To the reaction suspension was added slowly (R)-(−)-Citronellyl bromide (55.16 g, 251.8 mmol) in THF (100 mL), and stirred at 0° C. for 2.5 hours. It was warmed to room temperature and stirring was continued for an additional 1 hour. The mixture was cooled to 0° C. and quenched with saturated ammonium chloride solution. The suspension was then extracted into ether, washed with water, and dried over MgSO 4 The solution was concentrated under reduced pressure to afford 36.3 g; 94% of (S)-2,6-Dimethyl-non-2-ene as an oil. MS, m/z (relative intensity): 153 [M−1H, 100%], 194 [M−1H+CH 3 CN, 45%].
[0827] (S)-4-Methyl-heptanoic acid 120
[0828] To the (S)-2,6-Dimethyl-non-2-ene 119 (39.0 g, 253.2 mmol) in acetone (1L) at 0° C. was added Jones reagent (2.7 M, 600 mL) dropwise over 1.5 hours and let stir at room temperature for 18 hours. The reaction mixture was poured into a saturated solution of Na 2 SO 4 and extracted into ether. It was washed with brine and concentrated in vacuo. The oily residue was dissolved in methanol (70 mL) and 1 M NaOH (700 mL) and then stirred for 30 minutes. The aqueous solution was washed with CH 2 Cl 2 , acidified with 10% HCl and extracted into CH 2 Cl 2 . The solution was dried over MgSO 4 and concentrated to dryness to give 24.22 g; 66% of (S)-4-Methyl-heptanoic acid as an oil. MS, m/z (relative intensity): 143 [M−1H, 100%].
[0829] (4R,5S)-4-Methyl-3-((S)-4-methyl-heptanoyl)-5-phenyl-oxazolidin-2-one 121
[0830] A procedure similar to the preparation of (4R,5S)-4-methyl-3-((R)-4-methyl-heptanoyl)-5-phenyl-oxazolidin-2-one 100 was utilized giving (4R,5S)-4-methyl-3-((S)-4-methyl-heptanoyl)-5-phenyl-oxazolidin-2-one 121 6.2 g; 80.0%, as an oil. MS, m/z (relative intensity): 304 [M+1H, 90%], 355 [M+1H+CH 3 CN, 60%].
[0831] (3S,5S)-5-Methyl-3-((4R,5S)-4-methyl-2-oxo-5-phenyl-oxazolidine-3-carbonyl)-octanoic acid tert-butyl ester 122
[0832] n-BuLi, 1.6 M in Hexane (18.0 mL, 30.1 mmol) was added dropwise to a solution of diisopropylamine (4.6 mL, 32.6 mmol) in dry THF (50 mL) under nitrogen at −5° C. keeping the temperature below 0° C. during addition. The mixture was let stir at −5° C. for 20 minutes and then cooled to −78° C. 121 (7.6 g, 25.1 mmol) in dry THF (12 mL) was added to the LDA solution and stirred at −78° C. for 30 minutes. t-Butylbromo acetate (4.8 mL, 32.6 mmol) as added to the reaction and stirring at −78° C. was continued for 2 hours. It was let warm to room temperature before stirring for an additional 18 hours. The reaction was quenched with a saturated solution NaH 2 PO 4 , extracted into ethylacetate, and dried over MgSO 4 . The solution was concentrated to give a solid residue which was dissolved in hot hexane. The hexane solution was allowed to cool to room temperature before cooling further in an ice bath. The resulting precipitate was collected and allowed to air dry to give 122 as a fluffy white solid. 4.3 g; 41%. MS, m/z (relative intensity): 362 [M−C(CH 3 ) 3 +1H, 100%], 418 [M+1H, 20%].
[0833] (S)-2-((S)-2-Methyl-pentyl)-succinic acid 4-tert-butyl ester and (3S,5S)-3-Hydroxymethyl-5-methyl-octanoic acid tert-butyl ester 123
[0834] To the ester 122 in a mixture of THF (203.0 mL) and water (61.0 mL) at 0° C. was added a premixed solution of 30% H 2 O 2 (12.2 mL) and LiOH (0.8 M, 42.7 mL). The resulting solution was stirred at 0° C. for 4 hours. To the reaction was added sodium bisulfite (7 g), sodium sulfite (13 g), and water (60 mL). A 1:1 mixture of ether/hexane (200 mL) was then added and the organic phase was separated. The aqueous phase was extracted with ether and the combined organic extract was dried over MgSO 4 and concentrated in vacuo. The residue was dissolved in heptane and let stir for 5 minutes. The resulting precipitate was filtered and the filtrate was concentrated to dryness to give as an oil.
[0835] (3S,5S)-3-Hydroxymethyl-5-methyl-octanoic acid tert-butyl ester 123
[0836] A procedure similar to the preparation of (3S,5R)-3-hydroxymethyl-5-methyl-octanoic acid tert-butyl ester 103 was followed giving 123 as an oil. 4.0 g; 76.0%. MS, m/z (relative intensity): 230 [M−C(CH 3 ) 3 +1H+CH 3 CN, 100%], 189 [M−C(CH 3 ) 3 +1H, 70%].
[0837] (3S,5S)-5-Methyl-3-(toluene-4-sulfonyloxymethyl)-octanoic acid tert-butyl ester 124
[0838] A procedure similar to the preparation of (3S,5R)-5-methyl-3-(toluene-4-sulfonyloxymethyl)-octanoic acid tert-butyl ester 104 was followed giving 6.9 g of 124. MS, m/z (relative intensity): 343 [M−C(CH 3 ) 3 +1H, 70%], 384 [M−C(CH 3 ) 3 +1H+CH 3 CN, 100%].
[0839] (3S,5S)-3-Azidomethyl-5-methyl-heptanoic acid tert-butyl ester 125
[0840] A procedure similar to the preparation of (3S,5R)-3-azidomethyl-5-methyl-octanoic acid tert-butyl ester 105 was followed giving 2.9 g; 66% of 125 as an oil. MS, n/z (relative intensity): 212 [M−C(CH 3 ) 3 −1H, 45%].
[0841] (3S,5S)-3-Aminomethyl-5-methyl-octanoic acid tert-butyl ester 126
[0842] A mixture of 125 (2.8 g, 10.4 mmol) and 10% Pd/C (1.0 g) in methanol (50.0 mL) was hydrogenated at 41 PSI for 96 hours. The solution was filtered to give 1.7 g of crude 126 which was used in the next step without further purification. MS, m/z (relative intensity): 244 [M+1H, 100%], 285 [M+1H+CH 3 CN, 25%].
Example 11
(3S,5S)-3-Aminomethyl-5-methyl-octanoic acid
[0843] A procedure similar to the preparation of example 10 (3S,5R)-3-aminomethyl-5-methyl-heptanoic acid was followed giving example 11. 380 mg; 29.0%. 1 H NMR (CD 3 OD) δ2.90 (dd, J=3.9, 8.8 Hz, 1H), 2.80 (dd, J=7.6, 5.1 Hz, 1H), 2.40 (dd, J=3.2, 12.51 Hz, 1H), 2.20 (dd, J=8.8, 6.8 Hz, 1H), 2.05 (m, 1H), 1.55 (m, 1H), 1.30 (m, 3H), 1.10 (m, 2H), 0.85 (m, 6H); MS, m/z (relative intensity): 187 [M+1H, 100%], 211 [M+1H+CH 3 CN, 30%].
Example 12
Synthesis of (3S,5S)-3-Aminomethyl-5-methyl-heptanoic acid
[0844] [0844]
[0845] (S)-2,6-Dimethyl-oct-2-ene 127
[0846] (R)-(−)-Citronellyl bromide (49.1 g, 224.2 mmol) was dropwise added to a solution of LAH 1.0 M in THF (336 mL, 336 mmol) at 0° C. over a 45-minute period. Stirring was continued for an additional 4 hours at 0° C. The reaction was slowly quenched with a saturated solution of ammonium chloride followed by the addition of ether (100 mL). The resulting white slurry was filtered and the filtrate was dried over MgSO 4 . The solution was concentrated under reduced pressure to afford 26.2 g; 83% of 127 as an oil. MS, m/z (relative intensity): 180 [M−1H+CH 3 CN, 100%], 139 [M−1H, 90%].
[0847] (S)-4-Methyl-hexanoic acid 128
[0848] A procedure similar to that used to prepare compound 120 was used giving 15.9 g of 128 as an oil. MS, m/z (relative intensity): 129 [M−1H, 100%], 170 [M−1H+CH 3 CN, 70%].
[0849] (4R,5S)-4-Methyl-3-((S)-4-methyl-hexanoyl)-5-phenyl-oxazolidin-2-one 129
[0850] A procedure similar to that used to prepare (4R,5S)-4-Methyl-3-((S)-4-methyl-heptanoyl)-5-phenyl-oxazolidin-2-one 121 was used giving 35.0 g of crude (4R,5S)-4-methyl-3-((S)-4-methyl-hexanoyl)-5-phenyl-oxazolidin-2-one 129 as an oil. It was used in the next step without further purification. MS, m/z (relative intensity): 290 [M+1H, 100%], 331 [M+1H+CH 3 CN, 20%].
[0851] (3S,5S)-5-Methyl-3-((4R,5S)-4-methyl-2-oxo-5-phenyl-oxazolidine-3-carbonyl)-heptanoic acid tert-butyl ester 130
[0852] A procedure similar to that used to prepare (3S,5S)-5-methyl-3-((4R,5S)-4-methyl-2-oxo-5-phenyl-oxazolidine-3-carbonyl)-octanoic acid tert-butyl ester 122 was used to give 4.6.0 g, 25.4% of 130 as a white solid. MS, m/z (relative intensity): 348 [M−C(CH 3 ) 3 +1H, 100%], 443 [M−1H+CH 3 CN, 100%], 402 [M−1H, 55%], 404 [M+1H, 45%].
[0853] (3S,5S)-3-Hydroxymethyl-5-methyl-heptanoic acid tert-butyl ester 131
[0854] A procedure similar to that used to prepare (3S,5S)-3-Hydroxymethyl-5-methyl-octanoic acid tert-butyl ester 123 was giving 1.2 g, 52.1% of 131 as an oil. MS, m/z (relative intensity): 175 [M−C(CH 3 ) 3 +1H, 100%], 173 [M−C(CH 3 ) 3 -1H, 100%], 216 [M−C(CH 3 ) 3 +1H+CH 3 CN, 95%].
[0855] (3S,5S)-5-Methyl-3-(toluene-4-sulfonyloxymethyl)-heptanoic acid tert-butyl ester 132
[0856] A procedure similar to the preparation of (3S,5R)-5-methyl-3-(toluene-4-sulfonyloxymethyl)-octanoic acid tert-butyl ester 104 was followed giving 2.1 g of 132 as an oil. The product was used in the next step without further purification. MS, m/z (relative intensity): 329 [M−C(CH 3 ) 3 +1H, 85%], 370 [M−C(CH 3 ) 3 +1H +CH 3 CN, 65%].
[0857] (3S,5S)-3-Azidomethyl-5-methyl-heptanoic acid tert-butyl ester 133
[0858] A procedure similar to the preparation of (3S,5R)-3-azidomethyl-5-methyl-octanoic acid tert-butyl ester 105 was followed giving 0.76 g, 54.0% of 133 as an oil. MS, m/z (relative intensity): 198 [M−C(CH 3 ) 3 −1H, 100%]
[0859] (3S,5S)-3-Aminomethyl-5-methyl-heptanoic acid tert-butyl ester 134
[0860] A procedure similar to that used for (3S,5S)-3-aminomethyl-5-methyl-octanoic acid tert-butyl ester 126 was used giving 0.62 g of 134 as an oil. The product was used in the next step without further purification. MS, m/z (relative intensity): 230 [M+1H, 100%], 271 [M+1H +CH 3 CN, 45%].
Example 12
(3S,5S)-3-Aminomethyl-5-methyl-heptanoic acid
[0861] A procedure similar to that used for Example 11 was used giving (3S,5S)-3-aminomethyl-5-methyl-heptanoic acid (0.3 g, 65.1 %) as a white solid. 1 H NMR (CD 3 OD) δ2.80-3.00 (m, 2H), 2.40 (m, 1H), 2.20 (dd, J=8.2, 7.1 Hz, 1H), 2.05 (m, 1H), 1.30-1.50 (m, 3H), 1.00-1.20 (m, 2H), 0.9 (m, 6H); MS, m/z (relative intensity): 187 [M+1H, 100%], 211 [M+1H+CH 3 CN, 30%]. MS, m/z (relative intensity): 174 [M+1H, 100%], 172 [M−1H, 100%], 215 [M+1H +CH 3 CN, 20%].
Example 13
Synthesis of (3S,5R)-3-Aminomethyl-5-methyl-nonanoic acid hydrochloride
[0862] [0862]
[0863] (R)-4-Methyl-octanoic acid 136
[0864] Lithium chloride (0.39 g, 9.12 mmol) and copper (I) chloride (0.61 g, 4.56 mmol) were combined in 45 ml THF at ambient temperature and stirred 15 minutes, then cooled to 0° C. at which time ethylmagnesium bromide (1 M solution in THF, 45 mL, 45 mmol) was added. (S)-citronellyl bromide (5.0 g, 22.8 mmol) was added dropwise and the solution was allowed to warm slowly to ambient temperature with stirring overnight. The reaction was quenched by cautious addition of sat. NH 4 Cl (aq), and stirred with Et 2 O and sat. NH 4 Cl (aq) for 30 minutes. The phases were separated and the organic phase dried (MgSO 4 ) and concentrated. The crude product was used without purification.
[0865] To a solution of alkene 135 (3.8 g, 22.8 mmol) in 50 mL acetone at 0° C. was added Jones' reagent (2.7 M in H 2 SO 4 (aq), 40 mL, 108 mmol) and the solution was allowed to warm slowly to ambient temperature with stirring overnight. The mixture was partitioned between Et 2 O and H 2 O, the phases were separated, and the organic phase washed with brine, dried (MgSO 4 ), and concentrated. The residue was purified by flash chromatography (8:1 hexanes:EtOAc) to afford 2.14 g (59%) of acid 136 as a colorless oil: LRMS: m/z 156.9 (M+); 1 H NMR (CDCl 3 ): δ2.33 (m, 2H), 1.66 (m, 1H), 1.43 (m, 2H), 1.23 (m, 5H), 1.10 (m, 1H), 0.86 (m, 6H). Jones' reagent was prepared as a 2.7M solution by combining 26.7 g CrO 3 , 23 mL H 2 SO 4 , and diluting to 100 mL with H 2 O.
[0866] (4R, 5S)-4-Methyl-3-((R)-4-methyl-octanoyl)-5-phenyl-oxazolidin-2-one 137
[0867] To acid 136 (2.14 g, 13.5 mmol) in 25 mL CH 2 Cl 2 at 0° C. was added 3 drops DMF, followed by oxalyl chloride (1.42 mL, 16.2 mmol) resulting in vigorous gas evolution. The solution was warmed directly to ambient temperature, stirred 30 minutes, and concentrated. Meanwhile, to a solution of the oxazolidinone (2.64 g, 14.9 mmol) in 40 mL THF at −78° C. was added n-butyllithium (1.6 M soln in hexanes, 9.3 mL, 14.9 mmol) dropwise. The mixture was stirred for 10 minutes at which time the acid chloride in 10 mL THF was added dropwise. The reaction was stirred 30 minutes at −78° C., then warmed directly to ambient temperature and quenched with sat. NH 4 Cl. The mixture was partitioned between Et 2 O and sat. NH 4 Cl (aq), the phases were separated, and the organic phase dried (MgSO 4 ), and concentrated to furnish 3.2 g of oxazolidinone 137 as a colorless oil. LRMS: m/z 318.2 (M+); 1 H NMR (CDCl 3 ): δ7.34 (m, 5H), 5.64 (d, J=7.3 Hz, 1H), 4.73 (quint, J=6.8 Hz, 1H), 2.96 (m, 1H), 2.86 (m, 1H), 1.66 (m, 1H), 1.47 (m, 2H), 1.26 (m, 5H), 1.13 (m, 1H), 0.88 (m, 9H). The crude product was used without purification.
[0868] (3S,5R)-5-Methyl-3-((4R,5S)-4-methyl-2-oxo-5-phenyl-oxazolidine-3-carbonyl)-nonanoic acid tert-butyl ester 138
[0869] To a solution of diisopropylamine (1.8 mL, 12.6 mmol) in 30 mL THF at −78° C. was added n-butyllithium (1.6 M soln in hexanes, 7.6 mL, 12.1 mmol), and the mixture stirred 10 minutes at which time oxazolidinone 137 (3.2 g, 10.1 mmol) in 10 mL THF was added dropwise. The solution was stirred for 30 minutes, t-butyl bromoacetate (1.8 mL, 12.1 mmol) was added quickly dropwise at −50° C., and the mixture was allowed to warm slowly to 10° C. over 3 hours. The mixture was partitioned between Et 2 O and sat. NH 4 Cl (aq), the phases were separated, and the organic phase dried (MgSO 4 ), and concentrated. The residue was purified by flash chromatography (16:1 to 8:1 hexanes:EtOAc) to provide 2.65 g (61%) of ester 138 as a colorless crystalline solid, mp=84-86° C. [α] D 23 +17.1 (c=1.00, CHCl 3 ); 1 H NMR (CDCl 3 ): δ7.34 (m, 5H), 5.62 (d, J=7.3 Hz, 1H), 4.73 (quint, J=6.8 Hz, 1H), 4.29 (m, 1H), 2.67 (dd, J=9.8, 16.4 Hz, 1H), 2.40 (dd, J=5.1, 16.4 Hz, 1H), 1.69 (m, 1H), 1.38 (s, 9H), 1.28 (m, 7H), 1.08 (m, 1H), 0.88 (m, 9H); 13 C NMR (CDCl 3 ) δ176.45, 171.22, 152.71, 133.64, 128.86, 125.86, 80.83, 78.87, 55.33, 40.02, 38.21, 37.59, 36.31, 30.86, 29.29, 28.22, 23.14, 20.41, 14.36, 14.26. Anal. Calcd for C 25 H 37 NO 5 : C, 69.58; H, 8.64; N, 3.25. Found: C, 69.37; H, 8.68; N, 3.05.
[0870] (S)-2-((R)-2-Methyl-hexyl)-succinic acid 4-tert-butyl ester 139
[0871] To a solution of ester 138 (2.65 g, 6.14 mmol) in 20 mL THF at 0° C. was added a precooled (0° C.) solution of LiOH monohydrate (1.0 g, 23.8 mmol) and hydrogen peroxide (30 wt% aqueous soln, 5.0 mL) in 10 mL H 2 O. The mixture was stirred vigorously for 90 minutes, then warmed to ambient temperature and stirred 90 minutes. The reaction was quenched at 0° C. by addition of 100 mL 10% NaHSO 3 (aq), then extracted with Et 2 O. The phases were separated, and the organic phase washed with brine, dried (MgSO 4 ), and concentrated. The crude acid 139 was used without purification.
[0872] (3S,5R)-3-Hydroxymethyl-5-methyl-nonanoic acid tert-butyl ester 140
[0873] To a solution of the crude acid 139 (6.14 mmol) in 30 mL THF at 0° C. was added borane-dimethyl sulfide complex (2.0 M soln in THF, 4.6 mL, 9.2 mmol), and the mixture was allowed to warm slowly to ambient temperature overnight. Additional BH 3 -DMS was added until the acid was completely consumed (ca. 5 mL). The reaction was quenched by addition of MeOH, then partitioned between Et 2 O and sat. NaHCO 3 (aq). The phases were separated, and the organic phase washed with brine, dried (MgSO 4 ), and concentrated to provide alcohol 140. LRMS: m/z 226.1; 1 H NMR (CDCl 3 ): δ3.63 (dd, J=11.0, 4.2 Hz, 1H), 3.42 (dd, J=11.0, 6.8 Hz, 1H), 2.30 (dd, J=14.9, 7.6 Hz, 1H), 2.20 (dd, J=14.9, 5.6 Hz, 1H), 2.03 (m, 2H), 1.42 (s, 9H), 1.24 (m, 6H), 1.02 (m, 2H), 0.85 (m, 6H). The crude product was used without purification.
[0874] (3S,5R)-5-Methyl-3-(toluene-4-sulfonyloxymethyl)-nonanoic acid tert-butyl ester 141
[0875] To alcohol 140 (6.14 mmol) in 30 mL CH 2 Cl 2 at 0° C. was added DMAP (0.1 g),p-toluenesulfonyl chloride (1.37 g, 7.2 mmol), and then triethylamine (1.8 mL, 13 mmol) was added quickly dropwise. The mixture was warmed immediately to ambient temperature following addition and stirred overnight, and did not proceed to completion. The mixture was partitioned between Et 2 O and 1N HCl (aq), the phases were separated, and the organic phase washed with sat. NaHCO 3 (aq), dried (MgSO 4 ), and concentrated to provide tosylate 141. The product was used without further purification.
[0876] (3S,5R)-3-Azidomethyl-5-methyl-nonanoic acid tert-butyl ester 142
[0877] A procedure similar to the preparation of (3S,5R)-3-azidomethyl-5-methyl-octanoic acid tert-butyl ester 105 was followed giving azide 142 as a colorless oil. LRMS: m/z 200.1; 1 H NMR (CDCl 3 ): δ3.31 (dd, J=12.2, 4.2 Hz, 1 H), 3.19 (dd, J=12.2, 5.9 Hz, 1H), 2.22 (m, 1H), 2.10 (m, 1H), 1.39 (s, 9H), 1.21 (m, 8H), 1.00 (m, 2H), 0.81 (m, 6H).
Example 13
(3S,5R)-3-Aminomethyl-5-methyl-nonanoic acid hydrochloride
[0878] The azide 142 (1.0 g) was hydrogenated in the presence of 20% Pd/C, EtOH, at 45 psi of H 2 for 15 hours to provide the crude amino ester 143 which was concentrated and used without purification. To the amino ester 143 was added 6 mL 6N HCl (aq) and the mixture was heated to reflux 90 minutes, cooled, and concentrated. Recrystallization from EtOAc:hexanes provided 0.38 g (45% from azide) of (3S,5R)-3-aminomethyl-5-methyl-nonanoic acid hydrochloride as a colorless crystalline solid (HCl salt), and a second crop of 82 mg (10% from azide) was also obtained. mp=146-156° C. LRMS: m/z 200.1 (M+); 1 H NMR (CDCl 3 ): δ2.87 (dd, J=13.2, 5.4 Hz, 1H), 2.79 (dd, J=13.2, 7.3 Hz, 1H), 2.29 (d, J=6.8 Hz, 2H), 2.08 (m, 1H), 1.31 (m, 1H), 1.09 (m, 7H0, 0.92 (m, 1H), 0.68 (m, 6H). Anal. Calcd for C 11 H 24 NO 2 Cl: C, 55.57; H, 10.17; N, 5.89. Found: C, 55.69; H, 10.10; N, 5.86.
Example 14
Synthesis of (3S,5S)-3-Aminomethyl-5-methyl-nonanoic acid
[0879] [0879]
[0880] The (S)-acid 145 was prepared from (R)-citronellyl bromide according to the procedure outlined above for (R)-4-methyl-octanoic acid 136. The yield was comparable and the 1 H NMR spectrum was identical to that of the (R)-acid enantiomer. LRMS: m/z 158.9 (M+1).
[0881] Oxazolidinone 146 was prepared from acid 145 as described above for (4R,5S)-4-methyl-3-((R)-4-methyl-octanoyl)-5-phenyl-oxazolidin-2-one 137. LRMS: m/z 290.1 (M−27); 1 H NMR (CDCl 3 ): δ7.38 (m, 3H), 7.28 (m, 2H), 5.64 (d, J=7.1 Hz, 1H), 4.74 (quint, J=6.8 Hz, 1H), 2.92 (m, 2H), 1.71 (m, 1H), 1.42 (m, 7H), 1.18 (m, 1H), 0.88 (m, 9H).
[0882] t-Butyl ester 147 was prepared from oxazolidinone 146 as described above for compound 138. LRMS: m/z 348.1 (M−83).
[0883] Alcohol 149 was prepared from the t-butyl ester 147 as described above for (3S,5R)-3-hydroxymethyl-5-methyl-nonanoic acid tert-butyl ester 140. LRMS: m/z 156.9 (M−100); 1 H NMR (CDCl 3 ): δ3.60 (dd, J=11.0, 4.6 Hz, 1H), 3.45 (dd, J=11.0, 6.8 Hz, 1H), 2.24 (m, 2H), 2.04 (m, 2H), 1.42 (s, 9H), 1.17-1.38 (m, 7H), 1.11 (m, 1H), 0.84 (m, 6H).
Example 14
(3S,5S)-3-Aminomethyl-5-methyl-nonanoic acid
[0884] (3S,5S)-3-Aminomethyl-5-methyl-nonanoic acid was obtained from 149 as described above for (3S,5R)-3-aminomethyl-5-methyl-nonanoic acid hydrochloride. The crude HCl salt thus obtained was purified by ion exchange chromatography on Dowex 50WX8 50-100 mesh, H-Form resin, using 10%NH 4 OH as eluant to provide the free base. The waxy solid was washed twice with Et 2 O and dried to furnish an amorphous white solid, mp 144-146° C. LRMS: m/z 172.0 (M−28); 1 H NMR (CDCl 3 ): δ2.76 (d, J=5.9 Hz, 2H), 2.14 (m, 1H), 1.96 (m, 2H), 1.25 (m, 1H), 1.12 (m, 6H), 0.96 (m, 2H), 0.66 (m, 6H).
Example 15
Synthesis of (3S,5R)-3-Aminomethyl-5-methyl-decanoic acid
[0885] [0885]
[0886] (R)-2,6-Dimethylundec-2-ene 153
[0887] A procedure similar to the preparation of (S)-2,6-dimethyl-non-2-ene 119 was used giving 153 as a colorless oil (20.16 g, 98%). 1 H NMR (400 MHz, CDCl 3 ) δ5.10-5.06 (m, 1H), 2.10-1.89 (m, 2H), 1.66 (s, 3H), 1.58 (s, 3H), 1.34-1.23 (m, 4H), 1.15-1.06 (m, 2H), 0.88-0.81 (m, 11H).
[0888] (R)-4-methylnonanoic acid 154
[0889] (R)-2,6-Dimethylundec-2-ene 153 (10.03 g, 55.03 mmol) was dissolved in acetone (270 mL) and cooled to 0° C. Jones reagent (CrO 3 /H 2 SO 4 ) (2.7 M, 120 mL) was added dropwise, and the reaction allowed to warm to room temperature over 18 hours. The reaction was poured on to water/Na 2 SO 4 (200 mL), and the aqueous layer extracted with ethyl acetate (4×100 mL). The combined organics were dried over MgSO 4 , filtered and rotovapped to give an oil. The crude oil was dissolved in CH 2 Cl 2 (400 mL) and cooled to −78° C. Ozone was bubbled into reaction until blue to remove traces of the impurity (6E)(3S)-3,7-dimethylocta-1,6-diene. Dimethylsulfide (5 mL) was added, and the reaction stirred at room temperature for 2 hours. The solvent was removed, and the crude material chromatographed on silica eluting with 20% EtOAc/hex to give oil. The oil was dissolved in ether (100 mL) and extracted with 10% NaOH (2×25 mL). The aqueous layers were combined and extracted with ether (50 mL). The aqueous layer was cooled to 0° C. and acidified with HCl. The acidic layer was extracted with EtOAc (3×100 mL), and the combined extracts dried over MgSO 4 , filtered and rotovapped to give 154 as an oil (6.86 g, 54%). 1 H NMR (400 MHz, CDCl 3 ) δ2.40-2.25 (m, 4H), 1.70-1.62 (m, 2H), 1.47-1.11 (m, 8H), 0.87-0.84 (m, 6H); [α] D =−11.4 (c1 in CHCl 3 ).
[0890] (4R,5S)-4-Methyl-3-((R)-4-methyl-nonanoyl)-5-phenyl-oxazolidin-2-one 155
[0891] Compound 154 (6.504 g, 37.76 mmol) was dissolved in THF (95 mL) and cooled to 0° C. Triethylamine (19.74 mL, 141.6 mmol) was added dropwise, followed by dropwise addition of trimethylacetyl chloride (6.98 mL, 56.64 mmol). The thick white suspension was stirred at 0° C. for 90 minutes. LiCl (1.86 g, 41.54 mmol), (4R)-4-methyl-5-phenyl-1,3-oxazolidin-2-one (6.824 g, 38.51 mmol), and THF (70 mL) were added, and the reaction warmed to room temperature overnight. The solvent was evaporated. The solids were taken up in EtOAc, filtered off, and washed generously with EtOAc. The filtrate was washed with water (2×50 mL), and brine. The organics were dried over MgSO 4 , filtered, and rotovapped. The crude material was chromatographed on silica eluting with 10% EtOAc/hexanes to give 155 as an oil (10.974 g, 88%). 1 H NMR (400 MHz, CDCl 3 ) δ7.44-7.35 (m, 3H), 7.31-7.26 (m, 2H), 5.66 (d, J=7.33 Hz, 1H), 4.76 (quin, J=7.03 Hz, 1H), 3.04-2.96 (m, 1H), 2.93-2.86 (m, 1H), 1.74-1.66 (m, 1H), 1.52-1.47 (m, 1H), 1.46-1.36 (m, 2H), 1.27-1.16 (m, 2H), 0.92-0.87 (m, 8); [α] D =+34.1 (c1 in CHCl 3 ).
[0892] (3S,5R)-5-Methyl-3-((4R,5S)-4-methyl-2-oxo-5-phenyl-oxazolidine-3-carbonyl)-decanoic acid tert-butyl ester 156
[0893] A procedure similar to the preparation of (3S,5S)-5-methyl-3-((4R,5S)-4-methyl-2-oxo-5-phenyl-oxazolidine-3-carbonyl)-octanoic acid tert-butyl ester 122 was followed giving (3S,5R)-5-methyl-3-((4R,5S)-4-methyl-2-oxo-5-phenyl-oxazolidine-3-carbonyl)-decanoic acid tert-butyl ester 156 as an oil (0.668g, 90%). 1 H NMR (400 MHz, CDCl 3 ) δ7.41-7.28 (m, 5H), 5.63 (d, J=7.33 Hz, 1H), 4.74 (quin, J=6.84 Hz, 1H), 4.33-4.26 (m, 1H), 2.68 (dd, J=16.4, 9.77 Hz, 1H), 2.41 (dd, J=16.6, 4.88 Hz, 1H), 1.68 (quin, J=6.6 Hz, 1H), 1.50-1.32 (m, 10H), 1.28-1.21 (m, 1H), 1.15-1.08 (m, 1H), 0.90-0.86 (m, 9H); MS (APCI) m/z 348 (M+−97, 100%); [α] D =+18.8 (c1 in CHCl 3 ).
[0894] (S)-2-((R)-2-Methyl-heptyl)-succinic acid 4-tert-butyl ester 157
[0895] Compound 156 (5.608 b, 12.59 mmol) was dissolved in THF/H 2 O (60 mL/14 mL) and cooled to 0° C. LiOH (IN, 18.89 mL) and H 2 O 2 (35%, 4.45 mL, 50.4 mmol) were combined, and then added to the reaction dropwise keeping T <5° C. the reaction was stirred at 0° C. for 4 hours, and quenched with Na 2 SO 3 (6.3 g) and NaHSO 3 (3.4 g) in 50 mL H 2 O added dropwise. The reaction was stirred for 15 minutes, and the layers separated. The aqueous layer was extracted with EtOAc (3×100 mL), and the combined extracts dried over MgSO 4, filtered, and rotovapped to give an oil. The crude material was dissolved in EtOAc (10 mL) and added dropwise to heptane (250 mL). The suspension was stirred for 20 minutes, and the solids filtered and washed with heptane. The filtrate was washed with 60° C. H 2 O (100 mL), dried over MgSO 4 , filtered, and rotovapped to give 157 as an oil (3.52 g). the material was used directly in the next step.
[0896] (3S,5R)-3-Hydroxymethyl-5-methyl-decanoic acid tert-butyl ester 158
[0897] Compound 157 (3.52 g, 12.3 mmol) was dissolved in anhydrous THF (123 mL) and cooled to 0° C. Borane dimethylsulfide complex (10 M, 3.69 mL) was added dropwise, and the reaction then warmed to room temperature and stirred for 1 hour. the reaction was cooled to 0° C., and quenched with MeOH (20 mL) added dropwise. The reaction was stirred for 18 hours, and the solvent rotovapped off. The crude material was chromatographed on silica eluting with 20% EtOAc/hexanes to give 158 (2.28 g, 68%) as an oil. 1 H NMR (400 MHz, CDCl 3 ) δ3.65-3.59 (m, 1H), 3.43 (dd, J=11.1, 6.96 Hz, 1H), 2.31 (dd, J=14.9, 7.57 Hz, 1H), 2.21 (dd, J=15.1, 5.62 Hz, 1H), 2.06-2.02 (m, 1H), 1.43 (s, 9H), 1.40-1.25 (m, 4H), 1.07-1.13 (m, 1H), 1.03-0.96 (m, 1H), 0.86-0.84 (m, 6H); MS (APCI) m/z 216 (M + −56, 100%).
[0898] (3S,5R)-5-Methyl-3-(toluene-4-sulfonyloxymethyl)-decanoic acid tert-butyl ester 159
[0899] Compound 158 (2.27 g, 8.33 mmol) was dissolved in CH 2 Cl 2 (30 mL) and cooled to 0° C. Tosyl chloride (1.91 g, 10.0 mmol) and catalytic DMAP were added, followed by dropwise addition of triethylamine (2.55 mL, 18.33 mmol). The reaction was then stirred at 0° C. for 18 hours. The solvent was rotovapped off (removed under reduced pressure), and the crude material washed with EtOAc and filtered. The solids were washed with EtOAc, and the filtrate washed with 0.5N HCl (20 mL), brine (30 mL), dried over MgSO 4, filtered and rotovapped. The oil was chromatographed on silica eluting with a 5% EtOAc/hexanes gradient to 10% EtOAc/hexanes to give 159 (3.399 g, 96%) as an oil. 1 H NMR (400 MHz, CDCl 3 ) δ7.75 (d, J=8.30 Hz, 2H), 7.31 (d, J=8.30 Hz, 2H), 3.99 (dd, J=9.65, 3.54 Hz, 1H), 3.89 (dd, J=9.52, 5.37 Hz, 1H), 2.42 (s, 3H), 2.28 (dd, J=14.7, 6.23 Hz, 1H), 2.19-2.14 (m, 1H), 2.10 (dd, J=14.9, 6.35 Hz, 1H), 1.38 (s, 9H), 1.31-1.17 (m, 3H), 1.08-0.81 (m, 2H), 0.79-0.76 (m, 6H); [α] D =−10.1 (c1 in CHCl 3 ).
[0900] (3S,5R)-3-Azidomethyl-5-methyl-decanoic acid tert-butyl ester 160
[0901] Compound 159 (3.01 g, 7.05 mmol), sodium azide (1.26 g, 19.40 mmol) and DMSO (12 mL) were combined and heated to 60° C. for 3 hours. EtOAc (100 mL) was added to the reaction and filtered. The solids were washed with EtOAc (20 mL), and the filtrated evaporated. The crude material was chromatographed on silica eluting with 5% EtOAc/hexanes to give 160 as an oil (1.86 g, 89%).
[0902] (3S,5R)-3-Aminomethyl-5-methyl-decanoic acid tert-butyl ester 161
[0903] A solution of compound 160 (1.86 g, 6.25 mmol) in THF (50 mL) was shaken over 5% Pd/C under hydrogen and pressure for 8 hours with three purges of hydrogen. The catalyst was filtered off and the filtrate evaportated. The crude material was chromatographed on silica eluting with methanol to give 161 as an oil (1.21 g, 71%). 1 H NMR (400 MHz, CDCl 3 ) δ2.70 (dd, J=12.9,4.40 Hz, 1H), 2.54 (dd, J=12.7, 6.59 Hz, 1H), 2.26 (dd, J=14.5, 6.96, 1H), 2.12 (dd, J=14.5, 6.47 Hz, 1H), 1.91 (m, 1H), 1.91 (m, 1H), 1.43 (s, 12H), 1.39-1.25 (m, 4H), 1.14-1.07 (m, 1H), 1.03-0.97 (m, 1H), 0.86-0.82 (m, 6H).
Example 15
(3S,5R)-3-Aminomethyl-5-methyl-decanoic acid
[0904] Compound 161 (1.20 g, 4.44 mmol) was heated to 50° C. in 3N HCl (30 mL) for 4 hours. The solvent was evaporated, and the oil washed with toluene, and evaporated. The crude material was passed through an ion exchange column (Dowex 50WX8-100, strongly acidic) eluting with water, then 0.5N NH 4 OH. Isolate (3S,5R)-3-aminomethyl-5-methyl-decanoic acid as a white solid (0.725 g, 75%): mp=174-175° C.; 1 H NMR (400 MHz, CDCl 3 ) δ2.83 (dd, J=12.69, 4.88 Hz, 1H), 2.70 (dd, J=13.1, 7.45 Hz, 1H), 2.08 (d, J=6.59 Hz, 2H), 1.98 (m, 1H), 1.28-1.20 (m, 1H), 1.19-1.09 (m, 2H), 0.99-0.91 (m, 2H), 0.66 (m, 6H); MS (APCI) m/z 215 (M + , 10%), 174 (M + −41, 100%); [α] D =5.7 (c1.025 in H 2 O).
Example 16
Synthesis of (3S,5S)-3-Aminomethyl-5-methyl-decanoic acid
[0905] [0905]
[0906] (S)-2,6-Dimethyl-undec-2-ene 162
[0907] nPropylmagnesium chloride/ether solution (2.0 M, 228 mL) was cooled to −20° C. under a N 2 atmosphere. LiCl (3.87 g, 91.25 mmol), CuCl 2 (6.13 g, 45.63 mmol), and distilled THF (456 mL) were combined and stirred for 30 minutes. The Li 2 CuCl 4 solution was added via cannula to the Grignard reagent, and the resulting solution stirred for 30 minutes at −20° C. R-(−)-Citronellyl bromide (50 g, 228.1 mmol) was dissolved in THF (60 mL) and added dropwise to the Grignard solution. The reaction was stirred at 0° C. for 1 hour. The reaction was cooled to −40° C. and quenched with NH 4 Cl (sat'd, 200 mL) added dropwise. The layers were separated and the aqueous layer extracted with ether (3×100 mL). The combined organics were dried over MgSO 4, filtered, and rotovapped to give an oil. The crude material was chromatographed on silica eluting with hexanes to give 162 as a colorless oil (9.15 g, 22%). 1 H NMR (400 MHz, CDCl 3 ) δ5.10-5.06 (m, 1H), 2.10-1.89 (m, 2H), 1.66 (s, 3H), 1.58 (s, 3H), 1.34-1.23 (m, 4H), 1.15-1.06 (m, 2H), 0.88-0.81 (m, 11H).
[0908] (S)-4-Methylnonanoic Acid 163
[0909] Compound 162 (7.97 g, 43.7 mmol) was dissolved in acetone (214 mL) and cooled to 0° C. Jones reagent (CrO 3 /H 2 SO 4 ) (2.7 M, 95 mL) was added dropwise, and the reaction allowed to warm to room temperature over 18 hours. The reaction was poured on to water/Na 2 SO 4 (200 mL), and the aqueous layer extracted with ethyl acetate (4×100 mL). The combined organics were dried over MgSO 4 , filtered, and rotovapped to give an oil. The crude oil was chromatographed on silica eluting with hexanes to give 163 as an oil (5.56 g, 74%). 1 H NMR (400 MHz, CDCl 3 ) δ2.40-2.25 (m, 4H), 1.70-1.62 (m, 2H), 1.47-1.11 (m, 8H), 0.87-0.84 (m, 6H); MS APCI m/z 170.9 (M−1, 100%).
[0910] (4R,5S)-4-Methyl-3-((S)-4-methyl-nonanoyl)-5-phenyl-oxazolidin-2-one 164
[0911] A procedure similar to that used to prepare compound 155 was used except that (S)-4-methylnonanoic acid 163 (5.56 g, 32.27 mmol) was used as a reactant to give 164 as an oil (10.70 g 100%). 1 H NMR (400 MHz, CDCl 3 ) δ7.42-7.34 (m, 3H), 7.28 (d, J=6.59 Hz, 2H), 5.64 (d, J=7.33 Hz, 1H), 4.74 (quin, J=6.78 Hz, 1H), 2.94-2.85 (m, 2H), 1.73-1.67 (m, 1H), 1.47-1.43 (m, 1H), 1.39-1.22 (m, 7H), 0.90-0.84 (m, 8H).
[0912] (3S,5S)-5-Methyl-3-((4R,5S)-4-methyl-2-oxo-5-phenyl-oxazolidine-3-carbonyl)-decanoic acid tert-butyl ester 165
[0913] A procedure similar to that used to prepare compound 156 was used to give 165 as a solid (4.25 g, 61%). MS (APCI) m/z 446 (M + +1, 10%), 390 (M + −55, 100%, -tBu).
[0914] (S)-2-((S)-2-Methyl-heptyl)-succinic acid 4-tert-butyl ester 166
[0915] A procedure similar to that used for compound 157 was used except that ester 165 (8.42 g, 18.89 mmol) was used as a reactant to give 166 as an oil (5.81 g). The material was used directly in the next step. MS (APCI) m/z 285 (M−1, 100%).
[0916] (3S,5S)-3-Hydroxymethyl-5-methyl-decanoic acid tert-butyl ester 167
[0917] A procedure similar to that used to prepare compound 158 was used except that (S)-2-((S)-2-methyl-heptyl)-succinic acid 4-tert-butyl ester 166 (5.78 g, 20.18 mmol) was used as a reactant to give 167 as an oil (4.18 g, 76%). 1 H NMR (400 MHz, CDCl 3 ) δ3.64-3.58 (m, 1H), 3.84-3.42 (m, 1H), 2.28-2.20 (m, 1H), 2.09-2.02 (m, 1H), 1.43 (s, 9H), 1.26-1.18 (m, 8H), 1.11-1.04 (m, 2H), 0.87-0.83 (m, 6H); MS (APCI) m/z 217 (M + −55, 50%, -tBu).
[0918] (3S,5S)-5-Methyl-3-(toluene-4-sulfonyloxymethyl)-decanoic acid tert-butyl ester 168
[0919] A procedure similar to that used to prepare compound 159 was used except that (3S,5S)-3-Hydroxymethyl-5-methyl-decanoic acid tert-butyl ester 167 (4.164 g, 15.29 mmol) was used as a reactant to give 168 as an oil (4.17 g, 64%). 1 H NMR (400 MHz, CDCl 3 ) δ7.75 (d, J=8.30 Hz, 2H), 7.31 (d, J=8.30 Hz, 2H), 3.97 (dd, J=9.52, 4.15 Hz, 1H), 3.90 (dd, J=9.52, 5.13 Hz, 1H), 2.42 (s, 3H), 2.28, 2.19-2.13 (m, 2H), 1.37 (s, 9H), 1.27-1.01 (m, 11H), 0.85 (t, J=7.08 Hz, 3H), 0.76 (d, J=6.35 Hz, 3H).
[0920] (3S,5S)-3-Azidomethyl-5-methyl-decanoic acid tert-butyl ester 169
[0921] A procedure similar to that used to prepare compound 160 was used except (3S,5S)-5-methyl-3-(toluene-4-sulfonyloxymethyl)-decanoic acid tert-butyl ester 168 (4.155 g, 9.74 mmol) was used as a reactant to give 169 as an oil (2.77 g, 96%). MS (APCI) m/z 270 (M + −27, 30%, —N 2 ), 214 (M + −87, 100%, -tBu, —N 2 ).
[0922] (3S,5S)-3-Aminomethyl-5-methyl-decanoic acid tert-butyl ester 170
[0923] A procedure similar to that used to prepare compound 161 was used except that (3S,5S)-3-Azidomethyl-5-methyl-decanoic acid tert-butyl ester 169 (2.50 g, 8.405 mmol) was used as a reactant to give 170 as an oil (1.648 g, 72%). MS (APCI) m/z 272 (M + +1, 100%).
Example 14
(3S,5S)-3-Aminomethyl-5-methyl-decanoic acid
[0924] A procedure similar to that used for Example 15 was used except tert-butyl (3S,5S)-3-(aminomethyl)-5-methyldecanoate 170 (1.6 g, 6.00 mmol) was used as a reactant to give Example 16 as a white solid (72%). MS (APCI) m/z 272 (M + +1, 100%). mp=174-175° C.; 1 H NMR (400 MHz, CD 3 OD) δ2.91 (dd, J=12.9, 3.91 Hz, 1H), 2.83 (dd, J=12.7, 7.57 Hz, 1H), 2.43 (dd, J=15.6, 3.17 Hz, 1H), 2.19 (dd, J=15.6, 8.80 Hz, 1H), 2.08-2.04 (m, 1H), 1.53 (m, 1H), 1.38-1.27 (m, 7H), 1.78-1.03 (m, 2H), 0.90-0.86 (m, 6H), 0.66 (m, 6H); MS (APCI) m/z 216 (M + +1, 100%), 214 (M −1 , 100%); [α] D =+21.4 (c1 in MeOH).
Example 17
Synthesis of (3R,4R)-3-Aminomethyl-4,5-dimethyl-hexanoic acid
[0925] [0925]
[0926] (S)-2-Benzyl-3-methyl-butan-1-ol 172
[0927] Ref. JACS 1997;119:6510. Amide 171.
[0928] Large scale procedure for the synthesis of acetic acid (S)-2-benzyl-3-methyl-butyl ester 173 from 171
[0929] A of n-butyl lithium (10 M in hexane, 100 mL, 1000 mmol, 3.9 equiv.) was added to a solution of diisopropylamine (108.9 g, 150.9 mL, 1.076 mol, 4.20 equiv.) in THF (600 mL), at −78° C. The resulting solution was stirred for 10 minutes and warmed to 0° C., and hold at the temperature for 10 minutes. Borane-ammonia complex (31.65 g, 1.025 mmol, and 4.0 equiv) was added in one portion, and the suspension was stirred at 0° C. for 15 minutes, and at 23° C. for 15 minutes, and then cooled to 0° C. A solution of amide 171 (86 g, 256.41 mmol, 1 equiv.) in THF was added to the cold hydride via a cannula over 3 minutes. The reaction was stirred at 23° C. for overnight, then cooled to 0° C. Excess hydride was quenched by the slow addition of 3N HCl (700 mL). The reaction mixture was diluted with more aqueous HCl (3N, 200 mL), and brine and then extracted with ether (4×15 mL). The ether solution was concentrated to a small volume, and 200 mL 2N NaOH was added, and stirred at 23° C. for 2.5 hours. More ether was added and the layers were separated. The aqueous layer was saturated with salt and extracted with ether (3×200 mL). The combined organic was washed with brine and dried on sodium sulfate. The residue was flash chromatographed (Pet. ether-25% ether -TEA ) to give alcohol 172, 50 g. NMR (CDCl 3 ) δ7.35-7.16 (m, 5H, C 6 H 5 ), 3.55 (app. t, 2H, —CH 2 OH), 2.71 (dd, 1H, ArCH 2 CH—), 2.52 (dd, 1H, ArCH 2 CH), 1.87 (m, 1H, CHCH(Me), 1.67 (m, 1H, CH(Me) 2 ), 0.98 (d, 3H, CH 3 ) and 0.96 (d, 3H, CH 3 ).
[0930] A sample 3.3 g was saved for characterization and the rest was immediately acetylated (triethylamine 50 mL, DMAP 4.6 g, acetic acid anhydride 32 mL) overnight at room temperature. Work up followed by chromatography on silica gel eluted with pet ether and then 10% ether in pet ether gave 62 g of 173. NMR (CDCl 3 ) δ7.30-7.14 (m, 5H, C 6 H 5 ), 3.98 (m, 2H, —CH 2 OAc), 2.71 (dd, 1H, ArCH 2 CH—), 2.51 (dd, 1H, ArCH 2 CH), 1.99 (s, 3H, CH 3 C═O), 1.82 (m, 1H, CHCH(Me) and CH(Me) 2 ), 0.97 (d, 3H, CH 3 ) and 0.95 (d, 3H, CH 3 ).
[0931] (S)-Acetoxymethyl-4-methyl-pentanoic acid 174 and (S)-4-Isopropyl-dihydrofuran-2-one 175
[0932] Acetate 173 (15 g, 68.18 mmol) was dissolved in CH 3 CN (150 mL), carbon tetrachloride (150 mL) and HPLC grade water (300 ML) and stirred. Sodium periodate (262.50 g, 1220 mmol) was added followed by ruthenium chloride (650 mg, 3.136 mmol). After overnight stirring it was diluted with ether and water, and filtered through a pad of Celite. The organic portion was separated and the aqueous phase was further extracted with ether. After drying on magnesium sulfate the solvent was evaporated. Potassium carbonate (42 g) was added to the residue and refluxed overnight in methanol (250 mL) and cooled to room temperature. After evaporation, water was added to dissolve the solid, and conc. HCl was added to bring the pH to 2. Chloroform was added and extracted overnight. The organic phase was separated, and aqueous was further extracted with chloroform. The combined organic extracts were dried, evaporated, and the product was purified on a silica gel column and the compound was eluted with 20% ether in methylene chloride. Fractions were monitored by tlc, and spots were detected with I 2 /KI solution. Fractions were combined to give 4.6 g of lactone 175. NMR (CDCl 3 ) δ4.38 (dd, 1H, CH a H b O), 3.93 (app. t, 1H, CH a H b O), 2.54 (dd, 1H, CH c H d C═O), 2.23 (m, 2H, CHCH(Me) and CH c H d C═O), 1.60 (m, 1H, CH(Me) 2 ), 0.92 (d, 3H, CH 3 ) and 0.85 (d, 3H, CH 3 ).
[0933] (3R,4R)-3-Benzyl-4-isopropyl-dihydro-furan-2-one 176
[0934] Lithium bis(trimethylsilyl)amide (1.0 M solution in THF, 92 mL, 92 mmol) was added in 3-5 minutes to a solution of (S)-β-(2-propyl)-γ-butyrolactone 175 (11.68 g, 91.25 mmol) in dry THF 100 mL at −78° C. under argon atmosphere. It was stirred for 1 h and a solution of benzyl iodide (21.87 g, 100.37 mmol )in dry THF was added rapidly. Stirring was continued for 1.5 hours and quenched at −78° C. by the addition of a solution of brine followed by ethyl acetate. The organic phase was separated and the aqueous was further extracted with ether. Chromatography on silica gel first eluted with 5% methylene chloride in pet ether, and finally with 10% ether in pet ether gave desired compound 11.6 g, 58%. NMR (CDCl 3 ) δ7.19 (m, 5H, C 6 H 5 ), 4.02 (app. t, 1H, CH a H b O), 3.87 (dd, 1H, CH a H b O), 2.98 (d, 2H, ArCH 2 ), 2.57 (q, 1H, BnCHC═O), 2.05 (m, 1H, CHCH(Me) 2 , 1.55 (m, 1H, CH(Me) 2 ), 0.81 (d, 3H, CH 3 ) and 0.72 (d, 3H, CH 3 ).
[0935] (2R,3R)-2-Benzyl-3-bromomethyl-4-methyl-pentanoic acid ethyl ester 177
[0936] Lactone 176 (6.5 g, 29.8 mmol) was dissolved in abs. ethanol (80 mL) and cooled in ice bath. Anhydrous HBr was bubbled through the solution for 1 hour and stirred at room temperature overnight while maintaining reaction under dry atmosphere. It was poured onto ice cooled mixture of pet ether and brine. The organic phase was separated, and the aqueous was further extracted with pet ether. The combined organic solution was washed repeatedly with cold water and dried. Solvent was removed in vacuo to give crude compound 7.0 g. NMR (CDCl 3 ) δ7.27 (m, 5H, C 6 H 5 ), 4.02 (m, 2H, CH 3 CH 2 O), 3.70 (dd, 1H, CH a H b Br), 3.55 (dd, 1H, CH a H b Br), 2.97 (m, 2H, ArCH 2 ), 2.83 (q, 1H, BnCHC═O), 2.11 (m, 1H, CHCH(Me) 2 , 1.97 (m, 1H, CH(Me) 2 ), 1.10 (t, 3H, CH 3 CH 2 O), 0.96 (d, 3H, CH 3 ) and 0.93 (d, 3H, CH 3 ).
[0937] (2R,3R)-2-Benzyl-3,4-dimethyl-pentanoic acid ethyl ester 178
[0938] Bromoester 177 (7.25 g, about 80% pure), in ethanol (100 mL) containing triethylamine (3.2 mL) was hydrogenated overnight in the presence of 20% Pd/C (1.0 g). It was filtered through a pad of Celite, and the cake was washed with ethanol. Solvent was evaporated, and the residue was taken up in ether, whereupon solid (Et 3 N.HCl) separated. The solid was removed by filtration. The filtrate was concentrated, and the procedure was repeated to eliminate all hydrochloride salt. Product was chromatographed on a silica gel column which was eluted with pet ether to give the desired debrominated compound 3.35 g. NMR (CDCl 3 ) δ7.21 (m, 5H, C 6 H 5 ), 3.95 (m, 2H, CH 3 CH 2 O), 2.85 (m, 2H, ArCH 2 ), 2.64 (q, 1H, BnCHC═O), 1.85 (m, 1H, CHCH(Me) 2 , 1.62 (m, 1H, CH(Me) 2 ), 1.05 (t, 3H, CH 3 CH 2 O), 0.95 (d, 3H, CH 3 ) 0.84 (d, 3H, CH 3 ) and 0.82 (d, 3H, CH 3 ). MS gave 290 (M+CH 3 CN), 249 (M+1), and others at 203. Further elution with ether gave lactone (2.25 g) that was carried over from previous step.
[0939] Acetic acid (2R,3R)-2-benzyl-3,4-dimethyl-pentyl-ester 179
[0940] Ethyl ester 178 (3.20 g, 12.85 mmol) was dissolved in anhydrous ether and cooled in ice bath under inert atmosphere. Lithium aluminum hydride (500 mg, 13.15 mmol) was added, and the suspension was stirred at room temperature overnight. Excess LAH was destroyed by careful addition of ethyl acetate while the reaction was stirred in ice bath. Saturated sodium sulfate was added cautiously to coagulate the alumina that separated at room temperature as white precipitate. The reaction mixture was diluted with methylene chloride, and anhydrous sodium sulfate was added to dry the mixture. After filtration the solution was concentrated to give an oil 3.0 g.
[0941] The material (3.0 g) was dissolved in dichloromethane (30 mL) and triethylamine (2.5 mL), DMAP (200 mg), and acetic anhydride (1.5 mL) were added. It was stirred at room temperature for 3 hours, and diluted with ether. The ether solution was washed with waster, 1N HCl, saturated sodium bicarbonate, brine and dried. The solution was concentrated in vacuo to give the acetoxy compound 179 3.16 g. NMR (CDCl 3 ) δ7.19 (m, 5H, C 6 H 5 ), 4.03 (m, 2H, CH 3 CH 2 O), 2.69 (m, 2H, ArCH 2 ), 2.09 (m, 1H, BnCHCH 2 O), 2.02 (s, 3H, CH 3 C═O), 1.68 (m, 1H, CH 3 CHCH(Me) 2 , 1.23 (m, 1H, CH(Me) 2 ), 0.87 (d, 3H, CH 3 ), 0.84 (d, 3H, CH 3 ) and 0.81 (d, 3H, CH 3 ).
[0942] (R)-4-((R)-1,2-Dimethyl-propyl)-dihydro-furan-2-one 180
[0943] To a solution of aromatic compound 179 (5.0 g, 20.16 mmol) in HPLC grade acetonitrile (60 mL), carbon tetrachloride (60 mL), and water (120 mL) was added sodium periodate (86.24 g, 403.32 mmol, 20 equiv.), followed by RuCl 3 (414 mg, 10 mol %). The mixture was stirred vigorously overnight at room temperature, and diluted with methylene chloride (400 mL). The mixture was filtered through a pad of Celite to remove the solid precipitate. The organic portion was separated, and the aqueous was further extracted with methylene chloride. After the combined organic portions concentrated, the residue was dissolved in ether and applied to a column of Florisil. The compound was eluted with 3% methanol in ether, evaporated to a paste that was dissolved in methanol (100 mL). Potassium carbonate (8.0 g) was added, and the mixture was refluxed for 6 hours. The solvent was evaporated, and the solid residue was dissolved in water. The pH was adjusted to 2 by the careful addition of concentrated HCl while being cooled in ice water bath and stirred. Chloroform (200 mL) was added to the solution and stirred as such overnight at room temperature. The organic phase was separated, and the aqueous portion was further extracted with chloroform. After drying, the solvent was evaporated to give the lactone 180 5.0 g. NMR (CDCl 3 ) δ4.36 (app. t, 1H, CH a H b O), 3.85 (app. t, 1H, CH a H b O), 2.46 (m, 2H, CH c H d C═O), 2.13 (m, 2H, CHCH 2 C═O), 1.60 (m, 1H, CH(Me) 2 ), 1.35 (m, 1H, CH 3 CHCH(Me) 2 ), 0.86 (d, 3H, CH 3 ) and 0.72 (t, 3H, CH 3 ).
[0944] (3R,4R)-3-Bromomethyl-4,5-dimethyl-hexanoic acid ethyl ester 181
[0945] Lactone 180 (5.0 g) was dissolved in absolute ethanol (25 mL) and flushed with argon. While being cooled in ice water bath, anhydrous HBr gas was bubbled through the mixture for 45 minutes and allowed to stand at room temperature overnight. The mixture was poured into ice-salt water and hexane. The organic phase was separated, and the aqueous was further extracted with hexane. The combined organic extract was dried and evaporated. Flash chromatography with 10% ether in pet ether on a silica gel column gave the bromoester 181 3.54 g. NMR (CDCl 3 ) δ4.14 (q, 2H, CH 3 H 2 O), 3.60 (dd, 1H, CH a H b Br), 3.41 (dd, 1H, CH c H b Br), 2.54 (dd, 1H, CH a H b C═O), 2.44 (dd, 1H, CH a H b C═O), 2.22 (m, 1H, O═CCH 2 CHCH 2 Br), 1.67 (m, 1H, CHCH 3 CH(Me) 2 , 1.37 (m, 1H, CH(Me) 2 ), 1.26 (t, 3H, CH 3 CH 2 O), 0.94 (d, 3H, CHCH 3 CH(Me) 2 , 0.81 (d, 3H, ((CH 3 ) 2 )CHCH 3 CH) and 0.79 (d, 3H, ((CH 3 ) 2 )CHCH 3 CH).
[0946] (3R,4R)-3-Azidomethyl-4,5-dimethyl-hexanoic acid ethyl ester 182 and Example 17 (3R,4R)-3-Aminomethyl-4,5-dimethyl-hexanoic acid
[0947] Bromoester 181 (3.54 g, 13.34 mmol), sodium azide (1.04 g, 16.13 mmol) in anhydrous DMF (8.0 mL) was stirred at room temperature overnight. Water (16 mL) and hexane were added, the organic portion was separated, and the aqueous portion was further extracted with hexane. It was dried and evaporated to give azido ester 3.0 g. NMR (CDCl 3 ) δ4.14 (q, 2H, CH 3 H 2 O), 3.48 (dd, 1H, CH a H b N3), 3.21 (dd, 1H, CH c H b N 3 ), 2.34 (m 2H, CH a H b C═O), 2.20 (m, 1H, O═CCH 2 CHCH 2 N 3 ), 1.60 (m, 1H, CHCH 3 CH(Me) 2 . Compound was submitted for hydrogenation (HPL, 66480×100). The hydrogenated crude was dissolved in 6N HCl and refluxed overnight. The solvent was evaporated in vacuo the residue was azeotroped with toluene. The crude was further purified by loading onto an ion exchange column chromatography (Dowex 50 Wb×8-100), washed to neutral eluent with HPLC grade water followed by elution of compound with 0.5N NH 4 OH solution. Crystallization of product from methanol gave 720 mg. NMR (CD 3 OD) δ3.04 (dd, 1H, CH a H b NH 2 ), 2.82 (dd, 1H, CH c H b NH 2 ), 2.52 (dd, 1H, CH a H b C═O), 2.40 (dd, 1H, CH a H b C═O), 2.07 (m, 1H, O═CCH 2 CHCH 2 NH 2 ), 1.67 (m, 1H, CHCH 3 CH(Me) 2 , 1.35 (m, 1H, CH(Me) 2 ), 0.97 (d, 3H, CHCH 3 CH(Me) 2 , 0.88 (d, 3H, ((CH 3 ) 2 )CHCH 3 CH) and 0.83 (d, 3H, ((CH 3 ) 2 )CHCH 3 CH). [α] D −5.3 (c, MeOH, 1.9 mg/mL). Anal. Calcd for C 9 H 19 NO 2 : C 62.39, H 11.05, N 8.08. Found C 62.01, H 11.35, N 7.88. MS showed ions at 215 (M+CH 3 CN), 197 (M+Na + ), 174 (M+H + ). Analysis of derivative by reverse phase HPLC, Hypersil BDS C 18 5 micron and mobile phase 50/50 CH 3 CN-water containing 0.1%TFA gave 99.93% purity at retention time of 8.21 minutes.
Examples 18-20
Synthesis of 3-Aminomethyl-4-isopropyl-heptanoic acid
[0948] [0948]
[0949] 2-Cyano-4-methyl-2-pentenoic acid methyl ester 61
[0950] A solution of isobutyraldehyde (30.0 g, 416 mmol), methyl-cyano-acetate (20.6 g, 208 mmol), ammonium hydroxide (3.2 g, 41.6 mmol) and acetic acid (5.0 g, 83.2 mmol) in 500 mL of toluene is warmed to reflux under a Dean-Stark trap for 12 hours. The mixture is cooled to room temperature and extracted with saturated NaHSO 3 (3×100 mL), saturated NaHCO 3 (3×100 mL), and 100 mL of brine. The organic layer is dried over Na 2 SO 4 , and the solvent is evaporated. The remaining oil is distilled under high vacuum (0.5 mm Hg, B.P.=115-120° C.) to give 28.8 g of 2-cyano-4-methyl-2-pentenoic acid methyl ester 61 as an oil (90% yield).
[0951] 2-Cyano-3-isopropyl-hexanoic acid methyl ester 183
[0952] A 2.0 M solution of propyl magnesium chloride in Et 2 O (9.8 mL, 19.6 mmol) is added to a solution of 2-cyano-4-methyl-2-pentenoic acid (3.0 g, 19.6 mmol) in 50 mL of THF which is cooled in an IPA/dry ice bath to −40° C. under argon. The solution is stirred for 4 hours, and the reaction is quenched by addition of 50 mL of saturated KH 2 PO 4 . The THF is evaporated, and the remaining oil is chromatographed under medium pressure over silica gel with 50% CH 2 Cl 2 /hexane. Yield=1.9 g (50%) of 2-cyano-3-isopropyl-hexanoic acid methyl ester as an oil.
[0953] 2-Cyano-2-(1-isopropyl-butyl)-succinic acid 4-tert-butyl ester 1-methyl ester 184
[0954] A solution of 2-cyano-3-isopropyl-hexanoic acid methyl ester (1.9 g, 9.6 mmol) in 10 mL of THF is added to a slurry of NaH (washed with hexane, 0.23 g, 9.6 mmol) in 20 mL of THF which is cooled in an ice water bath under argon. The solution is stirred for 10 minutes, and t-butyl bromoacetate (2.1 g, 10.6 mmol) is added. The solution is warmed to room temperature. After 12 hours, the reaction is quenched by addition of 50 mL of saturated KH 2 PO 4 and the THF is evaporated. The organic products are extracted into Et 2 O (3×50 mL), and the combined organic layers are dried over MgSO 4 . The solvent is evaporated, and the remaining oil is chromographed under medium pressure over silica gel in 25% hexane/CH 2 Cl 2 . Yield of 2-cyano-2-(1-isopropyl-butyl)-succinic acid 4-tert-butyl ester 1-methyl ester=1.3 g (42%) as an oil.
[0955] 3-Cyano-4-isopropyl-heptanoic acid t-butyl ester 185
[0956] A mixture of 2-cyano-2-(1-isopropyl-butyl)-succinic acid 4-tert-butyl ester 1-methyl ester (1.3 g, 4.2 mmol), NaCl (0.25 g, 4.2 mmol), and H 2 O (0.15 g, 8.3 mmol) in 25 mL of DMSO is warmed to 130° C. for 12 hours. The mixture is cooled to room temperature and diluted with 100 mL of brine. The organic products are extracted into Et 2 O (3×50 mL). The organic layers are combined and washed with 50 mL of H 2 O and 50 mL of brine. Drying over Na 2 SO 4 and evaporation of the solvent gives 0.8 g (75% yield) of 3-cyano-4-isopropyl-heptanoic acid t-butyl ester as an oil.
[0957] 4-(1-Isopropyl-butyl)-2-pyrrolidone 186
[0958] 3-Cyano-4-isopropyl-heptanoic acid t-butyl ester (0.8 g, 3.2 mmol) is reduced under 50 psi of H 2 in MeOH containing TEA and Ra Ni. When the theoretical amount of H 2 is taken up, the catalyst is removed by filtration, and the solvent is evaporated to give 0.6 g (100% yield) of 4-(1-isopropyl-butyl)-2-pyrrolidone as an oil.
Example 18
3-Aminomethyl-4-isopropyl-heptanoic acid
[0959] 4-(1-Isopropyl-butyl)-2-pyrrolidone (0.6 g, 2.3 mmol) is warmed to reflux in 50 mL of 6.0 M HCl for 12 hours. The solution is cooled to room temperature and filtered through Celite. The filtrate is evaporated, and the solid remaining is recrystallized from MeOH/EtOAc. Yield 0.035 g (6% yield) of 3-aminomethyl-4-isopropyl-heptanoic acid as an HCl salt, mp 160-170° C. 1H NMR (CD 3 OD) δ0.9 (m, 9H), 1.30 (m, 5H), 1.78 (m, 1H), 2.30 (m, 2H), 2.45 (m, 1H), 2.95 (m, 2H). MS (APCI, CH 3 CN, H 2 O) 201 (M + , 100%).
Example 19
3-Aminomethyl-4-isopropyl-octanoic acid
[0960] Prepared according to the procedure of Example 18. Yield=0.13 g (15%) of 3-aminomethyl-4-isopropyl-octanoic acid. mp=160-170° C. 1H NMR (CD 3 OD) δ0.9 (m, 9H), 1.30 (m, 7H), 1.78 (m, 1H), 2.30 (m, 1H), 2.45 (m, 2H), 2.95 (m, 2H). MS (APCI, CH 3 CN, H 2 O) 198 (M−17, 100%), 216 (M + , 50%).
Example 20
3-Aminomethyl-4-isopropyl-hexanoic acid
[0961] Prepared according to the procedure of Example 18. Yield=0.11 g (42%) of 3-aminomethyl-4-isopropyl-hexanoic acid. mp=170-180° C. 1 H NMR (CD 3 OD) δ0.9 (m, 9H), 1.18 (m, 1H), 1.39 (m, 3H), 1.78 (m, 1H), 2.30 (m, 1H), 2.45 (m, 1H), 2.95 (m, 2H). MS (APCI, CH 3 CN, H 2 O) 188 (M + , 100%).
Example 21
[0962] [0962]
[0963] (i) MeO 2 CCH═PPh 3 , THF, 40° C.; (ii) MeNO 2 , DBU; (iii) Raney Nickel, H 2 , MeOH; (iv) Pd-C, MeOH, H 2 ; (v) 6N HCl
[0964] Synthesis of the Unsaturated Ester 188
[0965] (S)-(-)-citronellal 187 (2.0 mL, 11.03 mmol) was stirred at 40° C. in dry tetrahydrofuran (30 mL) with methyl triphenylphosphoranylidene acetate (3.69 g, 11.03 mmol). After 8 hours the mixture was cooled to room temperature and stirred overnight. The solvent was removed in vacuo and the residue stirred with n-pentane (50 mL). After 1 hour the solid was removed by filtration and the solvent removed in vacuo to give an oil which was purified by flash chromatography (silica, ethyl acetate:heptane 1:9) to give 2.05 g (88%) of 188 as a clear oil. 1 H NMR (400 MHz) (CDCl 3 ) δ0.90 (3H, d, J=6 Hz); 1.12-1.40 (2H, m); 1.60 (3H, s); 1.62 (1H, m); 1.68 (3H, s); 2.01 (3H, m); 2.21 (1H, m); 3.73 (3H, s); 5.08 (1H, m); 5.82 (1H, d, J=16 Hz); 6.94 (1H, m).
[0966] MS (CI + ) (m/z): 211 (MH + , 75%), 179 (78%), 151 (100%).
[0967] IR (thin film) (cm −1 ) v: 1271, 1436,1728, 2917.
[0968] Synthesis of the Nitroester 189
[0969] The ester 188 (2.02 g, 9.6 mmol) was dissolved in nitromethane (25 mL) with 1,8-diazabicyclo[5,4,0]undec-7-ene (1.44 mL, 9.6 mmol) and stirred at room temperature. After 23 hours the mixture was diluted with diethyl ether (150 mL) and washed with water (50 mL) and then 2N HCl (50 mL). The organic phase was collected, dried (MgSO 4 ), and the solvent removed in vacuo. The residue was purified by flash chromatography (silica, ethyl acetate:heptane 3:7) to give 2.26 g (87%) of 189 as a clear oil. Note that this and all subsequent compounds are equimolar mixtures of 2 diastereoisomers. 1 H NMR (400 MHz) (CDCl 3 ) δ0.90 (2×3H, each d, J=6 Hz); 1.09-1.58 (10H, m); 1.602 (6H, s); 1.685 (6H, s); 1.94 (4H, m); 2.42 (4H, m); 2.66 (2H, m); 3.70 (6H, s); 4.42 (4H, m); 5.07 (2H, m).
[0970] MS (CI + ) (m/z): 272 (MH + , 90%), 240 (100%), 151 (100%).
[0971] IR (thin film) (cm −1 ) v: 1554, 1739, 2918.
[0972] Synthesis of the Lactam 191
[0973] The nitro ester 189 (2.09 g, 7.7 mmol) was dissolved in methanol (75 mL) and shaken over Raney Nickel (catalytic, prewashed with water and then methanol) under an atmosphere of hydrogen gas (39 psi) at 35° C. After 17 hours the mixture was filtered through Celite. The solvent was removed in vacuo to give an oil. 1 H NMR showed there had been partial reduction of the double bond so this was carried on without further purification. A sample of this partial reduced product (440 mg, 2.1 mmol) was dissolved in methanol (40 mL) and shaken over 5% Pd-C under an atmosphere of hydrogen gas. After 18 hours the catalyst was removed by filtration through Celite to obtain 442 mg (99% from partial reduced material) as a clear oil which did not need purification. Note that this and all subsequent compounds are equimolar mixtures of 2 diastereoisomers. 1 H NMR (400 MHz) (CDCl 3 ) δ:0.88 (18H, m); 1.04-1.58 (20H, m); 1.96 (2H, m); 2.40 (2H, m); 2.58 (2H, m); 2.98 (2H, m); (3.45 (2H, m), 5.82 (2H, br s).
[0974] MS (CI + ) (m/z): 212 (MH + , 100%).
[0975] Synthesis of Example 21
[0976] The lactam 191 (428 mg, 2.0 mmol) was heated to reflux in 6N HCl (20 mL). After 5 hours the mixture was cooled to room temperature and washed with dichloromethane (2×10 mL). The aqueous phase was collected and the solvent removed in vacuo. The residue was dissolved in water (10 mL) and freeze-dried to give 382 mg (71%) of Example 34 as a white solid. Note that this compound is an equimolar mixture of 2 diastereoisomers. 1 H NMR (400 MHz) (d 6 -DMSO) δ0.82 (18H, m); 0.95-1.55 (20H, m); 2.05-2.45 (6H, m); 2.75 (4H, m); 7.98 (6H, br s).
[0977] MS (CI + ) (m/z): 230 ([MH-HCl] + , 90%), 212 (100%).
[0978] Microanalysis: Calculated for C 13 H 28 NO 2 Cl:
[0979] C 58.74; H 10.62; N 5.27. Found: C 58.46; H 10.50; N 5.33.
[0980] To one skilled in the art, the use of (R)-(+)-citronellal would afford compounds of opposite C5-stereochemistry to Example 21.
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The instant invention is a series of novel mono- and disubstituted 3-propyl gamma aminobutyric acids of Formula I
The compounds are useful as therapeutic agents in the treatment of epilepsy, faintness attacks, hypokinesia, cranial disorders, neurodegenerative disorders, depression, anxiety, panic, pain, neuropathological disorders, arthritis, sleep disorders, IBS, and gastric damage. Methods of preparing the compounds and useful intermediates are also part of the invention.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the field of computer systems. More specifically, the invention relates to an apparatus and method for preventing overheating of a computer system.
2. Background
Modern day computer systems place increasingly powerful central processing units (CPUs) in small enclosed structures or packages. The increased speed of the CPUs often results in generation of heat in the enclosed structure which requires a cooling system, usually a cooling fan, to keep the computer system from overheating. A failure of the fan may result in overheating of this computer system and damage to the circuitry within the computer. Such damage can be extremely expensive.
In order to minimize costs and to fully utilize the excess power provided by powerful CPUs, modern computer systems increasingly integrate as many functions as possible into the central processing unit. Operating system software controls operation of the central processing unit. Thus, in many designs, operating systems or other software controls a CPU which controls the fans that cool the computer system. As the computer system gets hotter, the cooling fans typically run faster increasing the rate of airflow and cooling the computer system to prevent overheating.
One problem with integration of cooling functions into the CPU is that when the CPU fails or the software controlling the CPU fails, the cooling system controlled by the CPU also fails. Cooling system failure may result in overheating of circuitry, and expensive damage to computer system circuits.
Thus, an apparatus or method is needed which will prevent the system from overheating in the event that the software or circuitry controlling the cooling system fails.
SUMMARY OF THE INVENTION
The present invention describes an apparatus for maintaining operation of a cooling system in the event that the software or a processor controlling a cooling system fails. In one embodiment of the invention, a watchdog timer periodically receives status signals from the processor controlling the cooling system. While the watchdog timer receives the periodic status signal from the processor indicating proper operation, the processor controls the cooling system. When the watchdog timer does not receive the expected periodic status signal from the processor, the watchdog timer asserts control of the cooling system. In one embodiment of the invention, the watchdog timer automatically adjusts the cooling system to handle a worst-case condition.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overall block diagram of one embodiment of the cooling system, as used in a computer system.
FIG. 2 is a flowchart describing the operation of the watchdog timer circuit for the cooling system of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
An apparatus and method for detecting failure of a processor which controls a cooling system and ensuring that when such failure occurs, the cooling system continues operation. In the following description, numerous specific details are set forth. For example, the cooling system described uses cooling fans to cool a computer system, although other cooling mechanisms may be used. Time delays are also included in order to provide an example and facilitate a thorough understanding of the present invention. However, it will be obvious to one skilled in the art that the invention may be practiced without these specific details.
FIG. 1 illustrates one embodiment of the invention to cool a computer system 100. A processor 104, typically a microprocessor or central processing unit (CPU) controls operation and performs computations for computer system 100. Software 108 such as operating systems software or bios typically directs processor 104 operation. The processor 104 may further be coupled to a memory 112 a power supply 116 and other elements used in a typical computer system 100. The entire computer system is typically encased in a casing 120 which protects the processor 104 and other circuit elements from damage. However, the casing 120 also traps heat generated by the circuit elements. The resulting heat accumulation can damage the circuit elements including processor 104 and memory 112.
In order to control heat build-up, the processor 104 typically controls a cooling system. In one embodiment, the cooling system cools the processor itself. A plurality of temperature sensors 128, 132 within the computer system 100 detect the temperature of the processor 104, the ambient air temperature within the case 120 or the temperature of various other components such as memory 112 or power supply 116. Typically, the sensors are positioned to sense the temperature near the most heat-sensitive component. The information from the temperature sensors 128, 132 is provided to the processor 104 which uses the information to control the cooling system during normal operation. Normal operation, for purposes of this invention is defined as when the processor 104 is operating as expected, typically receiving temperature signals from temperature sensors, computing appropriate cooling system setting and transmitting status signals to a watchdog timer 152.
During normal operation, the processor 104 running software 108 uses the information from temperature sensors 128 and 132 to determine settings for the cooling system. In the illustrated embodiment, the cooling devices used by the cooling system are cooling fans 136, 140 to move air through the case 120 of computer system 100 to prevent circuit components and devices from overheating. Other possible cooling devices include, but are not limited, to refrigeration systems and liquid based cooling systems. In the illustrated embodiment, the speed of the cooling fan 136, 140 typically determines the amount of cooling. Usually, the speed of the fans is kept to the minimum necessary to prevent overheating because higher cooling fan 136, 140 speeds result in increased fan power consumption and excessive fan noise. The noise of the cooling fans 136, 140 is typically unpleasant and can be distracting to a computer user. Thus, cooling fan speeds are kept at the minimum necessary, taking into account a margin of error, to prevent computer system 100 from overheating.
Fan speed controls 144, 148 adjust the speed of the corresponding cooling fan 136, 140. In the illustrated embodiment, a first cooling fan 144 controls the fan speed for a CPU cooling fan 136 which cools processor 104 and a second speed control 148 controls the speed of a storage cooling fan 140 which cools memory 112. Processor 104 transmits control signals to the respective cooling fans 136, 140, indicating the rotation speed of the fan needed in order to avoid overheating. In summary, temperature sensor 128, 132 transmits a temperature signal containing temperature information to the processor 104 which processes the information and transmits a control signal to the fan speed controls 144, 148. The control signal determines the speed of cooling fans 136, 140.
One problem with the described cooling system is that when processor 104 fails, or when problems occur with the software 108, the signal output by the processor 104 may be incorrect or in a worst case scenario, the processor 104 may not transmit any signal to the fan speed controls 144, 148. A low fan speed may result in insufficient air being transferred through the computer system 100 and overheating of circuitry. Thus, a watchdog timer 152 monitors status signals output by the processor 104. When the watchdog timer detects improper operation of the processor 104 or software 108, the watchdog timer 152 assumes control of the cooling system and transmits processor failure signals to the fan speed controls 144 and 148 instructing the cooling fans 136, 140 to operate at a sufficient speed to handle a worst-case condition. In one embodiment of the invention, the watchdog timer 152 causes the cooling device or cooling fans 136, 140 to operate at a maximum level or speed. The noise generated by operating the cooling fans 136, 140 at full power serves to notify users that a problem exists with the processor 104 or software 108.
Watchdog timer 152 determines when processor 104 has failed by monitoring status signals from the processor 104. Processor 104 is configured to periodically transmit a status signal to the watchdog timer 152. In one embodiment of the invention, the processor 104 automatically transmits periodically the status signal. In an alternate embodiment, the watchdog timer 152 transmits a request signal or poll signal requesting a status signal from processor 104. Failure of the processor 104 to respond to the poll signal or to periodically transmit a status signal indicates improper operation of the processor 104 or software 108. Instructions for providing a status signal to the watchdog timer 152 is preferably programmed in a kernel of the bios software running in the processor 104. Programming status signal instructions in a kernel minimizes processor time and is well-suited to automatic periodic status signal outputs.
In one embodiment of the invention, the status signal is a reset signal automatically output by the processor at preset time intervals. The reset signal resets the watchdog timer 152. In the described embodiment, the watchdog timer may be implemented using a counter. The counter counts down from a predetermined time or wait time, for example, three minutes. When the processor 104 transmits the reset signal, the counter in watchdog timer 152 resets and again begins a countdown for the predetermined length of time or wait time. When the processor 104 and software 108 operate properly, the counter in watchdog timer 150 never counts down the full wait time of three minutes because the status signals from processor 104 are received in time intervals of less than three minutes, resetting the counter before countdown is complete. However, when the processor fails, status signals are not received and when the counter within watchdog timer 152 counts down the wait time, the watchdog timer 152 causes the fan speed control 148, 144 to automatically drive the cooling fans 136, 140 at full power to create a maximum cooling condition.
Other methods of implementing watchdog timers are also available. Watchdog timers may be implemented by monitoring the time it takes to shift a bit through a series of registers. Under normal conditions, status signals are received before the bit shifts through the shift register. Watchdog timers with very short wait times on the order of milliseconds are commercially available from Dallas Semiconductor of Dallas, Tex. and Maxim of Sunnyvale, Calif. Wait time is defined as the time after a status signal which may elapse before the watchdog timer transmits a warning signal. However, it is preferable to have watchdog timers with longer wait times then those commercially available, in particular, wait times on the order of minutes are preferred to avoid burdening the processor with sending frequent status signals. Long wait times are suitable because thermal effects usually occur over several minutes. One embodiment of a watchdog timer with a wait time of several minutes may be implemented by coupling an alarm to a calendar circuit. However, the scope of this invention should not be limited to a particular implementation or type of watchdog timer used.
FIG. 2 is a flowchart illustrating the operation of the cooling system used in the computer system 100 of FIG. 1. In block 204, a sensor measures the temperature of components or ambient air within the computer system 100. The temperature readings are transmitted to a processor, typically a CPU, which processes the temperature readings to compute appropriate cooling requirements in block 208. In the illustrated embodiment, the cooling elements are fans, although other cooling systems such as liquid nitrogen or other liquid based systems may be used. In the illustrated embodiment in which the cooling system are fans, the processor uses the temperature readings to compute appropriate cooling requirements or fan speeds in block 208. The cooling requirements or fan speeds are transmitted to a fan speed control in block 212. In block 216, the fan speed control adjusts the speed of the cooling fans to prevent the computer system 100 from overheating.
In decision block 220, the watchdog timer must determine whether the processor controlling the cooling system, typically a CPU controlling the entire computer system is properly working. When the processor is properly working, the processor periodically sends status signals to the watchdog timer as illustrated in block 224. The watchdog timer uses the status signals to ascertain that the processor is properly working. In one embodiment of the invention, the status signals are reset signals which reset a timer or counter in the watchdog in block 228. Blocks 204 through 228 are repeated in a monitoring loop as long as the processor and software controlling the cooling elements operate properly.
In decision block 220, the watchdog timer may determine that the processor is not properly working. This occurs when the watchdog timer does not receive a status signal from the processor 104 after a predetermined time period or wait time. When an expected status signal is not received, the watchdog timer count down continues uninterrupted until it reaches a predetermined setting or zero time, as illustrated in block 232. When the counter in watchdog timer reaches a zero setting, the watchdog timer assumes control of the cooling system in block 236.
In one embodiment of the invention, the watchdog timer is a simple circuit and is not sophisticated enough to receive sensor control signals and process them. Thus, after determining that the processor controlling the cooling system has failed, the watchdog timer adjusts the cooling system controls (fan speed control is 144 and 148 in the embodiment illustrated in FIG. 1) to a setting or level sufficient to handle a worst case condition. One method of handling worst-case conditions sets the cooling fans to a maximum setting such that maximum speed cooling results. The additional noise generated by the cooling fans also serves to notify an end user that either the processor 104 or the software controlling the processor has failed.
The watchdog timer 152 retains control of the cooling system within the computer system 100 until the problem with the processor 104 or software 108 is corrected and the system return to normal operation. This may occur when a reset of the processor occurs as illustrated in block 240. Once the processor has been reset and the operation of the processor returns to normal, the processor may reset the watchdog timer and regain control of the cooling system in block 244.
The present invention described may be designed in many different ways using different design configurations and parameters. While the present invention has been described in terms of specific elements and embodiments, various other embodiments may come to mind to those skilled in the art without departing from the spirit and scope of the present invention. Thus, the preceding description should not be interpreted to limit the scope of the invention, instead the invention should be measured in terms of the claims which follow.
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A system and method for preventing a computer system from overheating when a processor or software controlling the processor which controls the cooling system fails. The apparatus utilizes a watchdog timer which receives periodic signals confirming proper operation of the processor. When these status signals are not received, the watchdog timer transmits signals causing the cooling system that prevents overheating of the computer system.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for extracting raw data from an image resulting from a camera shot.
[0003] More specifically but not exclusively, it relates to a method for presenting data extracted from an image along a desired view angle, from a digital image taken by a photographic or cinematographic camera whether integrated or not into a communication device under any incidence.
[0004] It is notably applied to transmission and storage of text data and digitized graphics viewed beforehand by a camera under any incidence and then processed by correcting the projective deformation and/or optionally by enhancing the resolution in order to obtain a corrected image having higher legibility, viewed along an angle of incidence different from that of the camera shot, for example under normal incidence or any predetermined incidence. Of course, with the invention useful information may be extracted before or after correction. Such a process is most particularly suitable for transmitting text and/or graphic information taken by a camera fitted onto a portable communications terminal, such as for example, a cellular radio transmitter/receiver.
[0005] 2. Description of the Prior Art
[0006] Of course, in order to extract raw data relating to printed or hand-written information in an image and to infer from them, zones to be corrected, the applicant has already proposed a solution consisting of extracting the information by calculating, as extracted raw data, a difference image D(C, L) (in fact, the contrast between the background's light level and the light level of the data to be extracted). A threshold value is used for selecting the values to be extracted from this difference image. This threshold value V s may thereby be selected as a threshold value of the gradient for removing the grid of lines (square pattern). However, this method has the following drawbacks:
[0007] If no grid of lines is present in the original image, value V s corresponds to the threshold for removing noise. It is found that this threshold is difficult to obtain by using a conventional histogram technique which does not provide satisfactory results.
[0008] If grid lines are present, the correct threshold for finding a pattern may be determined, but this threshold value cannot always be used as a threshold for extracting a piece of information. Indeed, this threshold value always does not remove either grid lines or noise completely because the non-predictive image contrast varies like a diffuse saturation and like fogged image surfaces due to random illumination conditions.
[0009] In the case of color images, three channels (red, green and blue) need to be considered and it is not clearly apparent whether one should have one threshold per channel or one threshold for all the channels.
[0010] Moreover, it is known that reading and/or interpretation by a person of a text or graphic reproduced from information delivered by a camera which views an original document, assumes that shooting is performed under or close to normal incidence in order to allow recognition of letters composing the text and interpretation of the graphic (which most often requires observance of the shapes and proportions).
[0011] Indeed, when the document is viewed by a camera under any incidence, the produced image has a projective deformation: accordingly, starting from a certain distance from the camera, disappearance of details which are required for character recognition and for consequently understanding the document, is reported.
[0012] In order to eliminate these drawbacks, the applicant has already proposed a solution consisting of extracting identifiable contextual data present in the image taken by the camera and correcting the raw or extracted data delivered by the camera by means of these contextual data, the corrected data being then stored in memory and/or transmitted to an addressee so as to be displayed for reading purposes.
[0013] The contextual data used for performing the correction of raw data may affect a pattern (a physical, plotted or printed contour) initially existing in the document or reported beforehand, certain parameters of which are known beforehand. The correction process may then comprise the following steps:
searching for this pattern in the raw image taken by the camera, calculating projective deformations exhibited by the raw image, from deformations of the pattern which it contains and which arise through changes in the aforementioned parameters, determining the corrections to be made to the raw data or to the extracted data depending on the projective deformations, generating an image containing the corrected data, while taking into account the corrections determined beforehand.
[0018] The pattern searching step is then obtained by a first searching sequence including:
detecting boundaries present in the image, extracting boundaries, the length of which exceeds a predetermined value, and detecting zones delimited by the boundaries found, with a sufficient surface area (larger than a predetermined value) and not touching the edge of the image.
[0022] For each area found, this process comprises a calculation step for determining the main axis of the zone, for finding a point external to the zone on said main axis, the construction of an external cone issued from the external point, the extraction of the points from the boundary, the external normal of which is opposed to the vector which joins it and starts from the external point, the calculation of the line borne by the main axis of the extracted points, when the four lines are found, the calculation of four apices of the quadrilateral derived from the four lines and then, when the surface area of the quadrilateral is close to the surface area of the zone, the calculation of the homography deforming the quadrilateral into a rectangle having pre-established proportions.
[0023] It is found that one of the drawbacks of this method precisely consists in that it involves proportions set beforehand. Of course, if these proportions set beforehand are not the initial ones, the homographic transformation performed on the image leads to changes in the proportions of the objects contained in the corrected image.
[0024] Moreover, it is found that the homographic calculations used hitherto, are particularly complicated. Indeed, for each pixel of the final image, a zone of the initial image needs to be determined, the luminance and chrominance values of which are read in order to subsequently assign them in the final image to the location which this pixel should have according to a homographic relationship.
[0025] Now, it is seen that the written text portion in an image generally does not comprise more than 20% of the pixels of this image so that the remaining 80% of the pixels of the image are of no interest.
OBJECT OF THE INVENTION
[0026] Accordingly, the object of the invention notably is to solve these problems.
[0027] For this purpose, first of all, it provides a method for accurately determining a noise contextual datum used for correcting the extracted raw data, and notably, the threshold value V s at which the printed or handwritten information may be extracted without being concerned with knowing whether the grid lines are present or not, regardless of the sought-after pattern. Further, this threshold value may be used as a gradient threshold for seeking the pattern in order to reduce the processing requirements to the one and only pattern searching step. If the intention is to extract information for a color image, each color component of the image should be considered for calculating a unique threshold in order to extract color information.
[0028] An image having a grey level is then considered, which may consist in a combination of three color channels of the image (red-green-blue) or in one of these channels.
SUMMARY OF THE INVENTION
[0029] More specifically, the invention provides a method for extracting raw data from an image resulting from a camera shot, characterized in that it comprises the following steps:
[0030] a) determining for each point located by column C and line L of the image, a value V s [C, L] consisting of a combination of components of the color of the image, expressed as:
[0000] V 0 [C,L]=α Red[ C,L]+β Green[ C,L]+γ Blue[ C,L]
[0031] formula wherein α, β, γ are coefficients which may for example satisfy the following relationships:
[0000] α+β+γ=1 and α,β,γ≧0
[0032] b) calculating for each point of the image, a background value V Back. (C, L)
[0033] c) calculating for each point of the image, the difference D[C, L]
[0000] D[C,L]=V Back. −V 0 [C,L ](dark data/bright background)
[0000] or
[0000] V 0 [C,L]−V Back. (bright data/dark background)
[0034] d) calculating a threshold value V S consisting of a noise contextual datum used for correcting the extracted raw data, from at least one contrast histogram and/or from the probability q that a regional maximum of the raw data D[C, L] contains noise
[0035] e) correcting the raw data D[C, L] by means of the noise contextual datum V S resulting in extracted data D*[C, L]
[0036] f) calculating for each point of the image, a corrected value I*[C,L], taking into account the corrected raw datum D*[C, L]
[0037] g) optionally presenting the extracted data or the image containing them under a desired angle.
[0038] Advantageously,
the background value V Back. may be determined by an operating sequence comprising the following steps:
calculating for each point of the image, a value V N+1 [C,L] which is the maximum (dark data on bright background) or minimum (bright data on dark background) value between the value V N [C,L] and different averages of V N values over symmetrical structuring items centered on [C,L], iterating said calculation a predetermined number of times (N_final) and then taking into account the values of the final image V N — final as the values of the background image V Back. , the calculation of value V N+1 [C,L] may be obtained by a relationship of the type:
[0000]
V
N
+
1
[
C
,
L
]
=
max
(
dark
bright
background
)
(
or
min
(
bright
dark
background
)
)
{
V
N
[
C
,
L
]
V
N
[
C
+
1
,
L
+
1
]
+
V
N
[
C
-
1
,
L
-
1
]
2
V
N
[
C
+
1
,
L
-
1
]
+
V
N
[
C
-
1
,
L
+
1
]
2
V
N
[
C
,
L
+
1
]
+
V
N
[
C
,
L
-
1
]
2
V
N
[
C
+
1
,
L
]
+
V
N
[
C
-
1
,
L
]
2
}
the background image V Back. may also be determined by an operating sequence comprising the following steps:
generating an image V N+1 , four times smaller than V N , comprising the calculation for each point of the image, of a value V N+1 [C,L] which is the maximum (dark data on bright background) or the minimum (bright data on dark background) between a local average of V N centered on the point [2C+½, 2L+½] (the four adjacent pixels here) and at least a local average including a larger number of pixels (the 16 adjacent pixels here); image V N+1 then being four times smaller than image V N , iterating said calculation, a predetermined number of times V NFinal , interpolating values of the image V N — Final in order to obtain the values of V Back. which has the same size as the initial image V 0 ,
the value V N+1 [C,L] may be determined by an operating sequence comprising:
[0000]
V
N
+
1
[
C
,
L
]
=
max
(
dark
bright
background
)
(
or
min
(
bright
dark
background
)
)
{
V
N
[
2
C
,
2
L
]
+
V
N
[
2
C
+
1
,
2
L
]
+
V
N
[
2
C
,
2
L
+
1
]
+
V
N
[
2
C
+
1
,
2
L
+
1
]
4
,
(
V
N
[
2
C
-
1
,
2
L
-
1
]
+
V
N
[
2
C
-
1
,
2
L
]
+
V
N
[
2
C
-
1
,
2
L
+
1
]
+
V
N
[
2
C
-
1
,
2
L
+
2
]
+
V
N
[
2
C
,
2
L
-
1
]
+
V
N
[
2
C
,
2
L
]
+
V
N
[
2
C
,
2
L
+
1
]
+
V
N
[
2
C
,
2
L
+
2
]
+
V
N
[
2
C
+
1
,
2
L
-
1
]
+
V
N
[
2
C
+
1
,
2
L
]
+
V
N
[
2
C
+
1
,
2
L
+
1
]
+
V
N
[
2
C
+
1
,
2
L
+
2
]
+
V
N
[
2
C
+
2
,
2
L
-
1
]
+
V
N
[
2
C
+
2
,
2
L
]
+
V
N
[
2
C
+
2
,
2
L
+
1
]
+
V
N
[
2
C
+
2
,
2
L
+
2
]
+
)
16
}
[0048] The raw data D[C,L] are generally affected by a perspective deformation due to the arbitrary position of the camera in front of the supporting medium. The perspective deformation of the extracted raw data may be corrected with a known method for extracting geometrical contextual data. Likewise, these extracted raw data are also affected by luminous and/or electronic noise which may be eliminated by thresholding as follows:
[0049] After having calculated the noise contextual datum V S , for each point of the image, a comparison of value D[C,L] with threshold value V S is made in order to determine the value D*[C,L] to be extracted in the following way:
if D[C,L]<V S then D*[C,L]=0 if D[C,L]≧V S , value D[C,L] is retained, i.e. D*[C,L]=D[C,L] or else it is replaced with D[C,L]−V S i.e. D*[C,L]=D[C,L]−V S
[0053] Generation of image I*(p) containing the extracted data according to the subtractive principle, results from the calculation I*(p)=I max −f·D*(p) (dark data/bright background), with I max , value of the bright background, which may be equal to 255 for example, or I*(p)=I min +f·D*(p) (bright data/dark background), I min may be equal to zero.
[0054] The threshold value V S is a noise contextual datum used for correcting raw data D[C,L]. It may be calculated according to a method based on the probability q that any regional maximum of raw data contains noise. This method comprises the following operating phases:
a first phase wherein for each pixel p of a grey image I (either a color channel or luminance) the following is performed:
[0056] a) for each direction d, with 0<|d|<D
[0057] if the following condition is satisfied:
convexity of I on [p−d, p+d], i.e.,
[0000] I ( p +(1−2×) d )≦λ I ( p−d )+(1−λ) I ( p+d ) for any 0≦λ≦1 in case of dark data bright background)
[0059] or
concavity of I on [p−d, p+d], i.e.,
[0000] I ( p +(1−2×) d )≧λ I ( p−d )+(1−λ) I ( p+d ) for any 0≦λ≦1(bright data/dark background)
[0061] then G(p,d)=(I(p+d)+I(p−d))/2 is calculated
[0062] or else G(p,d)=0
[0063] b) a value S(p) is calculated, which is equal to the maximum value of G(p,d) for all directions d with 0<|d|<D
[0064] as an alternative to this calculation of S(p), S(p) may be replaced with D(p), D(p) corresponding to the raw data,
a second step wherein a value S max is calculated, which is equal to the maximum value of S(p), for all pixels p a third step wherein a histogram H(s) is reset to 0 for all values of s between 0 and S max a fourth step for calculating the contrast histogram for the regional maximum pixels containing the noise to be eliminated, wherein this calculation may comprise: a step wherein for each pixel p in the image S(p), if S(p) is a regional maximum, H(S(p)) is incremented according to the relationship H(S(p))←H(S(p))+1 a step wherein the identities S=S max and N=1/q are determined and as long as H(S) is less than N, S is replaced with S−1, the final value of S is called 5 min, N is the minimum number of regional maximum pixels such that the mathematical expected value of the number of pixels containing noise is larger than or equal to 1 a step wherein value V S is calculated according to formula
[0000] V S =r·S min +(1 −r )· S max, with ½ ≦r≦ 1
[0071] The threshold value V S may also be calculated according to the following method:
[0072] 1) A first step for calculating a histogram of the pits, H_pits, including the following operating phases:
[0073] a) for each pixel p of image I, the following is performed:
[0074] i. for each direction d with 0<|d|<D:
[0075] if the following condition is satisfied:
convexity of I on [p−d, p+d]
[0000] I ( p +(1−2×) d )≦λ I ( p−d )+(1−λ) I ( p+d ) for any 0≦λ≦1
[0077] then G(p,d)=(I(p+d)+I(p−d))/2 is calculated
[0078] or else G(p,d)=0
[0079] ii. S(p)=maximum value of G(p,d), is calculated for all the directions d with 0<|d|<D
[0080] as an alternative to this calculation of S(p), S(p) may be replaced with a value D(p) which corresponds to the raw data (dark data/bright background)
[0081] b) the maximum value of the pits, S pits_max is calculated, which is equal to the maximum value of S(p) for all pixels p
[0082] c) the pit histogram, H_pits, is reset to zero for each value of s between 0 and the maximum value of the pits, S_pit max
[0083] d) for each pixel p of the image S(p) the following calculations are performed:
[0084] i. if S(p) is a regional maximum, H_pits (S(p)) is incremented in the following way:
[0000] H _pits( S ( p ))← H _pits( S ( p ))+1
[0085] 2) A second step for calculating the histogram of the bumps, H_bumps, includes the following operating phases:
[0086] a) for each pixel p of image I, the following is performed:
[0087] i. for each direction d with 0<|d|<D:
[0088] if the following condition is satisfied:
concavity of I on [p−d, p+d], i.e.,
[0000] I ( p +(1−2λ) d )≧λ I ( p−d )+(1−λ) I ( p+d ) for any 0≦λ≦1(bright data/dark background) are satisfied
[0090] then G(p,d)=(I(p+d)+I(p−d))/2 is calculated
[0091] or else G(p,d)=0
[0092] ii. S(p)=maximum value of G(p,d) is calculated for all the directions d with 0<|d|<D
[0093] as before, as an alternative to this calculation of S(p), the value S(p) may be replaced with a value D(p) which corresponds to the raw data (bright data/dark background)
[0094] b) the maximum value of the bumps, S bumps_max, is calculated, which is equal to the maximum value of S(p) for all pixels p
[0095] c) the bump histogram H_bumps(s) is reset to 0 for each s between 0 and the maximum value of the bumps, S bumps_max
[0096] d) for each pixel p of the image S(p), the following calculations are performed:
[0097] i. if S(p) is a regional maximum
[0098] H_bumps(S(p)) is incremented in the following way:
[0000] H _bumps( S ( p ))← H _bumps( S ( p ))+1
[0099] 3) A third step for superimposing pit histogram H_pits and bump histogram H_bumps, includes the following phases:
[0100] a) S_max is calculated according to the expression:
[0000] S _max=Max(maximum value of the pits, S _pits_max, maximum value of the bumps, S _bumps_max)
[0101] b) H_max is calculated according to the expression:
[0000] H _max=maximum value of the pits H _pits( S ) and the bumps H _bumps( S ) for all values of S
[0102] c) S0 is calculated according to the expression:
[0000] s 0=maximum value of s such that H _pits( s )=H_max
[0103] or H_bumps(s)=H_max
[0104] d) s=s0+1 is calculated and α is selected such that 0<α<½ and as long as:
[0000] |ln(1 +H _pits( s )−ln(1 +H _bumps( s ))|<α·ln(1 +H _max)
[0105] s←s+1 is performed (wherein ln is Napier's logarithm function)
[0106] finally, value S min is determined by the final value of s incremented by 1
[0107] 4) a step for calculating the extraction threshold V S according to the relationship:
[0000] V S =r·S min +(1 −r )· S max where ½ ≦r≦ 1
[0108] It is seen that step b) of the method for extracting raw data, is iterated a large number of times, so that the threshold values calculated by means of both methods described earlier via calculation of S(p) do not allow the extracted raw data to be corrected efficiently.
[0109] This drawback may be suppressed by using the alternative consisting of replacing S(p) with D(p).
[0110] Thus, in this case, when the probability q that any regional maximum of the raw data contains noise, is known, the process for extracting the noise contextual datum may comprise the following steps:
a first step wherein a value S max is calculated, which is equal to the maximum value of D(p) for all the pixels p=[C,L], D being the image of the raw data to be corrected a second step wherein a histogram is reset H(S)=0 for all values of S between 0 and S max a third step wherein for each pixel p in image D(p), if D(p) is a regional maximum, H(D(p)) is incremented according to the relationship
[0000] H ( D ( p ))← H ( D ( p ))+1 a fourth step wherein the identities S=S max and N=1/q are determined and as long as H(S) is less than N, S is replaced with S−1, the final value of S is called S min a fifth step wherein the value of the noise contextual datum V S is calculated according to formula
[0000] V S =r·S min +(1 −r )· S max with ½ ≦r≦ 1
[0116] If the probability q that any regional maximum of the raw data contains noise, is not known, the process for extracting the noise contextual datum V S may comprise the following steps:
[0117] 1) a first step for calculating a pit histogram, H_pits includes the following operating phases:
a) the maximum values of the pits S_pits_max is calculated, which is equal to the maximum value of D(p) for all the pixels p, D being the image of the extracted dark-on-bright-background raw data b) the pit histogram H_pits is reset to 0 for each value of s between 0 and the maximum value of the pits, S_pits_max c) for each pixel p of image D(p),
if D(p) is a regional maximum H_pits (D(p)) is incremented in the following way:
[0000] H _pits( D ( p ))← H _pits( D ( p ))+1
[0123] 2) A second step for calculating a bump histogram, H_bumps includes the following operating phases:
a) the maximum value of the pits S_bumps_max is calculated, which is equal to the maximum value of D(p) for all pixels p, D being the image of the extracted bright-on-dark-background raw data b) the pit histogram H_bumps is reset to 0 for each value of s between 0 and the maximum value of the pits, S bumps_max c) for each pixel p of the image D(p),
if D(p) is a regional maximum H_bumps(D(p)) is incremented in the following way:
[0000] H _bumps( D ( p ))← H _bumps( D ( p ))+1
[0129] 3) A third step for superimposing pit H_pits and bump H_bumps histograms includes the following operating steps:
a) calculating S_max according to the expression:
[0000] S max =Max(maximum value of the pits S _pits_max,maximum value of the bumps S _bumps_max) b) calculating H_max according to the expression:
[0000] H _max=maximum value of the pits H _pits( S ) and of the bumps, H _bump( S ) for all values of S c) calculating s0 according to the expression:
S0=maximum value of s such that
[0000] H _pits( s )= H _max or H_bumps(s)=H_max d) s=s0+1 is calculated and α is selected such that 0<α<½ and as long as:
[0000] |ln(1+ H _pits( s ))−ln(1 +H _bumps( s ))|<α·ln(1 +H _max) s←s+1 is performed (where ln is Napier's logarithm function) finally the value S min is determined by the final value of s incremented by 1
[0138] 4) a step for calculating the value of the noise contextual datum V S according to the relationship:
[0000] V S =r·S min +(1 −r )· S max where ½ ≦r≦ 1
[0139] Of course, information from a color image with red, green, blue color channels needs to be extracted. The steps of the method described earlier may be followed for each color channel, by determining a threshold for each channel. Extraction of the color information from the red, green, blue channels and their recombination into a final color image may be performed by extracting the red, green, blue values in each pixel for which it is seen that the threshold has been exceeded.
[0140] Moreover, with the purpose of eliminating the drawbacks of the searching methods for patterns (physical, plotted, or printed contours), expressing some contextual data and involving proportions set beforehand, the invention proposes determining the real height/width ratio of the quadrilateral formed by four identified points of a pattern present in the image of a contour which is used for determining some contextual data of the image and this, in order to be able to reconstruct a document having the same proportions.
[0141] For this purpose, the applicant provides a method for presenting information extracted from an image of the aforementioned type along a desired view angle, from a picture taken by a camera under any incidence, this method comprising:
searching for at least four identifiable characteristic points of a pattern present in the image taken by the camera, defining contextual data, optional extraction of the data according to predetermined criteria, calculating geometrical deformations to be made on the raw image, the information or the extracted data, from the relative position of four points with respect to relative reference positions, determining corrections to be made to the raw image or to the extracted data depending on the geometrical deformations, generating an image containing the extracted data, taking into account the thereby determined geometrical corrections.
[0147] This method is characterized in that, for obtaining an image containing extracted data having the same proportions as the object, it comprises the determination of the real height/width ratio of the quadrilateral defined by the aforementioned points and the taking into account of this ratio r in generating the corrected image.
[0148] More specifically, determination of the proportions of the quadrilateral (rectangle) is carried out according to a process comprising the following steps:
searching for four identifiable characteristic points of a pattern present in the image, determining the vanishing points from the sides of the quadrilateral defined by the four points and determining a horizon line connecting the vanishing points, determining the coordinates of the projection point F of the optical centre O of the camera on the horizon line, calculating the camera base point (orthogonal projection of the optical centre of the camera on the plane of the pattern) from distances between the vanishing points and the projection point F and from the distance between this projection point F and the optical centre O, calculating the focal length from the distances between the optical centre, the projection point F and the camera base point, calculating the coordinates of the intersection points M 1 N 1 , M 2 N 2 , between the vanishing lines and the lines connecting the camera base point and the vanishing points as well as points O 1 , O 2 , P 1 , P 2 , located on the vanishing lines, at conventional (elliptical) distances from the camera base point, calculating the ratio of the sides of the initial pattern from the coordinates calculated earlier by considering that the rectangle O 1 , O 2 , P 1 , P 2 , is the projection of a square extending in the plane of the pattern.
[0156] If only the vanishing lines of a same pair intersect at a vanishing point while both other vanishing lines are parallel (vanishing point projected to infinity), calculation of the r ratio will be carried out by starting with a pre-established focal length f of the camera.
[0157] If all the vanishing points are projected to infinity, ratio r is equal to the ratio of the lengths of the adjacent sides of the quadrilateral.
[0158] An important advantage of this method consists in that it is not very sensitive to lack of orthogonality of the adjacent sides of the quadrilateral which is frequently the case when the quadrilateral is a pattern plotted by hand. Indeed, conventional solutions are particularly sensitive to such defects (instability in the case of lack of orthogonality).
[0159] Another advantage of this solution consists in that texts may be reproduced in which there is no alignment of characters.
[0160] With the purpose of alleviating homographic calculations notably by avoiding unnecessary calculations and by only applying them to the pixels which are relevant to the written text in the image and by reusing as much as possible calculations which have already been performed, the applicant proposes an operating sequence including the following phases:
creating an initial (deformed) binary mask of the zones to be corrected by isolating the useful portion of the initial image containing the extracted data and by assigning the same binary value (0 or 1) to the pixels of this useful portion, calculating an ideal binary mask by a direct homographic transformation of the initial mask (based on the transformation of any polygonal shape into a reference polygonal shape), for each pixel (u, v) of the useful portion of the ideal binary mask, calculating by inverse homography, the position (x, y) in the initial image, determining the value of the final image at pixel (u, v) by an interpolated value at (x, y) in the initial image.
[0164] Advantageously, the calculation of the inverse homography may comprise a preliminary calculation by inverse homography of the lines and columns of each pixel of the ideal mask. It will then be possible to infer the position of a given pixel in the initial image by calculating the intersection of both lines.
BRIEF DESCRIPTION OF THE DRAWINGS
[0165] Embodiments of the invention will be described hereafter, as non-limiting examples, with reference to the appended drawings wherein:
[0166] FIG. 1 is a schematic illustration of the shooting of a document by a camera, the main parameters used in the method according to the invention may be shown with this illustration;
[0167] FIG. 2 is a projection of the view illustrated in FIG. 1 in the plane of the image of the document;
[0168] FIG. 3 is a projection of the FIG. 2 type, but wherein one of the two vanishing points is projected to infinity;
[0169] FIG. 4 is a diagram relating to the characterization of the inside of a quadrilateral;
[0170] FIG. 5 illustrates a projective geometrical invariant;
[0171] FIG. 6 is a schematic illustration of the operating steps for an image processing process according to the invention in order to obtain a corrected image;
[0172] FIGS. 7-11 are diagrams for illustrating the calculations performed according to the process illustrated in FIG. 6 ;
[0173] FIG. 12 shows an example of a pair of histograms, H_pits and H_bumps in a logarithmic coordinate reference system;
[0174] FIG. 13 is a schematic illustration for showing the main geometrical parameters of a camera;
[0175] FIG. 14 is a diagram illustrating the principle for constructing a rectangular pattern having a prescribed physical aspect ratio, in the case of absence of vanishing points.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0176] In the example illustrated in FIG. 1 , the original document which is intended to be shot with a camera is positioned on a planar supporting medium, horizontally.
[0177] The camera is positioned above the plane of the supporting medium and therefore of the document, at a determined height, the axis of the camera which is orientated towards the document being oblique (here, an angle of incidence of about 30°).
[0178] The image of the document taken by the camera is located in an image plane which extends perpendicularly to the optical axis of the camera.
[0179] The orthogonal projection of the optical centre C of the camera in the plane of the supporting medium is called the base of the camera.
[0180] The plane passing through point C which is parallel to the plane of the supporting medium is the apparent horizon of the supporting medium.
[0181] The pattern of a rectangle of document DT provides at the image, a quadrilateral A, B, C, D ( FIG. 2 ), the segments DC and AB of which are borne by two lines (vanishing lines) which intersect at a point F 1 while segments DA and CB are borne by two lines (vanishing lines) which intersect at a point F 2 . The line bearing the segment F 1 F 2 is the horizon line.
[0182] As illustrated in FIG. 2 :
X is the base of the camera (projection of the optical centre C in the plane of the document) M 1 is the intersection of lines (AD) and (F 1 X) N 1 is the intersection of lines (BC) and (F 1 X) M 2 is the intersection of lines (AB) and (F 2 X) N 2 is the intersection of lines (CD) and (F 2 X) δ is a positive constant representative of a conventional distance measured from point X on axes (F 1 ,X) and (F 2 ,X) i is the angle of incidence E is an ellipse with a major axis parallel to (FX); its major axis has a length δ/cos(i) and its minor axis has a length δ O1 and P 1 are the intersections of (F 1 ,X) with ellipse E O2 and P 2 are the intersections of (F 2 ,X) with ellipse E O is the centre of the image F is the orthogonal projection of the optical centre O of the camera on line (F 1 ,F 2 )
[0195] In accordance with the method according to the invention, calculation of the physical aspect ratio r (r=horizontal length/vertical length) of the rectangle forming the original pattern is achieved according to one of the following three operating sequences:
1) The case when points F 1 and F 2 exist, segments AB, BC, CD, DA not being parallel. In this case, the operating sequence comprises the following phases: a first phase for calculating the coordinates of point F by projecting the centre of the image O on the horizon line (F 1 , F 2 ) a second phase for calculating the position of the base of the camera by its distance to point F, dist (X,F) by means of the relationship:
[0000]
dist
(
X
,
F
)
=
dist
(
F
,
F
1
)
·
dist
(
F
,
F
2
)
dist
(
O
,
F
)
[0199] This results from the following demonstration in three steps:
[0200] a) the angle between the base of the camera and horizon is 90° and it is inferred that
[0000]
i
.
tan
(
i
)
=
OX
f
and
tan
(
π
2
-
i
)
=
OF
f
ii
.
therefore
XF
OF
=
1
+
OX
OF
=
1
cos
2
(
i
)
[0201] b) the angle between F 1 and F 2 is also 90° and it is inferred that
[0000]
i
.
tan
(
j
)
=
FF
1
g
and
tan
(
π
2
-
j
)
=
FF
2
g
[0202] with g=OF/cos(i) and j being the angle between F 1 and F 2
[0203] from this, we obtain
[0000]
ii
.
therefore
1
cos
2
(
i
)
=
FF
1
·
FF
2
OF
2
[0204] c) the final formula for XF is obtained by combining relationships a) ii. and b) ii.,
a third phase for calculating the focal length f with the relationship:
[0000] f =√{square root over ( dist ( O,X )· dist ( O,F ))}{square root over ( dist ( O,X )· dist ( O,F ))}(inferred from a ) i . above) a fourth phase for calculating the angle of incidence i expressed by:
[0000]
tan
(
i
)
=
dist
(
O
,
X
)
dist
(
O
,
F
)
(
inferred
from
a
)
i
,
above
a fifth phase for determining the coordinates of points M 1 , N 1 , O 1 and P 1 from the values calculated earlier
a sixth phase for determining the coordinates of points M 2 , N 2 , O 2 and P 2 from the values calculated earlier
a seventh phase for calculating the physical aspect ratio r by using the crossed ratios and the fact that the rectangle O 1 , O 2 , P 1 , P 2 is the projection of a square extending in the plane of the pattern centred on the base according to the relationship
[0000]
r
=
dist
(
M
1
,
N
1
)
dist
(
M
2
,
N
2
)
·
dist
(
F
1
,
O
1
)
dist
(
F
1
,
M
1
)
·
dist
(
F
1
,
P
1
)
dist
(
(
F
1
,
N
1
)
·
dist
(
F
2
,
M
2
)
dist
(
F
2
,
O
2
)
·
dist
(
F
2
,
N
2
)
dist
(
F
2
,
P
2
)
[0210] This results from the fact that [O1,P1] and [O2,P2] are projections of two segments of the same length: [O1,P1] and [O2,P2] may be used as segments and the relative lengths of segments [M1,N1] and [M2,N2] may be measured by using the crossed ratios and r may be inferred from them.
[0211] 2) The case when two of the segments are parallel (intersection point is projected to infinity) ( FIG. 3 ))
[0212] In this case, ratio r is obtained according to the following relationship:
[0000]
r
=
dist
(
A
,
B
)
·
dist
(
C
,
D
)
(
dist
(
C
,
D
)
-
dist
(
A
,
B
)
)
·
f
2
+
dist
(
O
,
F
2
)
2
[0000] formula wherein f is the focal length of the camera (with the understanding that this focal length f is calculated beforehand).
[0213] 3) The case when there is no vanishing point (segments AB, BC, CD, DA being parallel, two by two)
[0214] In this case, the ratio r is simply
[0000]
r
=
dist
(
A
,
B
)
dist
(
A
,
D
)
[0215] These relationships are essentially based on invariants in projective geometry and in particular on the crossed ratios of four points, the relationships of which are expressed facing FIG. 5 which shows two views A*B*C*D*-A* 1 B* 1 C* 1 D* 1 of a same object taken by a camera with optical centre O* with two different angles of incidence.
[0216] From points A*, B*, C*, and D*, a first series of crossed ratios
[0000]
A
*
B
*
A
*
D
*
÷
CB
*
CD
*
.
[0000] may be obtained.
[0217] Likewise, from points A* 1 , B* 1 , C* 1 , D* 1 a second series of crossed ratios
[0000]
A
1
*
B
1
*
A
1
*
D
1
*
÷
C
1
*
B
1
*
C
1
*
D
1
*
[0000] is obtained.
[0218] Conservation of the crossed ratio is then expressed as
[0000]
A
*
B
*
A
*
D
*
÷
CB
*
CD
*
=
A
1
*
B
1
*
A
1
*
D
1
*
÷
C
1
*
B
1
*
C
1
*
D
1
*
[0219] In the case when one of the points, for example point A, is projected to infinity, the ratio A*B*/A*D* is considered to be equal to 1.
[0220] As mentioned earlier, the invention also provides a method for reshaping the image allowing the complexity of the homographic calculations to be reduced, calculations which were hitherto used notably when this image contains text.
[0221] FIG. 6 illustrates the different steps of this re-shaping mode which comprises:
[0000] a) a first step for calculating a binary mask deformed from an image where the frame (or the page) has been detected, and the text (written) portion has been extracted. This step consists of affecting a zero value to all the pixels which are outside a quadrilateral surrounding the useful portion of the image as well as the pixels which do not correspond to the writing.
[0222] The position of a point inside or outside a quadrilateral may be determined according to the method illustrated in FIG. 4 .
[0223] This figure shows in an x,y coordinate reference plane, a quadrilateral A′, B′, C′, D′, as well as, inside this quadrilateral, two points P and G of coordinates xp, yp and xo, yo. The G point may consist of the centre of gravity of the quadrilateral A′, B′, C′, D′ or more simply of the centre of its diagonals, for example the centre of segment B′D′.
[0224] Segments A′B′-B′C′-C′D′ and D′A′ are borne by lines D 1 , D 2 , D 3 , D 4 , respectively.
[0225] The expression of these lines and more generally of a line Di with i=1, 2, 3, 4 is of the type:
[0000] ai·x+bi·y+ci= 0
[0000] ai, bi, ci being constants.
[0226] Point P is therefore inside the quadrilateral if and only if, it is always on the same side as G relatively to the limits of the quadrilateral (each limiting line D 1 -D 4 dividing the plane into two portions): this amounts to stating that:
[0227] ai·xp+bi·yp+ci and ai·xo+bi·yo+co have the same sign for i belonging to the set {1,2,3,4}. This is written in the following form:
[0000] ∀ i ε{1,2,3,4}( ai·xp+bi·yp+ci )·( ai·xo+bi·xo+ci )≧0
[0000] b) A second step for calculating the ideal mask by direct homography.
[0228] Reference will be made here to FIG. 7 which illustrates the principle for calculating the image of a point by homography. On this figure, a quadrilateral P 1 , P 2 , P 3 , P 4 determined by using the method described earlier (page) and a point of coordinates (u,v) located inside this quadrilateral, are illustrated.
[0229] Point O, if it exists, is the intersection of lines (P 1 , P 2 ) and (P 3 , P 4 ). Point Q is the intersection of lines (P 1 , P 4 ) and (P 2 , P 3 ). Point I is the intersection of segments OP and P 1 P 4 , whereas J is the intersection of segments QP and P 3 P 4 .
[0230] It is known that homography provides the transformation of a quadrilateral (here, P 1 -P 4 ) into a rectangle H(P 1 ), H(P 2 ), H(P 3 ), H(P 4 ) visible in FIG. 8 .
[0231] In this FIG. 8 , a point (x,y) with coordinates H(I), H(J) is also illustrated and the length D x and the width D y of the rectangle are shown.
[0232] Conservation of the crossed ratios then gives:
[0000]
OP
4
OP
3
·
JP
3
JP
4
=
Dx
-
1
-
x
x
QP
4
QP
1
·
IP
1
IP
4
=
Dy
-
1
-
y
y
[0233] The coordinates of H(P) may be inferred therefrom
[0000]
x
=
(
Dx
-
1
)
·
OP
3
·
JP
4
OP
3
·
JP
4
+
OP
4
·
JP
3
y
=
(
Dy
-
1
)
·
OP
1
·
JP
4
QP
1
·
IP
4
+
QP
4
·
IP
1
[0234] The calculation of the image of a line by homography obviously results from this calculation as the image of a line simply consists of the segment joining the images of both points of the original line.
[0235] The calculation of the ideal mask is performed according to the following process:
[0236] Let (i,j) be a pixel which corresponds to the writing in the deformed binary mask with its four subpixels which surround it ( FIG. 9 ):
[0000]
(
i
-
i
2
,
j
-
1
2
)
,
(
i
-
1
2
,
j
+
1
2
)
,
(
i
+
1
2
,
j
+
1
2
)
(
i
+
1
2
,
j
-
1
2
)
[0237] Let us assume that A, B, C and D are the images of these subpixels by direct homography ( FIG. 10 ). A, B, C, D is therefore a quadrilateral. Let us consider the smallest rectangle which this quadrilateral contains. All the pixels contained in this rectangle are set to the “true” value for example 1.
[0238] An ideal binary mask may be obtained from this. A mechanism should then be established for calculating the image of a point with coordinates in the form of (u±½, v+½) wherein u, v is a pixel.
[0239] For this purpose, a point P of the coordinate plane (u+½, v+½) is considered. This point is determined by the intersection of two intermediate lines: the vertical line of coordinate u+½ and the horizontal line of coordinate v+½. The image of point P is then at the intersection of the images of the horizontal and vertical lines obtained by homography.
[0240] Accordingly, the images of these intermediate lines (and intermediate columns) are calculated beforehand. As soon as these images have been precalculated, the images of the subpixels are obtained by the intersection of two precalculated images of intermediate lines.
[0000] c) A third inverse homography step.
[0241] In order to calculate the final image, to each pixel of the binary mask, an intensity value must be assigned, which is calculated by finding the position of this pixel in the initial image: for this purpose, an inverse homography calculation needs to be performed.
[0242] Thus, by repeating the symbology of FIGS. 7 and 8 , (x,y) is considered to be a pixel of the ideal mask. This pixel is at the intersection of line y and of column x. The position of this pixel in the deformed image is then obtained by obtaining the intersection of the images of the line and column by inverse homography.
[0243] The parameters of lines (QJ) and (OI) should then be found in order to calculate their intersection P. The position of points I and J should then be calculated. This result is easily obtained by finding distances JP 3 and IP 1 , for example.
[0244] This is possible by using the following form of crossed ratios:
[0000]
OP
4
OP
3
·
JP
3
P
3
P
4
JP
3
=
Dx
-
1
-
x
x
OP
4
OP
1
·
JP
1
P
1
P
4
JP
1
=
Dy
-
1
-
y
y
IP
1
=
P
1
P
4
·
(
Dy
-
1
-
y
)
·
QP
1
(
Dy
-
1
-
y
)
·
QP
1
+
y
·
QP
4
[0245] It then becomes possible to calculate the position of point P.
[0246] Practically, the images are calculated beforehand by inverse homography of the lines and columns of the ideal mask. The position of a given pixel is then inferred in the original image by calculating the intersection of two lines (in this example, the two lines avec (OI) and (QJ)).
[0247] Of course, the invention is not limited to this single method.
[0000] d) A fourth step for creating the final image:
[0248] Let (u,v) be a pixel of the ideal mask. Its position in the deformed initial image is calculated by the intersection of precalculated inverse images of line v and column u. The point which is found, is then called (x,y). An intensity value should then be assigned to pixel (u,v) which will be interpolated in point (x,y) of the initial image. To accomplish this operation, bilinear interpolation is used, for example.
[0249] If the pixels surrounding point (x,y) such as illustrated in FIG. 11 , are considered, the interpolated intensity is given by formula:
[0000] I ( x,y )=( y−j )[( i+ 1 −x ) I ( i,j+ 1)+( x−i ) I ( i+ 1 ,j+ 1)]+( j+ 1 −y )[( i+ 1 −x ) I ( I,j )+ I ( I+ 1 ,j )]
[0250] Pixel (u,v) in the final image will then have intensity I(x,y) with the understanding that the grey levels are quantified in the final image.
[0251] Advantageously, the image containing the corrected extracted data from the noise may be calculated according to the subtractive principle.
[0252] It is known that luminance is equal to a combination of the intensities of the fundamental colours (red, green, blue): for example L=0.5G+0.3R+0.2B.
[0253] Thus, in accordance with the method according to the invention, for each of the pixels, one successively proceeds with extracting the luminance, extracting the raw data D(p), calculating the noise contextual datum V S , extracting the noise corrected raw data D*(p) by means of the noise contextual datum, and then generating the luminance image corrected by the following calculation:
[0000]
I
*
(
p
)
=
{
I
max
-
f
·
D
*
(
p
)
(
dark
data
bright
)
(
I
max
may
be
equal
to
255
)
I
min
+
f
·
D
*
(
p
)
(
bright
data
dark
)
(
I
min
may
be
equal
to
zero
)
[0254] Advantageously, in the case of a colour image, the subtractive principle may be used by removing contrasts of determined chrominances from the background colour, as with a filter, in order to obtain the sought-after colour for the final image.
[0255] For example, the noise contextual datum V S may be extracted on the basis of the luminance image, and then the corrected raw data may be extracted from the noise (D* R ,D* G ,D* B ) of the colour channels by calculating the raw data of channels D R , D G , D B , expressing the contrast between the observed chrominance RGB and that of the background (V R Back. , V G Back. , V B Back. ) and thresholding by means of V S , and finally generating the corrected chrominance image.
[0000]
R
*
G
*
B
*
=
{
(
V
R
Back
,
V
G
Back
,
V
B
Back
)
-
f
·
(
D
R
*
·
D
G
*
,
D
B
*
)
(
dark
data
bright
)
(
(
V
R
Back
,
V
G
Back
,
V
B
Back
)
may
be
equal
to
(
255
,
255
,
255
)
)
(
V
R
Back
,
V
G
Back
,
V
B
Back
)
+
f
·
(
D
R
*
·
D
G
*
,
D
B
*
)
(
bright
data
dark
)
(
(
V
R
Back
,
V
G
Back
,
V
B
Back
)
may
be
equal
to
(
0
,
0
,
0
)
)
}
[0256] As an example, let us assume that at a pixel, the estimated chrominance of the background corresponding to a white area of the supporting medium is (V R Back. , V G Back. , V B Back. )=(160, 140, 110), and that this pixel represents a blue writing area with chrominance (V R 0 , V G 0 , V B 0 )=(120, 115, 105). Let us assume that the corrected white/blue contrast of the optical noise is (D* R ,D* G ,D* B )=(160-120, 140-115, 110-105)=(40, 25, 5). Let us set the chrominance of the pixels of the final image representing the white areas of the supporting medium to (R B , G B , B B )=(255, 255, 255), the corrected chrominance of this pixel in the final image is then determined by subtracting the contrast weighted earlier by an f factor, from that of the white, so that the corrected chrominance (R*,G*,B*) of the final image in this pixel will be, if f=1, (R*,G*,B*)=(R B −D* R ,G B −D* G ,B B −D* B )=(255−40, 255−25, 255−5)=(215, 230, 250).
[0257] The f factor mentioned earlier may be advantageously used for aligning the obtained colours with reference colours, displayed for example on a test pattern.
[0258] Of course, the invention is not limited to the embodiments described earlier.
[0259] Thus, it is notably found that the usual process for determining the threshold value V S at which a handwritten or printed piece of information may be extracted from each pixel of the difference image D(p) (based on knowing beforehand the probability q that a regional maximum of raw data D(p) is generated by noise), has the two following drawbacks:
First of all, probability q must be known experimentally for each camera module in order to perform extraction of information from their images. This prevents any extracted information derived from an image captured by an unknown camera module, from being considered as trustworthy information (for example, extraction of information from an image received on a server, for forwarding it by fax to an addressee). Next, it is mandatory to know beforehand whether the information is dark-on-bright-background information or vice versa.
[0262] The invention therefore provides an enhancement of this method with which the two drawbacks mentioned earlier may be avoided. This enhancement notably provides accurate determination of the threshold value V S , at which the printed or handwritten information may be extracted from the difference image D(p) (analogous to D[C,L]) and determination whether the information is dark on a bright background or vice versa, bright on a dark background.
[0263] By considering a grey level image I(p) which may either be a combination of the three colour channels of the image (red, blue, green) or one of these three channels, the method according to the invention comprises the following steps, with reference to FIG. 12 :
[0264] 1) A first step for calculating a pit histogram H_pits includes the following operating phases:
[0265] a) for each pixel p of image I, the following is performed:
[0266] i. for each direction d with 0<|d|<D:
[0267] if the condition
convexity of I on [p−d, p+d] i.e.
[0000] I ( p +(1−2×) d )≦λ I ( p−d )+(1−λ) I ( p+d ) for any 0≦λ≦1
[0269] is satisfied
[0270] then G(p,d)=(I(p+d)+I(p−d))/2 is calculated
[0271] or else G(p,d)=0
[0272] ii. S(p)=maximum value of G(p,d) is calculated for all directions d with 0<|d|<D
[0273] b) the maximum value of the pits, S_pits_max is calculated, which is equal to the maximum value of S(p) for all the pixels p
[0274] c) the pit histogram H_pits is reset to 0 for each value of s between 0 and the maximum value of the pits, S_pits_max
[0275] d) for each pixel p of image S(p) the following calculations are performed:
[0276] i. if S(p) is a regional maximum,
[0277] H_pit (S(p)) is incremented in the following way:
[0000] H _pit( S ( p ))← H _pit( S ( p ))+1
[0278] 2) A second step for calculating the bump histogram H_bumps includes the following operating phases:
[0279] a) for each pixel p of image I, the following is performed:
[0280] i. for each direction d with 0<|d|<D
if the following condition concavity of I on [p−d, p+d], i.e.,
[0000] I ( p +(1−2λ) d )≧λ I ( p−d )+(1−λ) I ( p+d ) for any 0≦≦λ≦1
[0283] then G(p,d)=(I(p+d)+I(p−d))/2 is calculated
[0284] or else G(p,d)=0
[0285] ii. S(p)=maximum value of G(p,d) is calculated for all directions d with 0<|d|<D
[0286] b) the maximum value of the bumps S bumps_max is calculated, which is equal to the maximum value of S(p) for all the pixels p
[0287] c) the bump histogram H_bumps(s) is reset to 0 for each s between 0 and the maximum value of the bumps, S bumps_max
[0288] d) for each pixel p of image S(p), the following calculations are performed:
[0289] i. if S(p) is a regional maximum
[0290] H_bumps(S(p)) is incremented in the following way:
[0000] H _bumps( S ( p ))← H _bumps( S ( p ))+1
[0291] 3) A third step for superimposing pit H_pits and bump H_bumps histograms includes the following operating steps:
a) calculating S_max according to the expression:
[0000] S max =Max(maximum value of the pits S _pits_max,maximum value of the bumps S _bumps−max) b) calculating H_max according to the expression:
[0000] H _max=maximum value of the pits, H _pits( S ) and of the bumps, H _bumps( S ), for all values of S c) calculating s0 according to the expression: s0=maximum value of s such that
[0000] H _pits( s )= H _max or H_bumps(s)=H_max d) s=s0+1 is calculated and α is selected such that 0<α<½ and as long as:
[0000] |ln(1+ H _pits( s ))−ln(1 +H _bumps( s ))<α·ln(1 +H _max)
[0298] s=s+1 is performed (where in is Napier's logarithm function)
[0299] finally, value 5 min is determined by the final value of s incremented by 1
[0300] 4) A step for calculating the value of the extraction threshold V S according to the relationship:
[0000] V S =r·S min +(1 −r )· S max where ½ ≦r≦ 1
[0301] 5) A step for comparing H_pits and H_bumps includes the following operating phases for β>0:
[0302] a) calculating a value N_pits from the relationship:
[0000] N _pits=sum of H _pits( s ) β for s= 5 min to s=S _pits_max
[0303] b) calculating a value N_bumps from the relationship:
[0000] N _bumps=sum of H _bumps( s ) β for s=S min to s=S _bumps_max
[0304] c) if N_pits is less than N_bumps, then the dark-on-bright-background information should be extracted or else the bright-on-dark-background information should be extracted
[0305] 6) A step for extracting luminance information L(p) includes the following operating phases:
[0306] a) calculating D according to a known method
[0307] b) for each pixel p in the difference image D(p),
[0000] if D(p)>V S , then D(p) is considered relevant and is extracted
[0308] i. if the information is dark-on-bright-background information, calculating a value, L(p)=I max −f·D(p), I max may be equal to 255
[0309] ii. or else the value L(p)=I min +f·D(p) is calculated, I min may be equal to 0
[0310] If D(p) is not considered relevant
[0311] i. if the information is dark-on-bright-background information, the value of L(p) is equal to I max (bright background)
[0312] ii. or else the value of L(p) is equal to I min (dark background)
[0313] As an example, satisfactory results may be obtained with the following parameters:
[0314] D=3
[0315] α=20%
[0316] r=85% for extraction
[0317] f=5
[0318] The invention also relates to the simulation of an image of a rectangle (A, B, C, D) with a prescribed physical aspect ratio r=CD/AD, a prescribed point of the projected rectangle in the image (for example point D) and a known projected distance (for example CD) with a camera having a prescribed focal length (f), a tilt angle (π/2)−i where i is the angle of incidence), α is an angle of rotation around the axis of the camera and if i≠0, a prescribed skew angle (β) relatively to one of the existing vanishing points (for example F 1 ). These different parameters are indicated in FIG. 13 which schematically illustrates a camera, with its optical axis and the focal point with the ox, oy, oz coordinate reference system which is bound to this focal point.
[0319] The solution of this problem comprises the three following steps which refer to FIGS. 2 and 3 and to FIG. 14 , i.e.:
A first step for calculating the position of the three unknown points A, B and C (point D being prescribed) in the new image which must be generated. The points must be consistent with the physical aspect ratio r of the pattern which must be projected on this new image and the position of the camera (focal distance, tilt angle, angle of rotation, skew angle) which must be simulated. A second step for calculating homographic relationships in order to project the information contained in the pattern of the original image on the calculated pattern of the simulated image. A third step for determining luminance and chrominance of the new image within the contour calculated from the original image with homographic relationships.
[0323] Calculation of the three unknown points of the pattern takes into account the three following cases:
[0324] If i≠0 (there is at least one vanishing point), the calculation comprises the four following operating phases:
1. OX=f·tan(i) 2. OF=f/tan(i) 3. Points X and F are placed on a line crossing through the centre of image O and forming an angle α relatively to the vertical 4. Point F 1 is placed such that
[0000] FF 1 =f tan(β)/sin( i )
[0329] a) if β≠0 (2 vanishing points)
i) point F 2 is placed such that FF 2 =(OF·XF)/FF 1 ii) points M 1 , C, N 1 , O 1 , P 1 , O 2 , P 2 and N 2 are inferred from points X, F 1 , F 2 (if β≠0), D and from distance DC, iii) point M 2 is placed so as to obtain the relationship
[0000]
r
=
dist
(
M
1
,
N
1
)
dist
(
M
2
,
N
2
)
·
dist
(
F
1
,
O
1
)
dist
(
F
1
,
M
1
)
·
dist
(
F
1
,
P
1
)
dist
(
F
1
,
N
1
)
·
dist
(
F
2
,
M
2
)
dist
(
F
2
,
O
2
)
·
dist
(
F
2
,
N
2
)
dist
(
F
2
,
P
2
)
[0333] b) if β≠0 (only one vanishing point: F 1 =F) ( FIG. 3 )
[0334] i) point A is placed on line (DF) such that
[0000]
AF
=
r
·
DF
·
f
2
+
OF
2
DC
+
r
f
2
+
OF
2
[0335] ii) point B is placed on line (FC) such that BF=CF·(AF/DF)
[0336] c) if i=0 (no vanishing point) ( FIG. 14 )
1) point C is placed by using point D, distance DC and the angle of rotation α 2) point B is placed such that (A, B, C, D) is a rectangle.
|
The method according the invention allows the extracting raw data from an image resulting from a camera shot.
It comprises determining, for each point of the image of a combination V 0 [C,L] of colour components of the image, calculating, for each point of the image, of a value V N+1 [C,L], iterating said calculating a predetermined number of times then taking into account the values of the final image V Nfinal [C, L] in each point of the image, calculating for each point of the image of the difference D [C, L]=V Nfinal [C, L]−V 0 [C, L], calculating of a noise contextual datum V S , correcting the extracted raw data D[C, L], with the contextual datum V S , calculating of a corrected value I*[C, L] taking into D*[C, L] and presenting the extracted data under a desired angle.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATION
The present application claims the benefit of Argentine Patent Application No. 20100101915 filed on 1 Jun. 2010, the entire disclosure of which is hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to the field of vehicles used in pharmacy and cosmetic industries as carriers of active compounds, especially those vehicles based on natural vegetable oils and, more specifically, those based on jojoba oil.
DESCRIPTION OF THE BACKGROUND ART
Jojoba oil is obtained from the seed of Simmondsia Chinensis , which contains about 50% by weight of this oil, and which on account of its chemical structure is not a fat but a liquid wax.
This liquid wax is made of a mixture of straight chain monounsaturated fatty acid esters from 20 to 22 carbon atoms and homologous alcohols most of the same size, with an average chain length from 40 to 42 carbon atoms having one unsaturated hydrocarbon on each side of the ester bond (Wisniak, Jaime, The chemistry and technology of jojoba oil. American Oil Chemists Society, USA 1987). Its general formula is as follows:
The unsaturated acids with the highest presence are eicosanoic acid (of 20 carbon atoms, C20), docosanoic acid (C22), with lower amounts of oleic acid (C18). Alcohols are mostly docosanoic alcohol and eicosanoic alcohol (Wisniak, Jaime, The chemistry and technology of jojoba oil. American Oil Chemists Society, USA 1987).
The intensive studies conducted and its use for more than 30 years in cosmetic products, show that jojoba oil is not toxic when it is applied on the human skin, or administered orally to mice, rats, marmots and rabbits (Verbiscar, Anthony; WO99/62451—Topical transdermal treatment).
Jojoba oil has been effectively used to treat different skin disorders together with other therapeutic agents, for example salicylic acid in the treatment of psoriasis, dandruff, acne and skin flaking. It is effective with zinc oxide in the treatment of contact dermatitis, cutaneous rash and allergic dermatitis. It is also effectively used for treating insect bites or fungal foot infections, as well as for treating first degree burns and sun burns, being a good protector against ultraviolet radiation during exposure to sun.
It is a first selection for treating wounds, even those associated with inflammatory processes and scars. It has been used as an auxiliary agent for the treatment of alopecia.
Jojoba oil is also successfully used for a wide range of disorders such as rheumatic pain and arthritis, otitis, ocular disorders, as well as in suppositories for treating anal fissures, hemorrhoids and non infectious vaginitis (El Mogy, Nabil Sadek; Patent Application US2003/0008022—Medical effect of Jojoba oil).
Jojoba oil esters are effective for promoting quick relief of infected zones or preventing future relapses. Jojoba oil is absorbed through the skin much more easily and quickly than other substances previously used without having to add surfactants or emollients (Purcell, Hal; U.S. Pat. No. 6,559,182 B1 (May 6, 2003), WO 2003/49674—Method of treatment of enveloped viruses using jojoba oil esters).
Jojoba oil can be used as a promoter of the therapeutic efficacy of other active principles, as it increases percutaneous absorption and accumulation in the epidermis, and is able to act as a carrier of the active principles to deep layers of the skin to perform their function. Examples of these active ingredients are anti-inflammatory drugs such as ibuprofen and ketoprofen; antifungal agents such as griseofulvin; liposoluble vitamins such as vitamin A, vitamin D and vitamin E; antineoplastic agents such as Taxol and Paclitaxel; hormonal agents such as testosterone, estrogen, cortisone and prostaglandins; as well as other antiviral agents such as nucleoside and immune response modulator analogue drugs (Purcell, Hal, U.S. Pat. No. 6,559,182 B1 (May 6, 2003), WO2003/49674—Method of treatment of enveloped viruses using jojoba oil esters).
However, jojoba oil itself, used as a vehicle, is only able to dissolve lipophilic active principles, but is not useful as a vehicle of hydrophilic active principles. Therefore, a new vehicle derived from jojoba oil and capable of carrying a wide range of active principles, either lipophilic or hydrophilic ones, and also exhibiting the advantages offered by products whose vehicle is aqueous in relation to the oily ones is desirable.
A composition containing derivative products of hydrolysed jojoba oil was described in U.S. Pat. No. 7,435,424. When this composition is included from 5% to 10% in other cosmetics, repellent or pesticides products, it increases the persistence of those products over an animal's skin or hair. In spite of this composition it is not itself an aqueous carrier that produces the dissolution of cosmetics or pharmaceuticals active principles, either lipophilics or hydrophilics.
An important field wherein the use of jojoba oil is also effective is the prevention and treatment of infections by virus such as herpes viruses, including but not limited to, Herpes simplex virus (HSV) type 1, mostly associated to facial infections on lips, mouth, nose and eyes; HSV type 2, mostly genital; varicella zoster virus also known as human herpes virus (HHV) type 3; HHV type 8, associated with Kaposi's sarcoma.
In this respect, it has been found that alcohols with a chain length from 16 to 20 carbons and at least one unsaturated carbon are effective in inhibiting replication of viruses with lipid coating in cell cultures; numerous studies have shown the antiviral activity of n-docosanol, and several patents support these publications (Verbiscar, Anthony; WO 2006/112938A1—Formulations useful for the treatment of varicella zoster virus infections and methods for the use thereof).
However, jojoba oil does not contain alcohols in free form but rather in esterified form. Therefore it is desirable to have a jojoba oil vehicle comprising the free alcohols which, considering their structural characteristics, are per se an active principle against lipid coated viruses.
SUMMARY OF THE INVENTION
Aqueous dispersions comprised of alcohols and acids obtained by hydrolysis of jojoba oil were developed.
Hydrolyzed jojoba oil products are treated by a process comprising neutralization of jojoba fatty acids with aliphatic organic amines dissolved in a co-solvent followed by the dispersion of both the neutralized fatty acids together with jojoba alcohols in an aqueous medium.
The products obtained named generically hydrolyzed jojoba oil (hereinafter HJO) are presented as high-viscosity, transparent, translucent or opaque, physically stable dispersions with a pH between 7.00 and 8.50.
The HJO is capable of carrying a wide range of pharmaceutical and cosmetic, either hydrophilic or lipophilic, active principles, preferably non-steroidal anti-inflammatory (NSAIDs), local anesthetics, antiviral and antifungal drugs, showing an important effect of promoting transdermal absorption.
The HJO remarkably broadens capacity and usefulness as a pharmaceutical and cosmetic vehicle compared to jojoba oil.
The HJO has the ability of emulsifying jojoba oil producing a semisolid product of bright texture named self-emulsified jojoba oil (hereinafter SEJO) useful as a skin-care cream. The SEJO is capable of carrying liposoluble and hydro soluble vitamins and other active principles of cosmetic use.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the characterization of the hydrolysis products of Jojoba oil by 1 H-NMR. The assignments of main signals shows the disappearance of the original product (disappearance of the signals HC—COO—CH δ=4.1 ppm characteristic of Jojoba oil ester group), and the presence of carboxylic acids (—HC—COOH, d=2.3 ppm) and the presence of alcohols (HC—OH, d=3.6 ppm) derived from jojoba wax in equal amounts in relation with the whole mass.
FIG. 2 shows the rheological behavior of the hydrolyzed jojoba oil product (WO), by a flow curve up to 60 rpm generated forward and backward at 25° C.
FIG. 3 shows analytical controls of the hydrolyzed jojoba oil product (HJO) by a titration curve of HJO with NaOH 0.05 N and with HCl 0.05 N.
FIG. 4 refers to a rat skin permeation assay of Diclofenac 1% w/w in HJO, determined by HPLC, wherein the promoting effect of transdermal permeability of the product HJO is noted.
FIG. 5 refers to a rat skin permeation assay of Acyclovir 5% w/w in HJO, determined by HPLC, wherein the promoting effect of transdermal permeability of the product HJO is noted.
DETAILED DESCRIPTION OF THE INVENTION
Procedure
Therefore, one embodiment of the invention is to provide a process for obtaining an aqueous dispersion of alcohols and salified acids from jojoba oil useful as a carrier in pharmaceutical and cosmetic compositions, comprising a first step wherein jojoba oil esters represented by the formula (I) are saponified by treatment with a base (II) to form a mixture of carboxylate (III) and jojoba alcohols (IV):
wherein R1 and R2 are alkenes of C20-C22; M is an alkaline metal or alkaline earth metal; and n is 1 or 2.
The base (II) is preferably an alkali metal hydroxide such as lithium hydroxide, sodium hydroxide, potassium hydroxide, or an alkali earth metal such as calcium hydroxide, magnesium hydroxide. More preferably, the base (II) is sodium hydroxide [NaOH] or potassium hydroxide [KOH].
The reaction is conducted in a reaction medium comprising a methyl alcohol:H 2 O solution, preferably at a ratio of 99:1, and at boiling temperature, preferably from 60-70° C.
Afterwards, the solvent is evaporated to dryness by means of reduced pressure and the product is treated with an aqueous solution of a strong inorganic acid and/or organic acid in a sufficient amount to neutralize the fatty acid salts and the excess of base present in the reaction medium. Preferably, the inorganic strong acid is hydrochloric acid at concentrations from 1 to 10% w/v.
In this way, the solid or semisolid product obtained comprises mainly a mixture of acids and alcohols of jojoba oil, which are separated from the aqueous medium.
In an alternative procedure prior to solvent evaporation the product is acidified by means of a strong inorganic acid or an organic acid solution to neutralize the fatty acid metallic salts and the excess of base present in the reaction medium. Preferably, the strong inorganic acid is hydrochloric acid at concentrations of 1 to 30% w/v.
The product obtained comprises an upper layer of an oily liquid comprising mainly a mixture of acids and alcohols of jojoba oil and an aqueous layer which may have a precipitated solid comprising the salts resulting from the acidification process. The oily product is recovered and washed by water.
The following step comprises salification of fatty acids, at a ratio from 50 to 100% of the number of existing carboxylic groups by adding the appropriate proportion of an aliphatic organic amine.
Preferably, said aliphatic organic amine is selected from the group consisting of dialkyl (C 1 -C 6 ) amines, dihydroxyalkyl (C 1 -C 6 ) amines, trihydroxyalkyl (C 1 -C 6 ) amines, and mixtures thereof.
More preferably, the aliphatic organic amine used is selected from the group consisting of triethanolamine [(HOCH 2 CH 2 ) 3 N], diethanolamine [(HOCH 2 CH 2 ) 2 NH], tromethamine [(HOCH 2 ) 3 CNH 2 ], diethylamine [(CH 3 CH 2 ) 2 NH], and mixtures thereof.
The aliphatic organic amine is previously dissolved in a suitable volume of a co-solvent to obtain a co-solvent concentration in the final product from 15% to 25% w/w.
Preferably, the co-solvent is selected from the group consisting of ethyl alcohol [CH 3 CH 2 OH], propylene glycol [CH 3 CHOHCH 2 OH], and mixtures thereof.
Afterwards the product obtained from salification of the fatty acids by adding the aliphatic organic amine, which also contains the jojoba alcohols and the co-solvent, is dispersed in a sufficient amount of distilled or purified water to obtain a high viscosity product, physically stable at a pH from 7.00 to 8.50 that contains from 15% to 30% weight by weight of the salified product of the hydrolysis of the jojoba oil. This aqueous dispersion we named hydrolyzed jojoba oil (HJO).
Another embodiment of the present invention is a procedure for obtaining self-emulsified jojoba oil (SEJO) containing jojoba oil emulsified in the aqueous dispersion of alcohols and salified acids of hydrolyzed jojoba oil (HJO) according to the preceding discussion. Said procedure comprises the addition of jojoba oil to the hydrolyzed jojoba oil (HJO) at room temperature with vigorously mechanical stirring the mixture, to obtain the self-emulsified jojoba oil product (SEJO) as a semisolid product of homogeneous aspect and bright texture.
Another option for preparing this self-emulsified jojoba oil product (SEJO) involves first contacting the solution comprising the alcohols and fatty acids salified by the aliphatic organic amine dissolved in a co-solvent with the jojoba oil under gently stirring until the complete incorporation of the phases. Afterwards adding water slowly under moderate and constant stirring, to obtain a semisolid product of high viscosity, homogeneous aspect, and bright texture.
Preferably, the self-emulsified jojoba oil (SEJO) contains from 1% to 40% weight by weight of jojoba oil dispersed in the hydrolyzed jojoba oil product (HJO). More preferably, the SEJO contains 15% weight by weight of jojoba oil dispersed in the hydrolyzed jojoba oil product (HJO).
I) Thus, depending on the starting material used, different aqueous dispersions of hydrolyzed jojoba oil can be obtained, preferably the following:
i) Aqueous dispersion of alcohols and salified acids of hydrolyzed jojoba oil (HJO) obtained by treating the fatty acids with triethanolamine in ethanol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
ii) Aqueous dispersion of alcohols and salified acids of hydrolyzed jojoba oil (HJO) obtained by treating the fatty acids with diethanolamine in ethanol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
iii) Aqueous dispersion of alcohols and acids of hydrolyzed jojoba oil (HJO) obtained by treating the fatty acids with diethylamine in ethanol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
iv) Aqueous dispersion of alcohols and salified acids of hydrolyzed jojoba oil (HJO) obtained by treating the fatty acids with tromethamine in ethanol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
v) Aqueous dispersion of alcohols and salified acids of hydrolyzed jojoba oil (HJO) obtained by treating the fatty acids with triethanolamine in propylene glycol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
vi) Aqueous dispersion of alcohols and salified acids of hydrolyzed jojoba oil (HJO) obtained by treating the fatty acids with diethanolamine in propylene glycol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
vii) Aqueous dispersion of alcohols and salified acids of hydrolyzed jojoba oil (HJO) obtained by treating the fatty acids with diethylamine in propylene glycol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
viii) Aqueous dispersion of alcohols and salified acids of hydrolyzed jojoba oil (HJO) obtained by treating the fatty acids with tromethamine in propylene glycol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
ix) Aqueous dispersion of alcohols and salified acids of hydrolyzed jojoba oil (HJO) obtained by treating the fatty acids with triethanolamine in a mixture of ethanol and propylene glycol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
x) Aqueous dispersion of alcohols and salified acids of hydrolyzed jojoba oil (HJO) obtained by treating the fatty acids with diethanolamine in a mixture of ethanol and propylene glycol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
xi) Aqueous dispersion of alcohols and salified acids of hydrolyzed jojoba oil (HJO) obtained by treating the fatty acids with diethylamine in a mixture of ethanol and propylene glycol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
xii) Aqueous dispersion of alcohols and salified acids of hydrolyzed jojoba oil (HJO) obtained by treating the fatty acids with tromethamine in a mixture of ethanol and propylene glycol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
II) Also, from those 12 different salified products of hydrolyzed jojoba oil (HJO) described, it is possible to obtain several self-emulsified jojoba oils (SEJO) by emulsification of jojoba oil in each of them as follows
i) Self-emulsified jojoba oil (SEJO) comprising an emulsion from 1% to 40% weight by weight of jojoba oil in HJO obtained by treating the fatty acids with triethanolamine in ethanol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
ii) Self-emulsified jojoba oil (SEJO) comprising an emulsion from 1% to 40% weight by weight of jojoba oil in HJO obtained by treating the fatty acids with diethanolamine in ethanol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
iii) Self-emulsified jojoba oil (SEJO) comprising an emulsion from 1% to 40% weight by weight of jojoba oil in HJO obtained by treating the fatty acids with diethylamine in ethanol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
iv) Self-emulsified jojoba oil (SEJO) comprising an emulsion from 1% to 40% weight by weight of jojoba oil in HJO obtained by treating the fatty acids with tromethamine in ethanol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
v) Self-emulsified jojoba oil (SEJO) comprising an emulsion from 1% to 40% weight by weight of jojoba oil in HJO obtained by treating the fatty acids with triethanolamine in propylene glycol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
vi) Self-emulsified jojoba oil (SEJO) comprising an emulsion from 1% to 40% weight by weight of jojoba oil in HJO obtained by treating the fatty acids with diethanolamine in propylene glycol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
vii) Self-emulsified jojoba oil (SEJO) comprising an emulsion from 1% to 40% weight by weight of jojoba oil in HJO obtained by treating the fatty acids with diethylamine in propylene glycol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
viii) Self-emulsified jojoba oil (SEJO) comprising an emulsion from 1% to 40% weight by weight of jojoba oil in HJO obtained by treating the fatty acids with tromethamine in propylene glycol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
ix) Self-emulsified jojoba oil (SEJO) comprising an emulsion from 1% to 40% weight by weight of jojoba oil in HJO obtained by treating the fatty acids with triethanolamine in a mixture of ethanol and propylene glycol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
x) Self-emulsified jojoba oil (SEJO) comprising an emulsion from 1% to 40% weight by weight of jojoba oil in HJO obtained by treating the fatty acids with diethanolamine in a mixture of ethanol and propylene glycol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
xi) Self-emulsified jojoba oil (SEJO) comprising an emulsion from 1% to 40% weight by weight of jojoba oil in HJO obtained by treating the fatty acids with diethylamine in a mixture of ethanol and propylene glycol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
xii) Self-emulsified jojoba oil (SEJO) comprising an emulsion from 1% to 40% weight by weight of jojoba oil in HJO obtained by treating the fatty acids with tromethamine in a mixture of ethanol and propylene glycol and dispersed in a sufficient amount of water to obtain a transparent or quasi-transparent product of high viscosity containing from 15% to 30% weight by weight of the salified product of hydrolyzed jojoba oil.
III) From the HJO described in I) transparent or translucent dispersions of an NSAID, wherein the NSAID is added to the HJO in a concentration from 0.1% to 1%; and wherein preferred NSAID are: ketoprofen, ibuprofen, naproxen, flurbiprofen, diclofenac, indomethacin and piroxicam.
Therefore, each of the twelve hydrolyzed jojoba oils (HJO) described in I) can be utilized to carry an NSAID, thus obtaining a pharmaceutical composition.
IV) From several HJO described in I) opaque dispersions of antiviral agents may be obtained, wherein an antiviral agent is added to the HJO in a concentration from 0.5% to 5%; and wherein preferred antiviral agent are: acyclovir, penciclovir, idoxuridine.
Therefore, each of the twelve hydrolyzed jojoba oils (HJO) described in I) can be utilized to disperse an antiviral agent, thus obtaining a pharmaceutical composition.
V) From several HJO described in I) transparent or translucent dispersions of local anesthetic drugs comprising 0.5% to 5% of a local anesthetic agent in the HJO; and wherein preferred local anesthetics agents are: lidocaine, benzocaine, tetracaine or procaine.
Therefore, each of the twelve hydrolyzed jojoba oils (HJO) described in I) can be utilized to dissolve a local anesthetic agent, thus obtaining a pharmaceutical composition.
VI) From several self-emulsified jojoba oils (SEJO) described in II) useful for skin care it is possible to obtain new cosmetic products as a result of their ability to carry liposoluble vitamins, preferably vitamins A, D, and E, and hydro soluble vitamins, preferably vitamin C, as well as other cosmetic active principles.
EXAMPLES
Example 1
Obtaining an Aqueous Dispersion of Alcohols and Acids of Hydrolyzed Jojoba Oil (HJO)
1) In a multi-neck round-bottom flask equipped with a condenser, magnetic stirring and a thermostatic bath at 60° C., was heated under reflux, 2.6 g of sodium hydroxide in 200 ml of a solution of methyl alcohol/H 2 O (99:1), until dissolution. Further 20 g of jojoba oil was added to this solution, and boiled for one hour and 30 minutes.
2) The product of the hydrolysis was recovered through evaporation of the solvent at reduced pressure obtaining a solid, which at a temperature higher than 25° C. is a light yellowish semisolid product. Adding to the semisolid product 35 ml of water while stirring, 35 ml of 2 N hydrochloric acid solution, the product obtained was placed in a cool place during 24 hours.
3) The aqueous phase was separated by decantation and the resulting product was washed with 100 ml of distilled water each time until the absence of chlorides in the washing liquids was verified with silver nitrate.
4) This semisolid product at room temperature was dissolved in a solution comprising 2.5 ml of triethanolamine in 22 ml of ethyl alcohol. A homogeneous and stable solution of intense gold color, called “solution of hydrolyzed jojoba oil,” was obtained.
5) Afterwards, the solution obtained was mixed with water, with gentle stirring to incorporate the phases completely thus obtaining a high-viscosity, transparent gel containing from 15% to 30% of the mixture of alcohols and salified acids of jojoba named hydrolyzed jojoba oil (HJO).
FIG. 2 shows the rheological behavior of the hydrolyzed jojoba oil (HJO), by a flow curve from 0 to 60 rpm generated forward and backward at 25° C.
FIG. 3 shows the neutralization level of carboxylic acids of jojoba oil, obtained by titration of HJO with NaOH 0.05 N and HCl 0.05 N
Example 2
Obtaining a Transparent or Translucent Dispersion of Diclofenac at a Concentration of 1% in an Aqueous Dispersion of Alcohols and Acids of Hydrolyzed Jojoba Oil (HJO)
To 50 ml of the solution of hydrolyzed jojoba oil obtained as described, in step 4, of Example 1, 1.00 g of Diclofenac was added under stirring, the mixture was warmed up to 40° C. to complete the solid's dissolution. 50 ml of water was slowly poured into the mixture while stirring to obtain a high-viscosity and transparent, homogeneous product.
FIG. 4 shows the results obtained by HPLC of a permeation assay to the product (HJO+Diclofenac 1% w/w) in rat skin, emphasizing the transdermal permeation promoting effect of the product.
Example 3
Obtaining an Opaque Dispersion of the Antiviral Acyclovir at a Concentration of 5% in an Aqueous Dispersion of Alcohols and Salified Acids of Hydrolyzed Jojoba Oil (HJO)
To 50 ml of hydrolyzed jojoba oil obtained as described in step 4, of Example 1, 5 g of Acyclovir as finely divided powder was slowly added while stirring to obtain a homogeneous dispersion. Then, 50 ml of water was slowly poured into the mixture while stirring to obtain an opaque semisolid product of fine texture and bright white color.
FIG. 5 shows the results obtained by HPLC of a permeation assay to the product (HJO+Aciclovir 5% w/w) in rat skin, emphasizing the transdermal permeation promoting effect of the product.
Example 4
Obtaining Self-Emulsified Jojoba Oil (SEJO)
Procedure A)
17.7 g of jojoba oil was added to 100 g of HJO while vigorously mixing to form a homogeneous, high-viscosity, brightly textured semisolid product. The SEJO obtained contains jojoba oil at a ratio of 15% w/w.
Procedure B)
17.7 g of jojoba oil was added to 55 ml of hydrolyzed jojoba oil solution obtained according to step 4 of Example 1, gently stirring the mixture until completing the incorporation of the phases. To this solution 55 ml of H 2 O was added slowly under stirring to form a homogeneous, high-viscosity and brightly textured semisolid product. The SEJO obtained contains jojoba oil at a ratio of 15% w/w.
Example 5
Obtaining a Cream with Vitamin A for Damaged Skin, from Self-Emulsified Jojoba Oil (SEJO)
A solution containing 600,000 IU of vitamin A Palmitate in 17.7 g of jojoba oil was added to 55 ml of hydrolyzed jojoba oil solution obtained as described in step 4 of Example 1, and the mixture was gently stirred until the complete incorporation of the phases. To this solution was dropped 55 ml of water under stirring to form a homogeneous, high-viscosity brightly textured semisolid product. The SEJO obtained contains 15% w/w of jojoba oil and 600,000 IU of vitamin A palmitate.
Therefore the above descriptions should not be construed as limiting, but merely as exemplifications of preferred embodiments.
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Processes for obtaining aqueous dispersions comprising alcohols and acids obtained by hydrolysis of jojoba oil. Hydrolyzed jojoba oil products are treated by a process comprising neutralization of jojoba fatty acids with aliphatic organic amines dissolved in a co-solvent followed by the dispersion of both the neutralized fatty acids together with jojoba alcohols in an aqueous medium. The products obtained, generically named hydrolyzed jojoba oil (HJO), promote transdermal absorption and are useful vehicles for carrying a wide range of pharmaceutical and cosmetic compositions, including pharmaceutical and cosmetic compositions comprising either lipophilic or hydrophilic active principles. The HJO can also be used to produce a semisolid, self-emulsified jojoba oil (SEJO), obtained by emulsifying the HJO in jojoba oil.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to articulating doors for motor vehicles, and more particularly to a handle for an articulating door of a motor vehicle having a linear pull action.
2. Discussion
It is well known in motor vehicle doors to provide a latch for latching the door in a closed position. It is also well known to provide a handle on the outside of the vehicle which is connected to the door latch by a suitable linkage so that operating the handle will release the door latch to permit opening of the door. Such handles are typically comprised of a lever which is rotated, or a button which is pushed, in order to actuate the linkage. Conventional door handle assemblies, either of the push button type or pull out type, typically include a series of bell-cranks for converting the movement of the push button or the handle transversely of the vehicle door into movement to operate the vehicle door latch.
It would be desirable to provide a new and improved door handle arrangement which would incorporate a linear pull action for operating a latching mechanism.
SUMMARY OF THE INVENTION
The present invention provides a new and improved vehicle door handle which improves upon prior known arrangements by efficiently incorporating a linear pull action. In one form, the present invention provides a handle assembly for selectively releasing a latch mechanism of a vehicle door. The vehicle door is mounted to a vehicle body for pivotal movement about an axis of rotation. The handle assembly includes a mounting portion attached to the vehicle door. The handle assembly further includes a handle proper operatively interconnected with the mounting portion and the latch mechanism. The handle proper is linearly translatable from a first position to a second position for releasing the latch mechanism.
In another form, the present invention provides a door assembly for mounting to a body of a motor vehicle for pivotal movement about an axis of rotation between an opened position and a closed position. The door assembly includes the door frame and a latch mechanism for selectively interconnecting a portion of the door frame with the body. The door assembly further includes a handle assembly attached to the door frame and interconnected with the latch mechanism. The handle assembly includes a manually controlled element linearly displaceable from a first position to a second position for releasing the latch mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional objects and advantages of the present invention will become apparent from a reading of the following detailed description of the preferred embodiment which makes reference to the drawings of which:
FIG. 1 is an environmental view of a handle assembly constructed in accordance with a preferred embodiment of the present invention shown incorporated into a rear liftgate of a motor vehicle.
FIG. 2 is a partially exploded view of the handle assembly of the present invention.
FIG. 3 is a front perspective view of the handle assembly of the present invention.
FIG. 4 is a rear perspective view of the handle assembly of the present invention.
FIG. 5 is a top view of the handle assembly of the present invention.
FIG. 6 is a side view of the handle assembly of the present invention illustrated in a latched position.
FIG. 7 is a side view of the handle assembly of the present invention illustrated in a unlatched position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With initial reference to FIG. 1, a handle assembly constructed in accordance with the preferred embodiment of the present invention is shown operatively associated with a handle assembly 10 of vehicle door 12. The vehicle door 12 shown is a rear tailgate for a minivan, sport utility or other vehicle 14, which is otherwise of conventional construction. The particular vehicle door 12 illustrated should be considered exemplary, as the teachings of the present invention are applicable for virtually any type of vehicle door.
Prior to addressing the construction and operation of the handle assembly 10 of the present invention, a brief understanding of the exemplary vehicle door 12 is warranted. While not specifically shown, it will be understood that the vehicle door 12 is mounted to the body of the vehicle 14 for pivotal movement about a horizontal axis adjacent a top of the door 12. The vehicle door 12 is movable between an open position (not shown) and a closed position (shown in FIG. 1). The handle assembly 10 is interconnected with a latching mechanism 16 through a cable 18. The latching mechanism 16 is of conventional construction and operates to release a striker (not shown) carried by the vehicle body when activated to permit movement of the vehicle door 12 from its closed position.
Turning now to FIGS. 2-7, the handle assembly of the present invention 10 will be described in detail. The handle assembly 10 is shown to generally include a handle proper 20, a base 22, a mounting plate 24 and a control linkage 26 interconnecting the handle proper 20 with the cable 18.
As shown most specifically in FIGS. 2 and 4, the handle assembly 10 is mounted through an elongated aperture 30 provided in the vehicle door 12. The base 22 includes a pair of rearwardly extending locating members 32 adapted to pass through the aperture 30 and engage holes 34 formed in the mounting plate 24. The mounting plate 24 is intended to be placed flush against an inner side 36 of the vehicle door 12. The base 22 is further shown to preferably include a retaining member 38 which is received within an aperature 40 formed in a tab 42 of the mounting plate 24. The retaining member 38 includes a deflectable portion 44 which allows the retaining member 38 to be easily inserted within the aperture 40 but prevents withdrawal.
The handle proper 20 is shown to include an elongated gripping portion 46 and a pair of rearwardly extending legs 48 cooperatively engaged with the control linkage 26. A longitudinal axis of the gripping portion 46 is disposed generally horizontally and thus parallel to the axis of door rotation. As seen in FIG. 5, the gripping portion 46 is slightly curved in top view, thereby providing comfort to the user and thereby contributing to an aesthetically pleasing vehicle appearance. An area 50 for receiving the operator's fingers is defined between the griping portion 46 and the base 22.
The legs 48 of the handle proper 20 are linearly translatable within channels 52 defined by the base 22. That is, the handle proper 20 is linearly movable between a first position (as shown in FIG. 6) in which the latching mechanism 16 is closed and a second position (as shown in FIG. 7) which the latching mechanism is open. The linear direction of movement of the handle proper 20 is identified in FIG. 5 and FIG. 7 with arrow A. As will become more apparent below, both of the rearwardly extending legs 48 of the handle proper 20 are formed to include recesses 56 passing vertically therethrough (shown in phantom lines in FIG. 4) for cooperating with the control linkage 26.
The control linkage 26 includes a bell-crank assembly 58 mounted for pivotal movement about an axis substantially parallel to the longitudinal axis of the gripping portion 46 of the handle proper 20. A pivot axis for the bell-crank assembly 58 is defined by an elongated pivot rod 60 passing through apertures formed in mounting flanges 62. The ends of the pivot rod 60 pass through apertures (not shown) in the bell-crank assembly 58.
The bell-crank assembly 58 is further shown to include a generally U-shape member having first and second lever arms 64 and 66 joined by an intermediate portion 68. The ends of the lever arms 64 and 66 pass through the vertical recesses 56 provided in the rearwardly extending legs 48 of the handle proper 20.
As shown more specifically in FIG. 4, the bell-crank assembly 58 is shown to further include a connecting portion 70 for connecting the bell-crank assembly 58 with the cable 18. This construction in other arrangements may be to a rod or other suitable latch actuating means. In the embodiment illustrated, the connecting portion 70 includes an arm 72 extending from one of the lever arms 64. The arm 72 terminates in an aperture 74 which facilitates connection to the cable 18 in a conventional manner.
The handle assembly 10 of the present invention is further shown to include a biasing member 76 for biasing the handle assembly 10 to its first position and thereby the latching mechanism 16 to its closed position. In the embodiment illustrated, the biasing mechanism is a coil spring 76 which surrounds the pivot rod 60. The coil spring functions to bias the bell-crank assembly 58 in a counterclockwise direction (as shown in FIG. 7).
The operation of the handle assembly 10 may now be understood referring generally to FIGS. 1-7 and specifically to FIGS. 6 and 7. As the handle proper 20 is linearly moved from its first position (as shown, for example, in FIGS. 5 and 6) to its second position (as shown in FIG. 7) the rearwardly extending legs 48 retract, thereby overcoming the biasing force of the coil spring 76 and causing the bell-crank assembly 58 to rotate clockwise (as shown in FIG. 7). The lever arms 64 and 66 of the bell-crank assembly 58 provide a mechanical advantage for operating the latch mechanism 18. The rotational movement of the bell-crank assembly 58 is converted to linear motion through the cable 18 which serves to release the latching mechanism 16. When the handle proper 20 is released, the biasing force of the coil spring 72 returns to the handle proper 20 to its first position and thereby returns the latching mechanism 16 to its closed position.
While the above description constitutes the preferred embodiment of the invention, it will be appreciated that the invention is susceptible to modification, variation, and change without departing from the proper scope or fair meaning of the accompanying claims. For example, it will be understood that the handle proper 20 may be mounted to the vehicle door 12 such that it is oriented in a generally vertical manner. Such an arrangement may be particularly desirable for vehicle doors mounted for pivotal movement about a vertical axis.
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A handle assembly for a motor vehicle door operative for selectively releasing a latch mechanism. The handle assembly includes a mounting portion attached to the motor vehicle door and a handle proper adapted to be manually grasped. The handle proper is linearly translatable between a first position and a second position for releasing the latch mechanism. In a preferred form, the handle proper is biased to the first position by a coil spring.
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This is a divisional of application(s) Ser. No. 08/176,557 filed on Dec. 30, 1993, now U.S. Pat. No. 5,413,734.
BACKGROUND OF THE INVENTION
The present invention relates to a fiber treatment compositions and to a method of making fiber treatment compositions. More particularly, the present invention relates to silicone emulsions and their ability to impart beneficial characteristics such as slickness, softness, compression resistance and water repellency to substrates such as fibers and fabrics that is not possible without the use of the compositions and method of the instant invention.
It is generally known to treat textile fibers with organopolysiloxanes to impart a variety of valuable properties to the fibers, such as water repellency, softness, lubricity, anti-pilling, good laundry and dry cleaning durability, and the like. The use of organopolysiloxanes to achieve such properties is now well established but there continues to be a need to improve these and other desirable properties of the fibers, especially the anti-pilling properties of the fabrics made from treated fibers. In particular, there has existed a desire to improve the properties of the fibers while improving the processes by which the organopolysiloxane compositions are applied to the fibers, and in this regard, the need to speed up the processing of the fibers is the most urgently needed.
Typical of prior art compositions and processes used for achieving the desirable processing and end use properties are those curable compositions disclosed in U.S. Pat. No. 3,876,459, issued Apr. 8, 1975 to Burrill in which there is set forth compositions obtained by mixing polydiorganosiloxanes having terminal silicon-bonded hydroxyl radicals with an organosilane (or partial hydrolysates thereof) of the formula RSiR' n (X) 3-n , in which R is a monovalent radical containing at least two amine groups, R' is an alkyl or aryl group, X is an alkoxy radical and n is 0 or 1.
The polydiorganosiloxanes are linear or substantially linear siloxane polymers having terminal silicon-bonded hydroxyl radicals and an average degree of substitution on silicon of 1.9 to 2.0 wherein the substituents are generally methyl radicals. The siloxane polymers have an average molecular weight of at least 750 with the preferred molecular weight being in the range of 20,000 to 90,000. The cure mechanism appears to arise through the reaction of the hydrolyzable groups on the silane with the silanol groups of the siloxane polymer, usually under the influence of a catalyst, and at elevated temperatures.
Burrill discloses in U.S. Pat. No. 4,177,176, issued Dec. 4, 1979, an additional composition for use in treating fibrous materials. The composition is disclosed as containing a polydiorganosiloxane having a molecular weight of at least 2500 and terminal --OX groups in which X is hydrogen, lower alkyl or alkoxyalkyl groups with the proviso that there also be present at least two substituents in the polydiorganosiloxanes which are amine groups. There is also present an organosiloxane having at least three silicon-bonded hydrogen atoms, the curing mechanism being based on the reaction of the silicon-bonded hydrogen atoms with the silanol end blocks of the polydiorganosiloxane polymers under the influence of a catalyst.
Also included in the prior art is the disclosure of Burrill, et al. in U.S. Pat. No. 4,098,701, issued Jul. 4, 1978 in which the inventors set forth yet another curable polysiloxane composition which has been found useful for treating fibers which comprises a polydiorganosiloxane in which at least two silicon-bonded substituents contain at least two amino groups, a siloxane having silicon-bonded hydrogen atoms, and a siloxane curing catalyst. A study of the '701 patent shows that "siloxane curing catalyst" is used in the sense that non-siloxane containing organofunctional compounds are used to cure siloxane curable materials, and that siloxane compositions that function as catalysts is not intended.
Also, there is disclosed in the prior art the curable system described by Spyropolous et al, in European patent application publication 0 358 329 wherein microemulsions are described in which the oil phase comprises a reaction product of an organosilicon compound having amino groups and an organosilicon compound having epoxy groups, wherein the reaction product has at least one amino group and two silicon-bonded --OR groups, and a method for making the microemulsions. The organosilicon compound having at least one silicon-bonded substituent of the general formula --R'NHR", wherein R' is a divalent hydrocarbon group having up to 8 carbon atoms, and R" denotes hydrogen, an alkyl group or a group of the general formula --RBH 2 , and (B) an organosilicon compound having at least one substituent of the general formula --R'--Y, wherein R' is as defined for those above, and Y denotes an epoxy group containing moiety, whereby the molar ratio of amino groups in (A) to epoxy groups (B) is greater than 1/1, there being present in the reaction product at least two silicon-bonded --OR groups, wherein R denotes an alkyl, aryl, alkoxyalkyl, alkoxyaryl or aryloxyalkyl groups having up to 8 carbon atoms.
Chen et al., in U.S. Pat. No. 5,063,260 discloses curable silicone compositions which impart beneficial characteristics to fibers, the compositions comprising an amino organofunctional substantially linear polydiorganosiloxane polymer, a blend of an epoxy organofunctional substantially linear polydiorganosiloxane polymer and a carboxylic acid organofunctional substantially linear polydiorganosiloxane polymer, and an aminoorganosilane. Chen et al. also discloses a process for the treatment of animal, cellulosic, and synthetic fibers by applying the composition described above the fiber and thereafter curing the composition on the fiber to obtain a treated fiber.
Yang in European Patent Application No. 0415254 discloses stable aqueous emulsion compositions containing an aminofunctional polyorganosiloxane containing at least two amino functionalized groups per molecule, one or more silanes and optionally a hydroxy terminated polydiorganosiloxane, textiles treated with the emulsion compositions, and processes for the preparation of the emulsion compositions. Revis in U.S. Pat. Nos. 4,954,401, 4,954,597, and 5,082,735 discloses a coating for a paper substrate produced by contacting and forming a mixture of an allyl ester with at least one methylhydrogensiloxane in the presence of a Group VIII metal catalyst, coating the mixture on the substrate, and heating the mixture of the allyl ester, the methylhydrogensiloxane, the substrate, and the Group VIII metal catalyst in the presence of ambient moisture until the methylhydrogensiloxane becomes cured and cross-linked. However, none of the references hereinabove disclose a one component fiber treating emulsion comprising an unsaturated acetate, at least one organohydrogensiloxane, a metal catalyst, and one or more surfactants which imparts beneficial characteristics to textile fibers.
SUMMARY OF THE INVENTION
The instant invention relates to compositions and to improved methods for their use to treat substrates such as fibers and fabrics to enhance the characteristics of the substrates. More specifically, the present invention relates to a fiber treatment composition comprising: (A) an unsaturated acetate; (B) at least one organohydrogensiloxane; (C) a metal catalyst; and (D) a dispersant selected from the group consisting of one or more surfactants and one or more solvents.
It has been discovered that a heat activated cross-linking composition consisting of a blend of an unsaturated acetate, an organohydrogensiloxane, a metal catalyst, and one or more surfactants can be used for the treatments of fibers and fabrics to impart slickness, softness, compression resistance and water repellency to the substrates. The composition remains a fluid until an activation temperature is reached at which point crosslinking occurs.
The present invention further relates to a method of treating a substrate, the method comprising the steps of (I) mixing (A) an unsaturated acetate, (B) at least one organohydrogensiloxane, (C) a metal catalyst, and (D) a dispersant selected from the group consisting of one or more surfactants and one or more solvents; (II) applying the mixture from (I) to a substrate; (III) heating the substrate.
The present invention also relates to a method of making a fiber treatment composition comprising (I) mixing (A) an unsaturated acetate; (B) at least one organohydrogensiloxane; (C) a metal catalyst; and (D) a dispersant selected from the group consisting of one or more surfactants and one or more solvents.
It is an object of this invention to provide a fiber treatment composition which imparts slickness, softness, compression resistance, and water repellency to fibers and fabrics.
It is also an object of this invention to provide a fiber treatment composition as a one component stable emulsion composition. It is an additional object of this invention to provide a fiber treatment composition which is non-toxic.
It is an additional object of this invention to provide fiber treatment composition which has a low cure temperature.
These and other features, objects and advantages of the present invention will be apparent upon consideration of the following detailed description of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a fiber treatment composition comprising: (A) an unsaturated acetate; (B) at least one organohydrogensiloxane; (C) a metal catalyst; and (D) a dispersant selected from the group consisting one or more surfactants and one or more solvents.
Component (A) in the fiber treatment compositions of the instant invention is an unsaturated acetate. The unsaturated acetate can be an allyl ester or vinyl ester such as allyl butyrate, allyl acetate, linallyl acetate, allyl methacrylate, vinyl acetate, allyl acrylate, vinyl butyrate, isopropenyl acetate, vinyl trifluoroacetate, 2-methyl-1-butenyl acetate, vinyl 2-ethyl hexanoate, vinyl 3,5,5-trimethylhexanoate, allyl 3- butenoate, bis-(2-methylallyl) carbonate, diallyl succinate, ethyl diallylcarbamate, and other known allyl esters. It is preferred for the compositions of the instant invention that the unsaturated acetate is selected from the group consisting of allyl acetate, linallyl acetate, and isopropenyl acetate.
The amount of Component (A) employed in the compositions of the present invention varies depending on the amount of organohydrogensiloxane, metal catalyst, and surfactant that is employed. It is preferred for purposes of this invention that from 0.1 to 50 weight percent of (A), the unsaturated acetate, be used, and it is highly preferred that from 2 to 10 weight percent of unsaturated acetate be employed, said weight percent being based on the total weight of the composition.
Component (B) in the compositions of the present invention is at least one organohydrogensilicon compound which is free of aliphatic unsaturation and contains two or more silicon atoms linked by divalent radicals, an average of from one to two silicon-bonded monovalent radicals per silicon atom and an average of at least one, and preferably two, three or more silicon-bonded hydrogen atoms per molecule thereof. Preferably the organohydrogensiloxane in the compositions of the present invention contains an average of three or more silicon-bonded hydrogen atoms such as, for example, 5, 10, 20, 40, 70, 100, and more.
The organohydrogenpolysiloxane is preferably a compound having the average unit formula R a 1 H b SiO.sub.(4-a-b)/2 wherein R 1 denotes said monovalent radical free of aliphatic unsaturation, the subscript b has a value of from greater than 0 to 1, such as 0.001, 0.01, 0.1 and 1.0, and the sum of the subscripts a plus b has a value of from 1 to 3, such as 1.2, 1.9 and 2.5. Siloxane units in the organohydrogenpolysiloxanes having the average unit formula immediately above have the formulae R 3 3 SiO 1/2 , R 2 3 HSiO 1/2 , R 2 3 SiO 2/2 , R 3 HSiO 2/2 , R 3 SiO 3/2 , HSiO 3/2 and SiO 4/2 . Said siloxane units can be combined in any molecular arrangement such as linear, branched, cyclic and combinations thereof, to provide organohydrogenpolysiloxanes that are useful as component (B) in the compositions of the present invention.
A preferred organohydrogenpolysiloxane for the compositions of this invention is a substantially linear organohydrogenpolysiloxane having the formula XR 2 SiO(XRSiO) c SiR 2 X wherein each R denotes a monovalent hydrocarbon or halohydrocarbon radical free of aliphatic unsaturation and having from 1 to 20 carbon atoms. Monovalent hydrocarbon radicals include alkyl radicals, such as methyl, ethyl, propyl, butyl, hexyl, and octyl; cycloaliphatic radicals, such as cyclohexyl; aryl radicals, such as phenyl, tolyl, and xylyl; and aralkyl radicals, such as benzyl and phenylethyl. Highly preferred monovalent hydrocarbon radicals for the silicon-containing components of this invention are methyl and phenyl. Monovalent halohydrocarbon radicals free of aliphatic unsaturation include any monovalent hydrocarbon radical noted above which is free of aliphatic unsaturation and has at least one of its hydrogen atoms replaced with a halogen, such as fluorine, chlorine, or bromine. Preferred monovalent halohydrocarbon radicals have the formula C n F 2n+1 CH 2 CH 2 -- wherein the subscript n has a value of from 1 to 10, such as, for example, CF 3 CH 2 CH 2 -- and C 4 F 9 CH 2 CH 2 --. The several R radicals can be identical or different, as desired. Additionally, each X denotes a hydrogen atom or an R radical. Of course, at least two X radicals must be hydrogen atoms. The exact value of y depends upon the number and identity of the R radicals; however, for organohydrogenpolysiloxanes containing only methyl radicals as R radicals c will have a value of from about 0 to about 1000.
In terms of preferred monovalent hydrocarbon radicals, examples of organopolysiloxanes of the above formulae which are suitable as the organohydrogensiloxane for the compositions of this invention include HMe 2 SiO(Me 2 SiO) c SiMe 2 H, (HMe 2 SiO) 4 Si, cyclo-(MeHSiO) c , (CF 3 CH 2 CH 2 )MeHSiO{Me(CF 3 CH 2 CH 2 )SiO} c SiHMe(CH 2 CH 2 CF 3 ), Me 3 SiO(MeHSiO) c SiMe 3 , HMe 2 SiO(Me 2 SiO) 0 .5 c (MeHSiO) 0 .5 c SiMe 2 H, HMe 2 SiO(Me 2 SiO) 0 .2 c (MePhSiO) 0 .4 c (MeHSiO) 0 .4 c SiMe 2 H, Me 3 SiO(Me 2 SiO) 0 .3 c (MeHSiO) 0 .7 c SiMe 3 and MeSi(OSiMe 2 H) 3 organohydrogenpolysiloxanes that are useful as Component (B).
Highly preferred linear organohydrogenpolysiloxanes for the compositions of this invention have the formula YMe 2 SiO(Me 2 SiO) p (MeYSiO) q SiMe 2 Y wherein Y denotes a hydrogen atom or a methyl radical. An average of at least two Y radicals per molecule must be hydrogen atoms. The subscripts p and q can have average values of zero or more and the sum of p plus q has a value equal to c, noted above. The disclosure of U. S. Pat. No. 4,154,7 14 shows highly-preferred organohydrogenpolysiloxanes.
Especially preferred as Component (B) are methylhydrogensiloxanes selected from the group consisting of bis(trimethylsiloxy) dimethyldihydrogendisiloxane, diphenyldimethyldisiloxane, diphenyltetrakis(dimethylsiloxy)disiloxane, heptamethylhydrogentrisiloxane, hexamethyldihydrogentrisiloxane, methylhydrogencyclosiloxanes, methyltris(dimethylhydrogensiloxy)silane, pentamethylpentahydrogencyclopentasiloxane, pentamethylhydrogendisiloxane, phenyltris(dimethylhydrogensiloxy)silane, polymethylhydrogensiloxane, tetrakis(dimethylhydrogensiloxy)silane, tetramethyltetrahydrogencyclotetrasiloxane, tetramethyldihydrogendisiloxane, and methylhydrogendimethylsiloxane copolymers.
The amount of Component (B) employed in the compositions of the present invention varies depending on the amount of unsaturated acetate, metal catalyst, and surfactant that is employed. It is preferred for purposes of this invention that from 40 to 99.9 weight percent of Component (B) be used, and it is highly preferred that from 70 to 90 weight percent of Component (B) be employed, said weight percent being based on the total weight of the composition.
Component (C) in the compositions of the present invention is a metal catalyst. Preferred metal catalysts for the present invention are the Group VIII metal catalysts and complexes thereof. By Group VIII metal catalyst it is meant herein iron, cobalt, nickel, ruthenium, rhodium, palladium, osmium, iridium and platinum. The metal catalyst of Component (C) can be a platinum containing catalyst component since they are the most widely used and available. Platinum-containing catalysts can be platinum metal, optionally deposited on a carrier, such as silica gel or powdered charcoal; or a compound or complex of a platinum group metal.
A preferred platinum-containing catalyst component in the compositions of this invention is a form of chloroplatinic acid, either as the commonly available hexahydrate form or as the anhydrous form, as taught by Speier, U.S. Pat. No. 2,823,218, incorporated herein by reference. A particularly useful form of chloroplatinic acid is that composition obtained when it is reacted with an aliphatically unsaturated organosilicon compound such as divinyltetramethyldisiloxane, as disclosed by Willing, U.S. Pat. No. 3,419,593, incorporated herein by reference, because of its easy dispersibility in organosilicon systems. Other platinum catalysts which are useful in the present invention include those disclosed in U.S. Pat. Nos. 3,159,601; 3,159,602; 3,220,972; 3,296,291; 3,516,946; 3,814,730 and 3,928,629, incorporated herein by reference. The preferred Group VIII metal catalyst as Component (C) for the compositions of the present invention is RhCl 3 , RhBr 3 , and RhI 3 and complexes thereof, although as described hereinabove other appropriate catalyst systems may be employed such as ClRh(PPh 3 ) 3 and complexes thereof; H 2 PtCl 6 ; a complex of 1,3-divinyl tetramethyl disiloxane and H 2 PtCl 6 ; and alkyne complexes of H 2 PtCl 6 . A more exhaustive list of appropriate catalyst systems which can be employed as Component (C) in the present invention is set forth in U.S. Pat. No. 4,746,750, which is considered incorporated herein by reference. The Group VII metal catalyst may be complexed with a solvent such as THF (tetrahydrofuran).
Also suitable as a catalyst for Component (C) in the compositions of the instant invention are the novel rhodium catalyst complexes disclosed in copending U.S. application for Pat. Ser. No. 08/176,118, filing data Dec. 30, 1993, and assigned to the same assignee as this present application, incorporated herein by reference. These novel rhodium catalyst complexes are generally compositions comprising a rhodium catalyst, an unsaturated acetate such as linallyl acetate, and alcohols having having 3 or more carbon atoms including diols, furans having at least one OH group per molecule, and pyrans having at least one OH group per molecule.
The amount of Group VIII metal catalyst, Component (C), that are used in the compositions of this invention is not narrowly limited and can be readily determined by one skilled in the art by routine experimentation. However, the most effective concentration of the Group VIII metal catalyst has been found to be from about one part per million to about two thousand parts per million on a weight basis relative to the unsaturated acetate of Component (A).
Also suitable for use as the metal catalyst Component (C) in the compositions of the instant invention are encapsulated metal catalysts. The encapsulated metal catalyst can be a microencapsulated liquid or solubilized curing catalyst which are prepared by the photoinitiated polymerization of at least one solubilized hydroxyl-containing ethylenically unsaturated organic compound in the presence of a photoinitiator for the polymerization of said compound, an optional surfactant, and a liquid or solubilized curing catalyst for organosiloxane compositions such as the catalysts described by Lee et al. in U.S. Pat. Nos. 5,066,699 and 5,077,249 which are considered incorporated herein by reference. It is preferred for purposes of the present invention that the encapsulated metal catalyst is a microencapsulated curing catalyst prepared by irradiating with UV light in the wavelength range of from 300 to 400 nanometers a solution containing (1) at least one of a specified group of photocrosslinkable organosiloxane compounds derived from propargyl esters of carboxylic acids containing a terminal aromatic hydrocarbon radical and at least two ethylenically unsaturated carbon atoms and (2) a liquid or solubilized hydrosilylation catalyst, such as the catalysts described by Evans et al. in U.S. Pat. No. 5,194,460 and in copending U.S. application for patent, Ser. No. 08/001,607, filing date Jan. 7, 1993, and assigned to the same assignee as this present application, now U.S. Pat. No. 5,279,898, which are considered incorporated herein by reference.
The amount of microencapsulated curing catalyst in the fiber treatment compositions of this invention are typically not restricted as long as there is a sufficient amount to accelerate a curing reaction between components (A) and (B). Because of the small particle size of microencapsulated curing catalysts it is possible to use curing catalyst concentrations equivalent to as little as 1 weight percent or less to as much as 10 weight percent of the microencapsulated curing catalyst as Component (C) in the compositions of the present invention, said weight percent being based on the total weight of the composition.
Component (D) in the compositions of the instant invention is a dispersant selected from the group consisting of one or more surfactants and one or more solvents. The (emulsifying agents) surfactants are preferably of the non-ionic or cationic types and may be employed separately or in combinations of two or more. Suitable emulsifying agents for the preparation of a stable aqueous emulsion are known in the art. Examples of nonionic surfactants suitable as component (D) of the present invention include polyoxyethylene alkyl ethers, polyoxyethylene alkylphenol ethers, polyoxyethylene lauryl ethers and polyoxyethylene sorbitan monoleates such as Brij™ 35L (from ICI Americas Inc., Wilmington, Del. 19897), Del. 19897), Brij™ 30 (ICI Americas Inc., Wilmington, Del. 19897), and Tween™ 80 (ICI Americas Inc., Wilmington, Del. 19897), polyoxyethylene alkyl esters, polyoxyethylene sorbitan alkyl esters, polyethylene glycol, polypropylene glycol, ethoxylated trimethylnonanols such as Tergitol® TMN-6 (from Union Carbide Chem. & Plastics Co., Industrial Chemicals Div., Danbury, Conn. 06817-0001), and polyoxyalkylene glycol modified polysiloxane surfactants. Examples of cationic surfactants suitable as component (D) in the compositions of the instant invention include quaternary ammonium salts such as alkyltrimethylammonium hydroxide, dialkyldimethylammonium hydroxide, methylpolyoxyethylene cocoammonium chloride, and dipalmityl hydroxyethylammonium methosulfate. Preferably, a combination of two or three nonionic surfactants, or a combination of a cationic surfactant and one or two nonionic surfactants are used to prepare the emulsions of the present invention.
Examples of the preferred surfactants for use as Component (D) in the compositions of this invention are the reaction products of alcohols and phenols with ethylene oxide such as the polyethoxyethers of nonyl phenol and octyl phenol and the trimethylnol ethers of polyethylene glycols, monoesters of alcohols and fatty acids such as glycerol monostearate and sorbitan monolaurate, and the ethoxylated amines such as those represented by the general formula ##STR1## in which R"" is an alkyl group having from about 12 to about 18 carbon atoms and the sum of a and b is from 2 to about 15. Silicone surfactants are also suitable for use as Component (D) in the instant invention. Preferred silicone surfactants include silicone polyethers such as polyalkylpolyether siloxanes and silicone glycol surfactants including silicone glycol polymers and copolymers such as those disclosed in U.S. Pat. No. 4,933,002, incorporated herein by reference. The emulsifying agents may be employed in proportions conventional for the emulsification of siloxanes, from about 1 to about 30 weight percent, based on the total weight of the composition.
Solvents may also be employed as Component (D) in the compositions of the instant invention. Preferred solvents for use as Component (D) in the instant invention include hydrocarbon solvents such as dichloromethane (methylene chloride) and acetonitrile. It is preferred for purposes of the present invention that Component (D), the dispersant, be a mixture of water and one or more of the surfactants described hereinabove. It is also preferred that emulsification of the compositions of the instant invention is carried out by adding one or more emulsifying agents, and water to components (A), (B), and (C) described hereinabove and the resulting composition be subjected to high shear.
The amount of Component (D) employed in the compositions of the present invention varies depending on the amount of organohydrogensiloxane, metal catalyst, and unsaturated acetate that is employed. It is preferred for purposes of this invention that from 0.25 to 99.5 weight percent of (D), the dispersant, be used, and it is highly preferred that from 1 to 95 weight percent of dispersant be employed, said weight percent being based on the total weight of the composition. When a surfactant is employed it is preferred that from 0.25 to 20 weight percent be used, and when a solvent is employed it is preferred that from 80 to 99.5 weight percent be used, said weight percent being based on the total weight of the composition.
The present invention further relates to a method of treating a substrate, the method comprising the steps of (I) mixing: (A) an unsaturated acetate, (B) at least one organohydrogensiloxane, (C) a metal catalyst, and (D) a dispersant selected from the group consisting of one or more surfactants and one or more solvents; (II) applying the mixture from (I) to a substrate; and (III) heating the substrate. Components (A), (B), (C), and (D) are as delineated above including preferred amounts and embodiments thereof.
The present invention also relates to a method of making a fiber treatment composition comprising (I) mixing (A) an unsaturated acetate; (B) at least one organohydrogensiloxane; (C) a metal catalyst; and (D) a dispersant selected from the group consisting of one or more surfactants and one or more solvents. Again, Components (A), (B), (C), and (D) are as delineated above including preferred amounts and embodiments thereof.
The compositions comprising components (A), (B), (C), and (D) may be applied to the fibers by employing any suitable application technique, for example by padding or spraying, or from a bath. For purposes of this invention, the compositions can be applied from a solvent, but is preferred that the compositions be applied from an aqueous medium, for example, an aqueous emulsion. Thus, any organic solvent can be employed to prepare the solvent-based compositions, it being understood that those solvents that are easily volatilized at temperatures of from room temperatures to less than 100° C. are preferred, for example, such solvents may include dichloromethane (methylene chloride) and acetonitrile, described hereinabove, toluene, xylene, white spirits, chlorinated hydrocarbons, and the like. The treating solutions can be prepared by merely mixing the components together with the solvent. The concentration of the treating solution will depend on the desired level of application of siloxane to the fiber, and on the method of application employed, but it is believed by the inventors herein that the most effective amount of the composition should be in the range such that the fiber (or fabric) picks up the silicone composition at about 0.05% to 10% on the weight of the fiber or fabric. According to the instant inventive method of treatment, the fibers usually in the form of tow, or knitted or woven fabrics, are immersed in an aqueous emulsion of the compositions whereby the composition becomes selectively deposited on the fibers. The deposition of the composition on the fibers may also be expedited by increasing the temperatures of the aqueous emulsion, temperatures in the range of from 20° to 60° C. being generally preferred.
Preparation of the aqueous emulsions can be carried out by any conventional technique. The compositions of this can be prepared by homogeneously mixing Components (A), (B), (C) and (D) and any optional components in any order. Thus it is possible to mix all components in one mixing step immediately prior to using the fiber treatment compositions of the present invention. Most conveniently (A), (B), and (C) are emulsified individually and the emulsions thereafter combined. The emulsions of the present invention may be macroemulsions or microemulsions and may also contain optional ingredients, for example antifreeze additives, biocides, organic softeners, antistatic agents, preservatives, dyes and flame retardants. Preferred preservatives include Kathon® LX (5-chloro-2-methyl-4-isothiazolin-3-one from Rohm and Haas, Philadelphia, Pa. 19106), Giv-gard® DXN (6-acetoxy-2,4-dimethyl-m-dioxane from Givaudan Corp., Clifton N.J. 07014), Tektamer® A. D. (from Calgon Corp., Pittsburgh, Pa. 152300), Nuosept® 91,95 (from HulsAmerica, Inc., Piscataway, N.J. 08854), Germaben® (diazolidinyl urea and parabens from Sutton Laboratories, Chatham, N.J. 07928), Proxel® (from ICI Americas Inc., Wilmington, Del. 19897), methyl paraben, propyl paraben, sorbic acid, benzoic acid, and lauricidin.
Following the application of the siloxane composition the siloxane is then cured. Preferably curing is expedited by exposing the treated fibers to elevated temperatures, preferably from 50° to 200° C.
The compositions of this invention can be employed for the treatment of substrates such as animal fibers such as wool, cellulosic fibers such as cotton, and synthetic fibers such as nylon, polyester and acrylic fibers, or blends of these materials, for example, polyester/cotton blends, and may also be used in the treatment of leather, paper, and gypsum board. The fibers may be treated in any form, for example as knitted and woven fabrics and as piece goods. They may also be treated as agglomerations of random fibers as in filling materials for pillows and the like such as fiberfil.
The composition of components (A), (B), (C), and (D) should be used at about 0.05 to 25 weight percent in the final bath for exhaust method applications, and about 5 gm/l to 80 gm/l in a padding method of application, and about 5 gm/l to 600 gm/l for a spraying application. The compositions employed in this process are particularly suitable for application to the fibers or fabrics from an aqueous carrier. The compositions can be made highly substantive to the fibers, that is they can be made to deposit selectively on such fibers when applied thereto as aqueous emulsions. Such a property renders the compositions particularly suited for aqueous batch treatment by an exhaustion procedure, such exhaustion procedures being known to those skilled in the art. The compositions of the instant invention are new and novel and provide a fast cure and wide cure temperature ranges for curing them on fibers or fabrics compared to the compositions of the prior art, having a temperature cure range of from 50° C. to 200° C. Further, the fibers have superior slickness and no oily feeling after cure. The compositions of the instant invention provide consistent performance, good bath life of more than 24 hours at 40° C., have good laundry and dry cleaning durability, and have very good suitability for application by spraying.
Fiber Slickness was tested by using a DuPont(R) unslickened fiberfil product, such as Hollofil® T-808, for the evaluation of slickness imparted by the application of the silicone emulsion of the present invention. A piece of Hollofil® T-808 is soaked in the diluted emulsion of interest and then passed through a roller to obtain 100% wet-pickup, i.e., the weight of the finished fiberfil is twice that of the unfinished fiberfil. After drying at room temperature, the finished sample is heated at 175° C. for 2-25 minutes. Thus prepared, the finished fiberfil usually contains approximately the same silicone level as that of the emulsion of interest.
The slickness of fiberfil is measured by staple pad friction which is determined from the force required to pull a certain weight over a fiberfil staple pad. The staple pad friction is defined as the ratio of the force over the applied weight. A 10 pound weight was used in the friction measurement. A typical instrument set-up includes a friction table which is mounted on the crosshead of an Instron tensile tester. The friction table and the base of the weight are covered with Emery Paper #320 from the 3M Company so that there is little relative movement between the staple pad and the weight or the table. Essentially all of the movement is a result of fibers sliding across each other. The weight is attached to a stainless steel wire which runs through a pulley mounted at the base of the Instron tester. The other end of the stainless steel wire is tied to the loadcell of the Instron tester.
Following are examples illustrating the compositions and methods of the present invention. In the examples hereinbelow, THF denotes tetrahydrofurfuryl, THFA denotes tetrahydrofurfuryl alcohol, and TPRh denotes (Ph 3 P)RhC 13 (tris-(triphenylphosphine)rhodium chloride).
EXAMPLES 1-20
In order to illustrate the effectiveness of the compositions of the present invention the following tests were conducted. Two catalysts were prepared, a rhodium catalyst and a microencapsulated curing catalyst. A 0.03 molar rhodium catalyst solution was prepared by dissolving 1 gram of RhCl 3 •6H 2 (rhodium trichloride hexahydrate), or TPRh in 120 grams of THF, THFA, or linallyl acetate. A 10% and 1% platinum catalyst solution was prepared by dissolving 10 grams and 1 gram, respectively, of a platinum catalyst prepared according to Example 3 of U.S. Pat. No. 5,194,460 in 90 grams and 99 grams, respectively, of linallyl acetate.
Into a glass container was added the unsaturated acetate. With gentle mixing using a round edge three blade turbine mixing impeller, the platinum or rhodium catalyst solution prepared above was added to the unsaturated acetate and mixed until the mixture was homogenous. Next, 100 grams of a trimethylsilyl terminated polymethylhydrogensiloxane having a viscosity of 30 centistokes at a temperature of 25° C. and having the formula Me 3 SiO(MeHSiO) 70 SiMe 3 was added to the mixture and stirred gently until the mixture was again homogenous. This was followed by adding about 1.78 grams of a polyoxyethylene lauryl ether surfactant or a methylene chloride solvent (in Examples 9-15, 18, and 19 a solvent was substituted for the surfactant), and about 38 grams of water containing up to 0.22 grams of preservative (sorbic acid) to the mixture. Mixing was then resumed at medium speed for 20 to 30 minutes. The mixture was then processed through a high shear device to produce the emulsions of the instant invention. The mean particle sizes of the emulsions ranged from 0.7 to 3.0 microns and the pH of the emulsions ranged from 3.0 to 4.5.
A relative ranking from 1 to 10 was established using known commercial finishes based upon slickness values obtained using the Staple Pad Friction frictional test described hereinabove. No finish was given a ranking of 1, a commodity finish was given a ranking of 6, and a premium finish was given a ranking of 10. The amount of acetate, acetate type, the amount of catalyst, catalyst type, the time it took the sample to cure in minutes (min.), and the performance of each example are reported in Table I hereinbelow.
TABLE I__________________________________________________________________________Acetate Acetate Catalyst Catalyst CureExample(g) Type (g) Type (Min.) Rating__________________________________________________________________________ 1 10 Allyl 0.3 RhCl.sub.3, THF 3 9 2 10 Isopropenyl 0.3 RhCl.sub.3, THF 3 9 3 10 Linallyl 0.3 RhCl.sub.3, THF 3 9 4 10 Linallyl 0.3 RhCl.sub.3, THF 5 9 5 10 Linallyl 0.3 RhCl.sub.3, THF 8 8 6 10 Linallyl 0.1 RhCl.sub.3, THF 5 9 7 5 Linallyl 0.1 RhCl.sub.3, THF 5 11 8 2 Linallyl 0.1 RhCl.sub.3, THF 5 10 9 10 Linallyl 0.2 RhCl.sub.3, THF 3 910 10 Linallyl 0.1 RhCl.sub.3, THF 6 911 10 Linallyl 0.05 RhCl.sub.3, THF 6 912 2 Linallyl 0.05 RhCl.sub.3, THF 6 1013 3 Linallyl 0.3 RhCl.sub.3, THFA 3 1014 2 Linallyl 0.2 RhCl.sub.3, THFA 3 1015 3 Linallyl 0.1 RhCl.sub.3, THFA 3 1016 10 Linallyl 0.3 10% Pt, Linallyl 8 717 0 Linallyl 0.3 10% Pt, Linallyl 8 818 2 Linallyl 0.2 1% Pt, Linallyl 10 819 0 Linallyl 0.2 1% Pt, Linallyl 10 820 4 Linallyl 0.2 TPRH, Linallyl 5 10__________________________________________________________________________
Examples 1, 2, and 3 show that various allyl acetates at varying weights can be used in the compositions of the instant invention and still maintain good slickness results. All the examples show a range of cure times with good results, in this case from 3-10 minutes and having a slickness rating of from about 7-10.
The examples hereinabove also show that catalysts of the instant invention and complexing solvents used to prepared the catalysts (THF, THFA, Linallyl) have no effect on slickness. It is also clear that catalyst concentrations can be varied with good results even with amounts as low as from 3-7 ppm.
COMPARISON EXAMPLE I
A silicone composition was prepared according to the disclosure of Revis, U.S. Pat. Nos. 4,954,401, 4,954,597, and 5,082,735. A 0.03 molar rhodium catalyst solution was prepared by dissolving 1 gram of RhCl 3 •6H 2 O (rhodium trichloride hexahydrate) in 120 grams of THF. Into a glass container was added 5 grams of allyl acetate. With gentle mixing using a round edge three blade turbine mixing impeller, 0.1 grams of the catalyst solution prepared above was added to the acetate and mixed until the mixture was homogenous. Next, 100 grams of a trimethylsilyl terminated polymethylhydrogensiloxane having a viscosity of 30 centistokes at a temperature of 25° C. and having the formula Me 3 SiO(MeHSiO) 70 SiMe 3 was added to the mixture and stirred gently until the mixture was again homogenous. Next, 4 grams of this mixture was added to 96 grams of water. This mixture was then stirred for 20 to 30 minutes.
The sample was ranked as described hereinabove and was obtained using the Staple Pad Friction frictional test described hereinabove. The sample took 10 minutes to cure and had a slickness value of 2. Thus in comparison to the compositions of the instant invention that compositions not containing a dispersant such as a solvent or surfactant gave much poorer results than do the compositions of the instant invention.
COMPARISON EXAMPLE II
A silicone composition was prepared according to Example 2 of Revis, U.S. Pat. No. 4,954,401. A catalyst was prepared according Example 1 of Revis, U.S. Pat. No. 4,954,401, by stirring 10 grams of RhCl 3 •3H 2 O in 1200 grams of THF at room temperature for about 12 hours. A mixture of 2.0 grams of trimethylsilyl terminated polymethylhydrogensiloxane having a viscosity of 30 centistokes at a temperature of 25° C., 3.5 grams of allyl acetate, and 0.02 grams of catalyst was combined and stirred gently until the mixture was homogenous.
The sample was ranked as described hereinabove and was this ranking obtained using the Staple Pad Friction frictional test described hereinabove. The sample took 10 minutes to cure and the sample fibers were fused together and became extremely brittle thus preventing the detection of a slickness value (i.e. the sample failed). Thus in comparison to the compositions of the instant invention, compositions which did not contain a dispersant such as a solvent or surfactant gave much poorer results than do the compositions of the instant invention.
COMPARISON EXAMPLE III
A silicone composition was again prepared according to Example 2 of Revis, U.S. Pat. No. 4,954,401. A catalyst was again prepared according Example 1 of Revis, U.S. Pat. No. 4,954,401, by stirring 10 grams of RhCl 3 .3H 2 O in 1200 grams of THF at room temperature for about 12 hours. The amounts of the ingredients in this example were varied however. In this example a mixture of 100 grams of trimethylsilyl terminated polymethylhydrogensiloxane having a viscosity of 30 centistokes at a temperature of 25° C., 10 grams of allyl acetate, and 0.1 grams of catalyst was combined and stirred gently until the mixture was homogenous.
The sample was again subjected to the tests described hereinabove. Again, the sample took 10 minutes to cure and the sample fibers were fused together and became extremely brittle thus preventing the detection of a slickness value (i.e. the sample failed). Thus in comparison to the compositions of the instant invention, compositions which did not contain a dispersant such as a solvent or surfactant gave much poorer results than did the compositions of the instant invention.
It should be apparent from the foregoing that many other variations and modifications may be made in the compounds, compositions and methods described herein without departing substantially from the essential features and concepts of the present invention. Accordingly it should be clearly understood that the forms of the invention described herein are exemplary only and are not intended as limitations on the scope of the present invention as defined in the appended claims.
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The present invention relates to fiber treatment compositions comprising an unsaturated acetate, an organohydrogensiloxane, a metal catalyst, and a dispersant selected from the group consisting of one or more surfactants and one or more solvents. The compositions of the present invention impart beneficial characteristics such as slickness, softness, compression resistance and water repellency to substrates such as fibers and fabrics.
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CLAIM OF PRIORITY
This application claims priority to U.S. Provisional Patent Application Ser. No. 61/493,598, filed Jun. 6, 2011, entitled Ribbon Security Clean-up, the contents of which are incorporated herein by reference.
FIELD OF INVENTION
The present invention generally relates to printing methods, more specifically, to a printing apparatus and method of providing security to desired information during a printing operation of a thermal transfer printer.
BACKGROUND
Printing systems such as copiers, printers, facsimile devices or other systems having a print engine for creating visual images, graphics, texts, etc. on a page or other printable medium typically include various media feeding systems for introducing original image media or printable media into the system. Examples include thermal transfer printers. Typically, a thermal transfer printer is a printer which prints on media by melting a portion of coating of ribbon stream so that it stays attached to the media on which the print is applied. It contrasts with direct thermal printing where no ribbon is present in the process. Typically, thermal transfer printers comprise a supply spindle operable for supplying a media web and ribbon, a print station having a printhead, and a take up spindle. During a printing operation, new ribbon and media is fed from the supply spindle to the print station for printing and then the ribbon is wound up by the take up spindle while the media is exited from the print station.
As the ribbon exits the print station it is rewound on the take up spindle. When printing sensitive information such as, for example, social security numbers, account numbers, and other similar private information, the unused portion of the ribbon will contain a negative image of the subject sensitive information. Undesirably, conventional thermal transfer printing methods provide no means of security to the information which is printed. Because the used ribbon on the take up spindle possesses a negative image of the previously printed image, the secrecy of the information printed on the media may be jeopardized.
It is therefore be desirable to provide a printing system and method which provides security means to information printed on media during a thermal transfer printing operation. It is also be desirable to provide a printing method which allows for the used ribbon of such a thermal transfer printer to be obscured such that the negative image is unable to be read.
SUMMARY OF THE INVENTION
The present invention is designed to overcome the deficiencies and shortcomings of the systems and devices conventionally known and described above. The present invention is designed to reduce the manufacturing costs and the complexity of assembly. In all exemplary embodiments, the present invention is directed to a method of securing and maintaining the integrity of desired information on a ribbon and media subsequent to a printing operation. According to aspects of the present invention, a printer is provided and generally comprises a print station having a printhead, a supply spindle for moving media through the print station and a ribbon drive assembly operable for feeding ribbon along a print path of the printer. In exemplary embodiments, the printhead is capable of being moved or lifted away from the media and ribbon subsequent to a print operation. Further, the ribbon fed through the ribbon drive assembly may be rewound a predetermined distance, thereby allowing for a second print operation on the space previously printed upon. More specifically, the used ribbon can be rewound and utilized to print a random pattern on a piece of waste media (stub) thus obscuring any previous images on the ribbon. In exemplary embodiments, the media can also be reversed a specific distance and reprinted with the used ribbon several times thus obscuring the image on the used ribbon.
If the waste media is printed on only once, the random pattern will reveal what was previously printer due to a lack of wax (ink) on the ribbon. Accordingly, in exemplary embodiments, the method steps are repeated a set number of times thereby eliminating negative images and also reducing the length of waste media required. The ribbon clean-up process can be printed after an original print operation has occurred.
Additional features and advantages of the invention will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as described herein, including the detailed description which follows, the claims, as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description present exemplary embodiments of the invention, and are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments of the invention, and together with the detailed description, serve to explain the principles and operations thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The present subject matter may take form in various components and arrangements of components, and in various steps and arrangements of steps. The appended drawings are only for purposes of illustrating exemplary embodiments and are not to be construed as limiting the subject matter.
FIG. 1 is a perspective front view of a ribbon drive assembly utilized in the printing operation according to aspects of the present invention.
FIG. 2 is a perspective rear view of the embodiment of FIG. 1 according to aspects of the present invention.
FIG. 3 is a perspective back view of the ribbon drive assembly with a ribbon supply on the supply spindle according to aspects of the present invention.
FIG. 4 is a plan view of an exemplary printed instrument containing examples of sensitive information according to aspects of the present invention.
FIG. 5 is a plan view of the negative image remaining on a print ribbon after printing the exemplary printed instrument described in FIG. 4 according to aspects of the present invention.
FIG. 6 a is a plan view of the negative image remaining on a print ribbon described in FIG. 5 after the security method described herein is utilized employing random characters.
FIG. 6 b is a plan view of the negative image remaining on a print ribbon described in FIG. 5 after the security method described herein is utilized employing sequential Xs.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will now be described more fully hereinafter with reference to the accompanying drawings in which exemplary embodiments of the invention are shown. However, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. These exemplary embodiments are provided so that this disclosure will be both thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Further, as used in the description herein and throughout the claims that follow, the meaning of “a”, “an”, and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein and throughout the claims that follow, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
In exemplary embodiments of the present invention, a printing method is provided which overcomes the shortcomings of the prior art by providing a means of security to desired information subsequent to a printing operation. The method includes the provision of a thermal transfer printer (not shown) having a supply spindle operable for supplying a media web (not shown) or ribbon, a print station (not shown) having a printhead (not shown), and a take up spindle. Those skilled in the art will appreciate that many other components may be included within the printer and many configurations may be employed. In all exemplary embodiments, during a printing operation, new or supply ribbon and media is fed from the supply spindle to the print station for printing and then the ribbon is wound up by the take up spindle while the media is exited from the print station. As the ribbon exits the print station it is wound to a take up spindle.
Referring now to the drawings and specifically, FIGS. 1-3 , a ribbon drive assembly in accordance with exemplary embodiments of the present invention is shown and generally referred to by reference numeral 10 . In exemplary embodiments, the ribbon drive assembly 10 assists in the provision of information security by being configured to rewind the ribbon supply a predetermined distance for additional print operations. In a general sense, the ribbon drive assembly 10 controls the feed of the ribbon supply 26 as it unwinds off a supply spindle 12 into a print station (not shown) and then is wound off onto a take-up spindle 14 .
In exemplary embodiments, the spindles 12 , 14 can be rotatably connected to a base plate 15 at one end and extend through a port 17 , 19 of a cover plate 13 such that their respective distal ends 21 , 23 are operative for receiving a roll of ribbon supply 26 . Each spindle 12 , 14 can be provided with an independently operated drive system comprising a plurality of gears 18 , 20 for rotating the spindles 12 , 14 , a motor 22 , 24 for driving the plurality of gears 18 , 20 , respectively, in both a clockwise or counter clockwise direction, and a rotary encoder (not shown). In exemplary embodiments, the drive system can be connected to the base plate 15 . It will be understood by those skilled in the art that it is contemplated that the motor 22 , 24 will be a DC motor, however, any type of motor suitable for powering the gears 18 , 20 and spindles 12 , 14 in a rotary movement may be employed. Further, in alternative exemplary embodiments, the motors 22 , 24 are independently operated.
The drive assembly 10 can further comprise a circuit board 16 connected to the base plate 15 having a control processor (not shown) for each motor 22 , 24 and attached to a side of the base plate 15 . The electronics of the circuit board 16 similarly can include two sets of drive components (not shown) for each spindle 12 , 14 . In exemplary embodiments, the drive assembly 10 can use a processor core (not shown) with programmable digital and/or analog functions and communication components. However, it will be understood by those skilled in the art that a variety of processors may be used. In an exemplary embodiment, the processor (not shown), motor drive IC's (not shown), opto encoders (not shown) and associated circuitry (not shown) can be located on a single board 16 of the drive assembly 10 . The processor (not shown) of the drive assembly 10 can be communicatively linked with a main processor of the printer PCB (not shown) via a SPI bus (not shown).
In exemplary embodiments, two independent control systems, one for each motor 22 , 24 , can be executed every 500 us seconds. By utilizing the independent motor system described above, subsequent to an initial print operation, the ribbon supply 26 may be rewound about the supply spindle 12 for additional print operations. Such print operations may be critical as the used ribbon oftentimes contains a reverse image of what was previously printed.
In exemplary embodiments, subsequent to the initial print operation, the print head (not shown) can be raised or lifted. Thereafter, the used ribbon 26 can be rewound a predetermined distance about the supply spindle 12 and utilized to print a random or block-out pattern on a piece of waste media (stub) thus obscuring any previous images on the ribbon 26 . In exemplary embodiments, the media can also be reversed or rewound predetermined distance and reprinted with the used ribbon 26 several times thus further obscuring the image on the used ribbon. The repeated print operations may be desirable because if the waste media is printed on only once, the random pattern will reveal what was previously printer due to a lack of wax (ink) on the ribbon. Printing on the media only once would produce a negative image of the previous image. Reversing the media several times eliminates the negative image and also reduces the length of waste media required.
Referring now to FIG. 4 , instrument 50 containing exemplary sensitive information is shown. In the exemplary embodiment, sensitive information can include, for example: a name 52 ; an address 54 ; an account number 56 ; and/or a prescription 58 . As will be appreciated by one skilled in the art, these examples are not limiting as it may be desired to protect additional forms of sensitive information.
Turning next to FIG. 5 , a drawing of a used printing ribbon 60 is shown. For purposes of illustration, the used printing ribbon 60 shown in FIG. 5 represents the used printing ribbon that would result from creating the instrument 50 depicted in FIG. 4 prior to the application of the method described herein. As is shown, the used printing ribbon 60 comprises a negative image of the sensitive information contained on the instrument 50 , such as, for example: a name 62 ; an address 64 ; an account number 66 ; and a prescription number 68 .
Finally turning to FIGS. 6 a and 6 b , drawings of used printing ribbons 60 a and 60 b are shown after the application of the method described herein. The used printing ribbon 60 a contains information that is obscured by random characters. The used printing ribbon 60 b contains information that is obscured by sequential Xs, i.e., an X-out pattern. The information obscured in FIGS. 6 a and 6 b includes, for example, names 62 a , 62 b , addresses 64 a , 64 b , account numbers 66 a , 66 b , and prescription numbers 68 a and 68 b . Alternative embodiments contemplate that other designs (not shown) and/or block-out printing (not shown) may be employed to obscure any sensitive information on the printer ribbon 60 and render it unreadable or eliminate the sensitive information from the printer ribbon 60 altogether.
Aspects according to the present invention contemplate that sensitive information will come is a plethora of forms. For exemplary purposes, such sensitive information can include: names, amounts, account numbers, addresses, memo entries, social security numbers, FEINs, ID numbers, medical information, financial information, passport numbers, draft numbers, document numbers; PINs, alphanumeric codes and any other similar information desired to be protected.
The embodiments described above provide advantages over conventional devices and associated methods of manufacture. It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. Furthermore, the foregoing description of the preferred embodiment of the invention and best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation—the invention being defined by the claims.
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An apparatus and method of securing and maintaining the integrity of desired information on a ribbon and media subsequent to a printing operation is provided. The apparatus and method includes a thermal transfer printer having a print station and a printhead operable for performing a printing operation. The printhead is capable of performing an initial print operation and then being raised from the media, thereby allowing the used ribbon to be rewound a predetermined distance about a supply spindle. Thereafter, a second print operation is performed on the space previously printed upon using characters, designs or block-out patterns and the used ribbon is then wound onto a take-up spindle. In exemplary embodiments, the used ribbon can also be reprinted with a waste media several times thus further obscuring the image on the used ribbon.
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BACKGROUND OF THE INVENTION
As described, the present invention relates to an improved construction for a splint-like protective device, such as for the knee made of a compartmentalized construction adapted for pneumatic inflation, whereas to circumferentially support and protect the knee joint of the user.
Heretofore, the need for a device to protect the knee during periods of physical contact has been well recognized. The recent increasing incidents of serious knee injuries, particularly to the ligaments and supporting structures, provides ample evidence that such a device has not yet been satisfactorily perfected.
In the past, many various devices have been tried, but all have fallen short of achieving this goal. The simplest is the age old elastic support. This garment is virtually useless, giving no support to the ligamentous structures. Other devices have been used, such as inflatable splints, metal braces with straps and the like. These have been also of no significant benefit for several reasons. The inflatable splint, as formerly devised, may splint the knee and offers some protection, but as constructed, will not allow normal function of the knee joint. Straps and metal splints are limited in their protection and are cumbersome and somewhat dangerous because of the exposed metal parts.
Typical of prior art patents relating to this subject matter include U.S. Pat. Nos. 2,093,888, 2,657,385, 3,186,405, 3,454,963 and 3,823,712.
SUMMARY OF THE INVENTION
In the present invention, it has been found that in order for the splint-like device to be effective, it must:
1. Protect the knee joint during the most vulnerable period, i.e., complete extension;
2. Allow complete freedom of the knee joint so that flexion is not impeded.
The foregoing objects are accomplished in the present invention by a pneumatic splint-like device of compartmentalized construction comprising an inner section and an outer section. The inner section includes the plurality of pneumatically interconnected generally circular bundles extending generally radially of the knee joint, and an outer section including a plurality of pneumatically interconnected longitudinal bundles extending generally at right angles to the circular bundles whereby the knee joint is held in a splinted condition when in full extension by the longitudinal bundles so that upon flexion, pressure is displaced, by the initiation of flexion, into the circular bundles. By this arrangement, the inner circular bundles act as reservoirs, and return substantially a major portion of the pressure to the longitudinal bundles during extension of the knee joint. In the invention, this "synergistic action" is accomplished by constructing and arranging the longitudinal bundles of the outer section with a larger cross-sectional area and/or of a increased distensibility material compared to the material of the inner section of circular bundles. Conversely, pneumatic pressure is forced into the smaller, less distensible inner circular bundles upon flexion of the knee joint. In the invention, the inner and outer bundle sections are selectively inflated to the desired predetermined pneumatic pressure by a manifold and valve arrangement, as will be hereinafter fully described.
Moreover, it is an object of the present invention to provide a splint-like protective pad device which is sufficiently light weight, compact and flexible to enable full and easy flexion of the knee, such as during the course of running and jumping as played in body contact sports, such as football, soccer, basketball, hockey, or the like.
Further, another object of the present invention is to provide such improved device that will impart a generally uniform circumferential compression to the knee joint and so as not to impede arterial or venous circulation.
Another object of the present invention is to provide such device which is light weight but sufficiently strong to withstand rugged application. In addition, it is believed that the device should under most all conditions provide complete protection to the knee joint by virtue of its circumferential application and its longitudinal splinting, thus preventing the femur and tibia from being displaced in opposite directions during periods of physical trauma.
The features of the invention which are believed to be novel are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and method of operation, together with further objects and features thereof may best be understood with reference to the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary front elevation view of the splint-like device of the present invention as typically worn circumferentially around the knee joint extending from mid-thigh to mid-calf:
FIG. 2 is a horizontal section view of the splint-like device of the present invention taken through the line 2--2 of FIG. 1;
FIG. 3 is a side elevation view showing the splint-like device in the open condition looking at the side which comprises the outer section of longitudional bundles arranged in accordance with the present invention, and
FIG. 4 is a longitudional section view taken along line 4--4 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now again to the drawings and in particular to FIG. 1 thereof, there is illustrated the splint-like device of the present invention, designated generally at 1, illustrated for use by circumferential disposition around the knee-joint between mid-thigh and mid-calf. Specifically, the knee joint is illustrated at 2, the femur portion at 4, and the tibial portion at 6. The patella portion 8 is illustrated as circumferentially engaged by the device 1 in the flexed condition of the knee-joint shown in FIG. 1.
In accordance with the present invention, the device 1 comprises an inner section 10 and an outer section 12 which are integrally connected to provide a composite structure, preferably made from a flexible, high strength material. In the invention, it is preferred that the material be of a fabric made of neoprene impregnated nylon.
As shown, the inner section 10 comprised of a series of pneumatically inter connected generally circular bundles 14 which during normal use are disposed radially of the knee-joint in the extended condition thereof. As applied to the knee-joint, the circular bundles 14 are disposed in a generally concentric, stacked relationship to apply a circumferential pressure to the joint. Preferably, each of the tubes 14 has a diameter of approximately 1 centimeter, with the diameter being in the range between 0.8 centimeters and 1.2 centimeters. Also, it is preferred that the wall thickness of the material comprising the tubes 14 be approximately 2 millimeters. Preferably, the range in thicknesses between 1.9 millimeters and 2.1 millimeters. By this construction, the inner circular bundles have reduced flexion and, hence, act as reservoirs to absorb the return air flow from the outer section being an extension of the joint.
In the invention, the outer section 12 comprises a plurality of inter-connected longitudinal bundles 16 which extend at right angles to the inner bundles 14. The outer bundles 12 are arranged in a similar fashion, but extend longitudinally between the femur and tibia portions of the knee-joint so as to provide a splint-like structure extending circumferentially around the area of the joint to be protected. In this case, the diameter of the tube 16 is preferably 2 centimeters. Preferably, the diameter is arranged between 1.9 centimeters and 2.1 centimeters. Similarly, the wall thickness of the tubes is approximately 1 millimeter. Preferably, the thickness is between approximately 0.9 millimeter and 1.1 millimeters. Hence, the bundles 16 have a cross sectional area and/or are made of a reduced thickness material as compared to the cross sectional area and/or thickness of the material of the inner circular bundles 14. Hence, upon extension of the joint, air pressure flows outwardly from the inner bundles to the outer bundles until a pneumatic equilibrium condition is reached in relation to the predetermined inflation pressure of the device. Conversely, upon flexion of the knee, air pressure flows from the outer bundles 16 into the inner bundles 14 by an amount sufficient to enable the knee joint to bend to its normal extent. As understood, the principal axis of movement of the knee joint is in the transverse direction, thereby classifying the knee joint as a hinge-joint. It is known that the tibia and femur muscles are substantially more massive and stronger than the knee ligaments, which functionally interconnect the two at the knee joint. Hence, it is preferred that impact torque forces applied to the tibial portion be absorbed by the femur muscles which are more massive and stronger than the knee-joint ligaments, and hence more able to resist large impact forces commonly encountered in athletic events, such as football, soccer, basketball, hockey games, or the like. Hence, the device of the present invention acts to provide a generally uniform circumferential compression and support force to the knee-joint so as to divert the impact forces from the knee ligament to the femur and tibial portions which are better suited to absorb such forces.
In the invention, the inner bundles 14 are pneumatically inter-connected to the outer bundles 16 by a series of equally spaced apertures, as at 20 (FIG. 2) which have a relatively small diameter of approximately 5 millimeters. The inner circular tubes 14, in turn, are connected at one end to a common manifold tube 22 (FIG. 3) which is provided with a valve 24 for simultaneously inflating both the inner 14 and outer 16 tubes via the common manifold 22. On the other hand, if desired, a separate manifold and valve arrangement could be provided for the inner and outer sections for independent inflation. Hence, in the invention, the inner 14 and outer 16 tubes are inflated to the same predetermined pressure, whereupon the valve 24 may be sealed for subsequent usage.
As shown, the device may be mounted interiorly beneath the material, as at 30, of the knee pad in a typical football uniform. In such application, a crease or sew line, as at 32, may be provided in the material of the outer section 12 in order to facilitate bending the device and hence, the knee joint.
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The present invention relates generally to an athletic protective pad device, and more particularly relates to an improved construction for a prophylactic splint-like device of the type to be utilized by a participant in protecting the body in a contact sport, such as football or the like. In the invention, the device has specific application to protect the knee during periods of physical contact during playing the game of football.
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RELATED APPLICATIONS
[0001] This application claims the benefit under 35 USC 119(e) of U.S. Provisional Application No. 62/493,164, filed on Jun. 23, 2016, which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] A common design of mechanical locks operated with a physical key involves using movable tumblers supported by springs or spring-loaded. The common types of tumblers are pin tumblers and lever tumblers shown in FIG. 1 . The tumblers block the movement of a bolt or a latch until the correct key contacts them and moves them into the positions the combination of which releases the bolt or the latch. The tumblers tightly contact the coded portion of the key's blade and their configuration corresponds to the key's blade shape. In other words, the key makes an imprint of its blade on the set of tumblers. This imprint is not stable; it is destroyed as soon as the tumblers lose their contact with the key. The tumblers are supported by springs, and under the springs' pressure they immediately return back to their initial position, as soon as the key is removed and the normal opening process is interrupted. The key has to be in contact with the tumblers during the entire opening process, therefore in such locks, the keyhole cannot be blocked (to prevent access to the lock's mechanism) during the opening process. Because of this such locks are vulnerable to picking through the key hole; and many tools exist for this purpose.
[0003] A set of movable spring-loaded parts—tumblers, is a core part of a vast majority of mechanical locks, operated with a physical key. The tumblers differ by its shape and the locks, depending on this, are called accordingly as Pin tumblers locks, Lever tumblers locks and the like. Those types of locks are widely in use currently. The tumblers are the pieces that in process of a lock opening interact directly with a key, which sets them in the positions accordingly to the keys coded portion. Depending of the configuration in which the key sets the tumblers, they will hold the bolt, or on the contrary, release the one. The bolt can be released only if the configuration of the tumblers will be formed by a “right” key for the lock. The tumblers huddle tight to the individual (coded for the lock) portions of the key's blade, thus the tumblers aligned in the configuration accordingly to the key's blade shape. Like so, the key makes some kind of “imprint” from its blade using a set of tumblers for that. Considering a method of tumblers work regarding of currently used locks, hat “key's imprint”—the composition of a tumblers, is not stable, it is destroyed as soon as the tumblers lose its contact with the key. That happening with locks currently in use, because its tumblers are spring-loaded, so—under its spring's pressure—they return immediately back to its initial position. So to maintain the opening process running—a key has to be in contact with tumblers through keyhole all the time during the entire opening process, so—a keyhole cannot be blocked at the time. Because of that, current locks are very defenseless from its picking from keyhole. Many types of pick tools exist now.
SUMMARY OF THE INVENTION
[0004] Embodiments of the invention include a method of opening a lock with a key, comprising inserting the key into a keyhole in the lock; bringing the key in contact with tumblers to make the configuration of the tumblers match the shape of the contacted portion of the key; removing the key so that the configuration of the tumblers is maintained; blocking the keyhole; and if and only if the configuration of the tumblers matches the lock's configuration, opening the lock.
[0005] In some embodiments, the tumblers are pin tumblers.
[0006] In some embodiments, wherein the tumblers are lever tumblers.
[0007] In some embodiments, wherein the configuration of the tumblers is maintained by friction.
[0008] The above and other features of the invention including various novel details of construction and combinations of parts, and other advantages, will now be more particularly described with reference to the accompanying drawings and pointed out in the claims. It will be understood that the particular method and device embodying the invention are shown by way of illustration and not as a limitation of the invention. The principles and features of this invention may be employed in various and numerous embodiments without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0009] In the accompanying drawings, reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale; emphasis has instead been placed upon illustrating the principles of the invention.
[0010] FIG. 1 shows schematic construction of existing locks
[0011] FIG. 2 shows functioning of an embodiment of the invention.
[0012] FIG. 3 shows one view a lock embodying the invention with its key outside the lock.
[0013] FIG. 4 shows another view a lock embodying the invention with its key outside the lock.
[0014] FIG. 5 shows tumblers used in a lock embodying the invention.
[0015] FIG. 6 shows a third view of a lock embodying the invention with its key outside the lock.
[0016] FIG. 7 shows a lock embodying the invention with the key inside the lock.
[0017] FIG. 8 shows a lock embodying the invention with the key removed from the lock.
[0018] FIG. 9 shows opening of a lock embodying the invention.
[0019] FIG. 10 shows of a lock embodying the invention in its locked configuration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Unlike of described above of currently in use method of the tumblers work, the new one gives to the tumblers an ability to keep fixed steady its position, which they have been obtained from their contact with a key, its mean—the set of tumblers keeps steady its configuration when the key removes from the lock. That new ability for the tumblers the new method implements using a well-known method of a Contour Gauge work—its pieces hold steady a contour of the surface to which they were pressed. Unlike of the opening process for the locks currently in use, which runs as continues one with a key all the time in the lock, - at the new method the entire opening process is divided on two steps, when a key presents only at the first one.
[0021] Step one—“The preparation for the opening” A key, inserted into a keyhole pushes the tumblers and aligns them accordingly to the key's blade coded for the lock contour. After that, the key has to be removed from the lock, accordingly of mentioned above—the key has made a steady “imprint” from its blade, so—the composition of the tumblers remains steady in its configuration. The key, removed from the lock, leaves in its steady imprint or duplicate for using it in the next step when the essential lock's opening will occur.
[0022] “The Essential Lock Opening” In process of opening any mechanical lock a key directly participate in the process. At the time the lock's mechanism tests the configuration of the tumblers set—whether its match to the “right” one for the lock? The key holds the tumblers in the position which corresponds to coded contour of its blade. In case of suggested” method of tumblers work” the essential opening process goes the same way: the lock's mechanism tests the configuration of the tumblers set—whether its match to the “right” one for the lock, but with one novelty; there is not necessity to hold the tumblers in the position by a key in which he has formed them, tumblers keep steady positions itself, which they obtained in “Step one”. So, the new method of tumblers work allows running “The Essential Lock Opening” with no key in the keyhole. The process of “The Essential Lock Opening” is shown on FIG. 2 & FIG. 9 . The person, who operates the lock opening, rotates the lock's handle ( 13 ) that hard connected with a cam ( 15 ) & lever ( 19 ), cam pushes the castor ( 16 ), attached to crotch ( 9 ), crotch moves into the notches ( 17 ) of tumbler set ( 9 ), if that tumblers were aligned by a “Right” key, the crotch enters freely into the notches, so handle ( 13 ) will rotate future with no stop and the lever ( 19 ) will move the bolt ( 14 ) to open side. In case of “Wrong” key—the crotch ( 9 ) cannot enter into the tumblers notches ( 17 ), the handle ( 13 ) will stop and the opening will be impossible.
[0023] “The preparation for the Opening” In current locks vectors of action from springs and a key FIG. 1 ( 2 , 5 ) are opposite each other, when one force eliminated—acts another one. Unlike of the current locks, vectors of action of the spring, that keeps tumblers together and the key that pushes tumblers, are shifted on 90 degrees FIG. 4 ( 2 , 5 ) At the “new method” tumblers are clamped in the clamp, so they have a side pressure, across of its pushing from a key. That side pressure on tumblers creates a Frequent force that keeps the tumblers together and prevents them from-change their positions when the key does not support them. It is easy to optimize that force to provide the tumblers ability to stay steady at the spot and at the same time be easy movable by key's pressure. The optimization can be done by changing strength of the spring, or quality of the connected surface.
[0024] In currently locks a key, inserted into a lock, interacts with a set of tumblers the same way as well known contour/profile gauge does and sets them in configuration accordingly to coded contour of its blade. But, unlike of the contour gauge, where its pins save steady its positions when they disconnected from the surface, to which they had been pressed before, the tumblers of current lock mechanism are not able to save their positions if they disconnected with a key. That happen because all the tumblers in locks mechanism are loaded by its individual springs, so, as soon as they loose contact with a key—the springs drive them to their initial positions. So, currently, to maintain the essential lock opening process—a key has to be permanently in contact with the tumblers, its means—a lock opening process has to run with a keyhole open for the key operated.
[0025] Unlike the current, “The new method of tumblers work”, fully uses a contour/profile gauge method of work, which gives to the tumblers an ability to remain steady in their position, when the key has been removed from the lock after its interaction with tumblers.
[0026] At the “New method”—the tumblers located in a clamp and they have not its individual springs that could force them to keep their initial position, instead of that, the tumblers are pressed to each other in the clamp which by any means necessary provides an optimal friction force between the tumblers which good enough to keep them together and prevent them from arbitrarily changing their position, when they loose contact with a key. And, at the same time, allows to tumblers easy to move under a keys pressure. That optimal tension from the clamp can be providing the same way as any clamps do: by a spring, by a screw or by a special design of a clam.
[0027] So, in case of “The new method of a tumblers work” a key, inserted into a lock, interacts with a set of tumblers as a contour gauge and aligns them in a steady composition that precisely represents its coded portion, by another words—the key, removed from the lock, leaves in it's “imprint”, or “duplicate”—a steady composition of tumblers.
[0028] After the key makes its “duplicate”, the key is removed from the lock and then lock's mechanism ready to use that keys imprint-duplicate for the essential operation of the lock opening instead of the key original.
[0029] At “The new method of tumblers work” the entire lock opening process runs in two stages: at first one a person, who operates the lock opening, inserts a key into a keyway to the bottom and removes the key from the lock. At the time—the key with its “coded” edge pushes tumblers and sets th'em in the position accordingly to the “coded” profile of its edge. That composition of tumblers remains steady, when the operator removes the key from the lock.
[0030] The first stage is accomplished and at that point the key has formed with a set of tumblers an imprint of its coded profile, other words: the key, removed from the lock, leaves in its “duplicate”, which is ready to be used for the essential lock opening.
[0031] At the second stage the “essential opening operation” is occurring. At the operation the a person, who operates the lock opening, twists a lock handle or knob to open way, and the lock mechanism tests the composition of the tumblers—is it matches with the “right” one to open the lock? At that point the lock mechanism uses the same method of the testing as all currently mechanical locks do.
[0032] The “essential” opening process occurs with a keyhole blocked from entering of any subject in the lock; a key hole only at the time being of essential opening operation is closed.
[0033] This can happen because “The new method of tumblers work” creates inside a lock a “duplicate” of the key original, so, the essential opening operation runs with the keys duplicate and that why a key hole do not needs to be open at that time. The open keyhole at the “essential” opening—makes the lock extremely defenseless before pick tools.
[0034] It is easy to optimize the tumblers steadiness by changing the strength of the springs or quality of the rubbing surfaces.
[0035] “The Essential Opening”, I call the core operation for any lock's—the process of the “Essential Opening” when its mechanism tests the cOl\lposition of its tumblers, which has been formed by a key—whether the composition matches to the “right” one or not? That operation in the present invention differs from the same operation for the locks with traditional tumblers by two points: ,a) A key does not participate in the step, because it already performed its role for the locks in the step 1)—when the key have formed a tumblers set accordingly to its coded blade shape, and they still keep steady its composition for the step 2)—[see point a) above].
[0036] There is no other principle changes in comparison with “The Essential Opening” that currently locks use.
[0037] At the beginning of the “Essential Opening” stage, the person, who operates the lock's opening, twists the lock's handl˜trying to move the bolt open. At the moment, a flap, connected to the lock's handle shaft, blocks the keyhole. As the lock's handle keeps spinning—the essential opening process occurs with no key, but with its “imprint” and with the keyhole blocked.
[0038] The “Essential Opening” in the present invention uses the same lock's opening principle as the current locks: the set of the tumblers was formed by means of a “Right” key—the lock will be opened.
[0039] The present invention needs one additional operation which current locks do not have it: after the lock is open—the composition of the tumblers formed with a key at “The Preparation for Opening”—(the “Frozen imprint”)—has to be destroyed and brought to its initial shape. This addition makes the lock's mechanism prepared for the next working cycle—“locked/opened”. This can be easy done with combination of cams and levers propelled by means of moving to open position bolt or handle shaft.
[0040] The present invention gives no chance to use a pick tools even when a keyhole is open (before the “Essential Opening”—for example), of course, at this time you can easy reach the tumblers with any tools and change their position, but three is no ability simultaneously to check—whether the new position, you just set, is the “Right” for the lock's opening? Because as soon as you turn the lock's handle trying to retract the bolt, the flap, that connected with the handle shaft, moves and jams the pick tool in the keyhole. So, you are forced after every single change of the tumbler's position take off a pick tool from the lock and then move the lock's handle—this takes unacceptable to much time—a months of continuous operation for the lock picking, because the tumbler's set of 5 pins or levers has a hundreds of thousands of variants of the tumblers positions.
[0041] The springs act on the tumblers right transversely to their movement under the key's pressure, so, if the key does not push the tumblers, the whole tumbler's package stays pressed to the side base—B as a solid piece. The diaphragms isolate the tumblers from each other - so, the movement of one of them is not transmitted to the adjacent ones.
[0042] In contrast with the locks described in the Background section, the present invention allows the tumblers to preserve their position or configuration after their contact with the key, and to maintain their configuration after the key is removed from the lock and after the keyhole is blocked. The tumblers function similarly to a contour gauge. The tumblers preserve the shape of the surface of the key, to which they were pressed.
[0043] Unlike the locks that require the key to stay in the keyhole for the entire duration of the opening process, some embodiments of the present invention split the opening process into two phases; only the first phase requires the key to be present in the keyhole.
[0044] The Preparatory Phase
[0045] A key is inserted into a keyhole. The key pushes the tumblers and aligns them in accordance with the key's blade contour. Then the key is removed from the lock.
[0046] The tumblers interact with the key similarly to a contour gauge, and maintain their alignment, for example, by friction. Therefore, the key leaves an imprint as the configuration or alignment of the tumblers.
[0047] The Opening Phase
[0048] The user rotates the lock's handle. First, the keyhole is blocked by the yoke 9 , regardless of the key or tumblers' configuration; this prevents access to the lock mechanism via the keyhole.
[0049] The user continues rotating the lock's handle. This tests whether the key imprint, as the configuration of the tumblers matches the lock configuration.
[0050] The lock is configured so that its opening requires that the notches 17 align along a straight line. Only when the notches are aligned, the yoke 9 moves to the right far enough to move the latch to open the lock.
[0051] 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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A lock including a set of tumblers preserving their position after contact with a key to permit blocking of the keyhole during the opening process.
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RELATED APPLICATION
This application hereby claims priority under 35 U.S.C. §119 to U.S. Provisional Patent Application No. 60/582,788, filed on 25 Jun. 2004, entitled “Photomask Image Registration in Scanning Electron Microscope Imagery,” by inventor Fereydoun Maali.
BACKGROUND
1. Field of the Invention
This invention relates to the process of fabricating semiconductor chips. More specifically, the invention relates to a method and apparatus for registering a database image against a noisy scanned image, such as an image taken using a Scanning Electron Microscope.
2. Related Art
The relentless miniaturization of integrated circuits has been a key driving force behind recent advances in computer technology. Today, integrated circuits are being built at deep sub-micron (DSM) dimensions. At these dimensions, photomask accuracy is becoming increasingly important in the chip manufacturing process.
A photomask is typically a high-purity quartz or glass plate that contains deposits of chrome metal, which represents the features of an integrated circuit. The photomask is used as a “master” by chipmakers to optically transfer these features onto semiconductor wafers.
The mask-making process involves complex physical, transport, and chemical interactions. As a result, the actual photomask is different from the “perfect” photomask. If this difference is too large, it can render the photomask useless. Hence, it is important to measure the features of the actual photomask, so that one can ensure that the difference is within the error tolerance.
Before the features on the actual photomask can be measured, the photomask needs to be scanned using an imaging process to generate a scanned image. Furthermore, the scanned image must be accurately aligned with the perfect image so that the features on the scanned image can be accurately measured. This alignment process is called “photomask image registration”.
Typically, photomask image registration only involves determining the translational differentials (in 2D space) between the scanned image and the perfect image.
Unfortunately, the scanned image can contain noise, which can sometimes be excessive, e.g., the noise in a Scanning Electron Microscope (SEM) image. Furthermore, the scanned image and the perfect image can have different pixel depths. Moreover, the scanned image can contain a large number of pixels. For example, the scanned image can be a 512×512 grayscale image with an 8-bit pixel depth. For these reasons, it is very difficult to accurately and efficiently compute the translational differentials between the scanned image and the perfect image of a photomask, especially when the scanned image has low signal-to-noise ratio (as in SEM images).
Consequently, image registration for noisy images (e.g., SEM images) is typically performed manually. Unfortunately, this manual step slows down the chip fabrication process, which increases the cost and the time taken to manufacture chips.
Hence, what is needed is a method and apparatus for accurately and efficiently computing the translational differentials between the scanned image and the perfect image of a photomask.
SUMMARY
One embodiment of the present invention provides a system for registering a noisy scanned image, such as a Scanning Electron Microscope (SEM) image, against its “perfect” image (henceforth called a database-image) counterpart. Specifically, the system determines the translational differentials between an image pair that share some degree of overlap. Note that the database image is a mere blueprint represented as a noise free binary image depicting synthesized integrated circuit (IC) features. On the other hand, the scanned image is the result of an imaging process, which invariably suffers from some degree of noise. Note that the database and scanned image images are not of the same modality.
In a variation on this embodiment, the system computes translational differentials between a database-image and a scanned-image of a photomask. Specifically, one embodiment of the present invention computes the translational differentials by exploiting the linear nature of the integrated circuit (IC) feature boundaries. During operation, the system receives a noise-free database-image and a scanned-image that is generated by an imaging process. Next, the system computes a set of candidate-translational-differentials using the database-image and the scanned-image. The system then generates one or more sets of translated directional-gradient-images based on the set of candidate-translational-differentials and using the database-image and the scanned-image. Next, the system converts the database-image into a set of smoothed directional-gradient-images. Finally, the system computes translational differentials by performing a normalized correlation using the set of smoothed directional-gradient-images and the one or more sets of translated directional-gradient-images. Note that the computational time is significantly reduced because the method performs normalized correlation using only the set of candidate-translational-differentials, instead of exhaustively performing normalized correlation using all possible translational differentials.
In a variation on this embodiment, the system converts the database-image and the scanned-image into a database-gradient-image and a scanned-gradient-image, respectively. Next, the system computes database-projection-vectors from the database-gradient-image and scanned-projection-vectors from the scanned-gradient-image by taking orthogonal projections along a set of directions. The system then extracts correlation-vectors from the database-projection-vectors. Next, the system maps the scanned-projection-vectors to obtain accumulator-vectors in an accumulator space by using the correlation-vectors. Finally, the system computes a set of candidate-translational-differentials based on the peak-cluster locations in the accumulator space, wherein a peak-cluster is a collection of contiguous elements around a peak (including the peak).
In a variation on this embodiment, the system creates a directional-gradient filter using the database-image, wherein the directional-gradient filter can be used to attenuate edgels that do not conform to the directional gradients of feature edges in the database-image. Next, the system converts the database-image and the scanned-image into a set of database directional-gradient-images and a set of scanned directional-gradient-images, respectively. The system then generates a raw database-gradient-image and a raw scanned-gradient-image from the set of database directional-gradient-images and the set of scanned directional-gradient-images, respectively. Finally, the system applies the directional-gradient filter to the raw database-gradient-image and the raw scanned-gradient-image to obtain the database-gradient-image and the scanned-gradient-image, respectively.
In a variation on this embodiment, the system de-projects only the cluster-peaks in the accumulator-vectors to obtain reconstructed scanned-projection-vectors. Next, the system de-projects the reconstructed scanned-projection-vectors to obtain reconstructed directional-gradient-images. Finally, the system generates one or more sets of translated directional-gradient-images by displacing the reconstructed directional-gradient-images using the set of candidate-translational-differentials. Note that by de-projecting only the cluster-peaks, the system improves the signal-to-noise ratio of the reconstructed directional-gradient-images.
In a variation on this embodiment, the system convolves the database-image with a horizontal and a vertical Point Spread Function (PSF) to generate a horizontal edgel-image and a vertical edgel-image, respectively. Next, the system computes a gradient-magnitude-image using the horizontal edgel-image and the vertical edgel-image. The system then applies a clip-low filter to the gradient-magnitude-image to obtain a clipped-gradient-image. Next, the system generates a histogram using the gradient orientations in the clipped-gradient-image. Finally, the system creates the directional-gradient filter using the histogram.
In a variation on this embodiment, the system converts the database-gradient-image into a set of unsmoothed directional-gradient-images. The system then applies a low-pass filter to the set of unsmoothed directional-gradient-images to obtain the set of smoothed directional-gradient-images.
In a variation on this embodiment, the system computes the translational differentials by selecting the set of translated directional-gradient-images that has the maximum aggregate-normalized-correlation with the set of smoothed directional-gradient-images.
In a variation on this embodiment, the system registers the scanned image against its database image, i.e., determines the translational differentials that maximize the similarity between a scanned image and its binary blueprint, wherein the similarity is measured as a normalized correlation coefficient.
In a variation on this embodiment, the system qualifies the image registration result using a figure of merit that provides a measure of confidence in the quality of the result.
In a variation on this embodiment, the photomask contains only rectilinear features. In another variation on this embodiment, the photomask contains a combination of rectilinear and non-rectilinear features. In yet another variation on this embodiment, the photomask contains only non-rectilinear features.
In a variation on this embodiment, the system computes the database-projection-vectors from the database-gradient-image and the scanned-projection-vectors from the scanned-gradient-image by taking an orthogonal projection along the horizontal direction and the vertical direction.
In a variation on this embodiment, if the database-image and the scanned-image have slightly different dimensions, the system computes the set of candidate-translational-differentials by using a smoothing filter to integrate double peaks in the accumulator space into a single peak.
In a variation on this embodiment, the system registers image pairs in which the scanned image and the database image have different sizes.
In a variation on this embodiment, the system can tolerate ambiguous contrast polarity. Specifically, the system does not rely on contrast direction between the scanned image regions and regional correspondence between the image pair based on contrast polarity.
In a variation on this embodiment, the system can tolerate moderate sizing problems. Note that sizing problem arise from dimension discrepancies between the synthesized IC features depicted in the database image and their actual dimension as imaged by imaging devices such an electron microscope.
In a variation on this embodiment, the system registers a database image against its scanned image when the latter is too noisy to tolerate correlation at coarser resolutions.
In a variation on this embodiment, the system computes the translational differentials between the database image and a noisy scanned image in an efficient manner when recourse to low resolution images would not work.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 illustrates the various steps in the design and fabrication of an integrated circuit in accordance with an embodiment of the present invention.
FIG. 2 illustrates a high level view of the photomask image registration process that precedes metrology in accordance with an embodiment of the present invention.
FIG. 3 illustrates a photomask image registration system that comprises a network which is coupled with a computer, a critical-dimension scanning-electron-microscope (CD SEM) system, and a file server in accordance with an embodiment of the present invention.
FIG. 4A and FIG. 4B present flowcharts that illustrate the process for computing the translational differentials in accordance with an embodiment of the present invention.
FIG. 5 presents a flowchart that illustrates the process of synthesizing a directional gradient filter.
FIG. 6 presents a flowchart that illustrates the process of applying a directional gradient filter to an image.
DETAILED DESCRIPTION
Integrated Circuit Design and Fabrication
FIG. 1 illustrates the various steps in the design and fabrication of an integrated circuit in accordance with an embodiment of the present invention. The process starts with a product idea (step 100 ). Next, the product idea is realized by an integrated circuit, which is designed using Electronic Design Automation (EDA) software (step 110 ). Once the design is finalized in software, it is taped-out (step 140 ). After tape-out, the process goes through fabrication (step 150 ), packaging, and assembly (step 160 ). The process eventually culminates with the production of chips (step 170 ).
The EDA software design step 110 , in turn, includes a number of sub-steps, namely, system design (step 112 ), logic design and function verification (step 114 ), synthesis and design for test (step 116 ), design planning (step 118 ), netlist verification (step 120 ), physical implementation (step 122 ), analysis and extraction (step 124 ), physical verification (step 126 ), resolution enhancement (step 128 ), and mask data preparation (step 130 ).
Photomask image registration can take place within the mask data preparation step 130 , which involves generating the “tape-out” data for production of masks that are used to produce finished chips. Note that the CATS™ family of products from Synopsys, Inc. can be used in the mask data preparation step 130 .
Photomask Image Registration
FIG. 2 illustrates a high level view of the photomask image registration process that precedes metrology in accordance with an embodiment of the present invention.
Once the logical design of an integrated circuit is finalized, the EDA software prepares a photomask data file (step 202 ), which describes the features on the photomask. Note that the photomask data file stores a digital representation of the “perfect” photomask image. Furthermore, note that the photomask data file is typically stored in a database. Accordingly, in the instant application, the term “database image” refers to this “perfect” photomask image.
Next, a mask-making machine creates the photomask (step 204 ) using the photomask data file. Specifically, when the circuit design is “taped out,” it is translated into GDSII format that is then given to the mask data preparation software. The mask data preparation software converts or “fractures” the GDSII design data into a format that describes the pattern to the mask-making machine.
A photomask is typically a high-purity quartz or glass plate that contains deposits of chrome metal, which represents the features of an integrated circuit. The photomask is used as a “master” by chipmakers to optically transfer these features onto semiconductor wafers.
Specifically, the mask-making machine uses a laser or an electronic-beam to write the features of the integrated circuit onto a layer of photosensitive resist that has been added over a chrome layer on top of a blank mask. After exposure, the resist is developed, which clears away and uncovers the underlying chrome only where the circuit pattern is desired. The bared chrome is then etched. After etching, the remaining resist is completely stripped away, leaving the circuit image as transparent patterns in the otherwise opaque chrome film.
Note that the mask-making process involves complex physical, transport, and chemical interactions. As a result, the actual photomask image is different from the database image. If this difference is too large, it can render the photomask useless. Hence, it is critically important to measure the features of the actual photomask image, so that we can ensure that the difference is within the error tolerance. This measurement process is called metrology (step 210 ).
Before metrology (step 210 ) can take place, the photomask needs to be scanned (or photographed) using an imaging device, such as a scanning electron microscope (step 206 ). Henceforth, in the instant application, the term “scanned image” refers to a picture of the photomask that is taken using the imaging device. Furthermore, note that the scanned image (from step 206 ) must be aligned with the database image (from step 202 ) so that the features on the scanned image can be accurately measured. This alignment process is called “photomask image registration” (step 208 ).
In general, image registration involves spatially aligning two similar images. Specifically, in the absence of non-linearity, an image registration process results in a transformation matrix, which when applied to one of the images, aligns it with the other image. Note that, in general, image registration involves resizing, rotating, and translating an image. But, typically, photomask image registration only involves determining the translational differentials (in 2D space) between the database image and the scanned image.
Photomask Image Registration System
FIG. 3 illustrates a photomask image registration system that comprises a network 302 which is coupled with a computer 304 , a critical-dimension scanning-electron-microscope (CD SEM) system 306 , and a file server 308 in accordance with an embodiment of the present invention.
Note that the network 302 can generally include any type of wire or wireless communication channel capable of coupling together network nodes. This includes, but is not limited to, a local area network, a wide area network, or a combination of networks. In one embodiment of the present invention, network 302 includes the Internet.
Furthermore, in one embodiment of the present invention, the computer 304 stores and executes the image registration software. Moreover, in one embodiment of the present invention, the image registration software is included in the EDA software. Note that computer 304 can generally include any type of device that can perform computations. This includes, but is not limited to, a computer system based on a microprocessor, a personal computer, a mainframe computer, a server, and a workstation.
It will be apparent to one skilled in the art that the image registration software can be stored and executed in a number of ways. For example, in one embodiment of the present invention, the image registration software is executed on the CD SEM system 306 .
In one embodiment of the present invention, the CD SEM system 306 can be used for taking detailed pictures of a photomask. Specifically, the resolution of the CD SEM system 306 can be less than the minimum feature size of the photomask. For example, in one embodiment of the present invention, the resolution of the CD SEM system 306 is a few nanometers, while the minimum feature size of the photomask is a few tenths of a micron.
Moreover, the CD SEM system 306 can be positioned with a high degree of precision. For example, in one embodiment of the present invention, the CD SEM system 306 can be positioned within a few nanometers of a target location.
It will be apparent to one skilled in the art that the present invention is not dependent on the type of imaging process that is used for taking pictures of the photomask. Accordingly, in the instant application, the CD SEM system 306 should be taken to represent any type of device that can take high resolution pictures.
In one embodiment of the present invention, the computer 304 can directly communicate with the CD SEM system 306 via the network 302 . Specifically, in one embodiment of the present invention, the computer 304 and the CD SEM system 306 communicate with each other using files that are stored on the file server 308 . Note that both the computer 304 and the CD SEM system 306 can communicate with the file server 308 via the network.
Process for Computing Translational Differentials
FIG. 4A and FIG. 4B present flowcharts that illustrate the process for computing the translational differentials in accordance with an embodiment of the present invention.
The process begins by receiving a database image (step 400 ) and a scanned image (step 450 ). Specifically, in one embodiment of the present invention, the database image is a noise-free 512×512 binary image, and the scanned image is a 512×512 grayscale image with an 8-bit pixel depth. Note that the modality of the two images is different. Furthermore, in one embodiment of the present invention, the photomask contains only rectilinear features. In another embodiment of the present invention, the photomask contains a combination of rectilinear and non-rectilinear features. In yet another embodiment of the present invention, the photomask contains only non-rectilinear features.
Next, the system synthesizes a directional-gradient filter (step 402 ). Specifically, in one embodiment of the present invention, the directional-gradient filter is synthesized using the database image. In another embodiment of the present invention, the directional-gradient filter is synthesized based on user input. Note that the directional-gradient filter can be used to attenuate edgels that do not conform to the directional gradients of feature edges in the database image.
The system then computes a raw database gradient-image and a raw scanned gradient-image using the database image and the scanned image, respectively (steps 404 and 454 ).
Specifically, the system first converts the database image and the scanned image into a set of database directional-gradient-images and a set of scanned directional-gradient-images, respectively. The system then computes the raw database gradient-image and the raw scanned gradient-image using the set of database directional gradient-images and the set of scanned directional gradient-images, respectively.
Next, the system filters edgel orientations in the raw database gradient-image and raw scanned gradient-image by applying the gradient-directional filter (steps 406 and 456 ). This step results in a database gradient-image and a scanned gradient-image.
The system then computes database projection-vectors from the database gradient-image and scanned projection-vectors from the scanned gradient-image by taking orthogonal projections along a set of directions (steps 408 and 458 ). Specifically, in one embodiment of the present invention, the system projects the pixels of the database gradient-image and the scanned gradient-image along virtual rays orthogonal to their direction and integrates them into elements of a multivariate projection vector. Note that if the features in the integrated circuit are rectilinear, the orthogonal projections can be taken in the horizontal and vertical directions. Moreover, in this case, the horizontal projection vector will have a dimension equal to the image width and the vertical projection vector will have a dimension equal to the image height.
Next, the system extracts correlation vectors from the database projection-vectors (step 412 ). In one embodiment of the present invention, the projection vectors are one-dimensional. Consequently, the correlation vectors can assume one of two possible directions: either towards the first element of the projection vector or away from it. Specifically, in one embodiment of the present invention, the vector correlations are directed towards the first element of the corresponding projection vectors.
The system then maps the scanned projection-vectors to obtain the accumulator vectors using vector correlation (step 414 ). Note that, vector correlation uses the correlation vectors to perform the mapping from the projection space to the accumulator space. Furthermore, in one embodiment of the present invention, the system can employ a generalized Hough transform to map the scanned projection-vectors to obtain accumulator-vectors in an accumulator space by using the correlation vectors.
Next, the system detects global and local peaks in the accumulation space (step 418 ). In one embodiment of the present invention, a primary and a secondary accumulator vector is created for each accumulator direction. Furthermore, in one embodiment of the present invention, the primary and secondary accumulator vectors undergo different amounts of smoothing. Specifically, in one embodiment of the present invention, the secondary accumulator vector undergoes a higher degree of smoothing than the primary accumulator vector. Next, the system identifies a global and two local peaks in the primary accumulator vector. Additionally, the system identifies only a global peak in the secondary accumulator vector.
Note that the location of each global or local peak represents a candidate translational differential. Hence, by identifying global and local peaks in the accumulator vectors, the system obtains a set of candidate translational differentials in each accumulator direction. In one embodiment of the present invention, the system obtains 4 candidate translational differentials in the horizontal and the vertical directions. In this way, the system obtains a total of 16 candidate translational differentials that are derived by taking the cross-product between the set of horizontal translational-differentials and the set of vertical translational-differentials.
The system then identifies peak-cluster locations in the accumulator space (step 420 ). Note that a peak cluster is a collection of contiguous elements around a peak (including the peak). In one embodiment of the present invention, the peak-clusters are identified based on the global and local peaks.
Next, the system de-projects the accumulator-vectors to the projection space to obtain reconstructed scanned-projection-vectors (step 422 ). Note that the system uses the correlation vectors to perform the de-projection.
The system then de-projects the scanned-projection-vectors to the directional-gradient-image space to obtain reconstructed directional gradient-images (step 424 ).
In one embodiment of the present invention, the system suppresses all elements in the reconstructed scanned-projection-vectors except those that contribute to the peak-clusters in the accumulator space. Next, the system de-projects these reconstructed scanned-projection-vectors to the directional-gradient-image space. By doing this, the reconstructed directional-gradient-images can have a higher signal-to-noise ratio than the original directional-gradient-images that were obtained directly from the scanned image.
Next, the system generates one or more sets of translated directional-gradient-images using the set of candidate-translational-differentials (step 426 ). In one embodiment of the present invention, the system generates 16 sets of translated directional-gradient-images, wherein each set includes a translated horizontal-gradient-image and a translated vertical-gradient-image. Note that each of the 16 sets of translated directional-gradient-images corresponds to the set of 16 candidate translational-differentials that were obtained by taking the cross-product of the set of candidate horizontal translational-differentials and the set of candidate vertical translational-differentials.
Furthermore, the system generates a set of directional-gradient-images based on the database gradient-image that is generated in step 406 . Moreover, note that the database gradient-image that is generated in step 406 has already been passed through the directional-gradient filter. Next, the system applies a low-pass filter to the set of directional-gradient-images to obtain a set of smoothed directional-gradient-images (steps 410 and 416 ).
The system then performs a normalized correlation between the set of smoothed directional-gradient-images and the one or more sets of translated directional-gradient-images (step 428 ). Note that the value of the normalized correlation can be viewed as a “figure of merit” that indicates the confidence of the match between the two sets of images.
Next, the system picks a winner out of the one or more sets of translated directional-gradient-images (step 430 ). In one embodiment of the present invention, the set of translated directional-gradient-images that results in the maximum aggregate correlation is chosen as the winner. It will be apparent to one skilled in the art that a variety of decision functions can be used to pick a winner out of the one or more sets of translated directional-gradient-images.
Finally, the system computes the translational differentials along with the associated confidence level based on the winning set of translated directional-gradient-images (step 432 ).
It will be apparent to one skilled in the art that the system is tolerant to moderate sizing problems between the database image and the scanned image. Note that sizing problems can arise from dimension discrepancies between the synthesized IC features depicted in the database image and their actual dimension as imaged by an imaging device, such as a SEM.
Furthermore, it will be apparent to one skilled in the art that the system is tolerant to ambiguous contrast polarity. Specifically, the system does not rely on contrast direction between the scanned image regions and regional correspondence between the image pair based on contrast polarity.
Additionally, the system registers a database image against its scanned image when the latter is too noisy to enable correlation at coarser resolutions.
Process of Synthesizing a Directional Gradient Filter
FIG. 5 presents a flowchart that illustrates the process of synthesizing a directional gradient filter.
The process starts by receiving a database image (step 402 ).
Next, the system convolves the database image with a horizontal and a vertical point spread function (PSF) to obtain a horizontal gradient-image and a vertical gradient-image, respectively (steps 502 and 504 ).
The system then computes a gradient magnitude image using the horizontal gradient-image and the vertical gradient-image (step 506 ).
Next, the system applies a clip-low filter to the gradient magnitude image (step 508 ). Note that the clip-low filter suppresses the pixels in the gradient magnitude image that contain a value below an adaptive threshold, which is derived by computing a fraction of the mean gradient magnitude image. It will be apparent to one skilled in the art that a variety of functions can be used to derive the adaptive threshold based on the gradient magnitude image.
The system then computes a gradient orientation image using the remaining pixels, i.e., using the pixels whose gradient magnitude is above the adaptive threshold (step 510 ).
Next, the system constructs a gradient orientation histogram using the gradient orientation image (step 512 ).
The system then identifies the modes in the histogram (which correspond to the desired directions) and suppresses the other bins (which correspond to the unwanted directions) (step 514 ).
Next, the system smoothes the histogram (step 516 ).
Finally, the system constructs the directional gradient-filter using the smoothed histogram (step 518 ).
Process of Applying a Directional Gradient Filter
FIG. 6 presents a flowchart that illustrates the process of applying a directional gradient filter to an image.
The system starts by computing a horizontal gradient-image and a vertical gradient-image of an image (steps 602 - 606 ).
Note that the horizontal gradient-image and the vertical gradient-image can be generated by convolving the image with a horizontal PSF and a vertical PSF, respectively. It will be apparent to one skilled in the art that a variety of PSFs can be used for generating the directional gradient-images. Specifically, in one embodiment of the present invention, the database directional-gradient-images are generated by convolving the database image with a Sobel kernel. Furthermore, the scanned directional-gradient-images are generated by convolving the scanned image with the first derivative of a Gaussian. Note that in both cases, the convolution is performed in the vertical and the horizontal directions.
Next, the system computes the gradient-magnitude image from the horizontal gradient-image and the vertical gradient-image (step 608 ).
The system then applies a clip-low filter to the gradient magnitude image (step 610 ). Note that the clip-low filter suppresses the pixels in the gradient magnitude image that contain a value below an adaptive threshold, which is derived by computing a fraction of the mean gradient magnitude image. It will be apparent to one skilled in the art that a variety of functions can be used to derive the adaptive threshold based on the gradient magnitude image.
Next, the system computes a gradient orientation image using the remaining pixels, i.e., using the pixels whose value of the gradient magnitude is above the adaptive threshold (step 612 ).
Finally, the system applies the directional gradient filter to the gradient orientation image to obtain the filtered image (step 614 ).
Conclusion
The foregoing descriptions of embodiments of the present invention have been presented only for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the forms disclosed. Accordingly, many modifications and variations will be apparent to practitioners skilled in the art. Additionally, the above disclosure is not intended to limit the present invention. The scope of the present invention is defined by the appended claims.
Furthermore, the data structures and code described in this detailed description are typically stored on a computer-readable storage medium, which may be any type of device or medium that can store code and/or data for use by a computer system. This includes, but is not limited to, magnetic and optical storage devices such as disk drives, magnetic tape, CDs (compact discs) and DVDs (digital versatile discs or digital video discs), and computer instruction signals embodied in a transmission medium (with or without a carrier wave upon which the signals are modulated). For example, the transmission medium may include a communications network, such as the Internet.
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One embodiment of the present invention provides a system that computes translational differentials between a “perfect” image (henceforth called a database-image) and a scanned-image of a photomask. During operation, the system receives a noise-free database-image and a scanned-image that is generated by an imaging process. Next, the system computes a set of candidate-translational-differentials using the database-image and the scanned-image. The system then generates one or more sets of translated directional-gradient-images based on the set of candidate-translational-differentials and using the database-image and the scanned-image. Next, the system converts the database-image into a set of smoothed directional-gradient-images. Finally, the system computes translational differentials by performing a normalized correlation using the set of smoothed directional-gradient-images and the one or more sets of translated directional-gradient-images. Note that the computational time is significantly reduced because the method performs normalized correlation using only the set of candidate-translational-differentials, instead of exhaustively performing normalized correlation using all possible translational differentials.
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CROSS REFERENCE OF RELATED APPLICATION
[0001] The present application claims priority under 35 U.S.C. 119(a-d) to CN 201410624318.7, filed Nov. 7, 2014.
BACKGROUND OF THE PRESENT INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates to an organic-inorganic hybrid hollow fiber membrane technique, and more particularly to a method for preparing an aromatic polyamide porous hollow fiber membrane. The aromatic polyamide is poly-p-phenylene terephthalamide (PPTA).
[0004] 2. Description of Related Arts
[0005] In general, a phase-to-phase interface layer exists between different polymers. Due to existence of the phase-to-phase interface, the polymers are easy to have separation phenomena during the process of manufacture or utilizing. Thus, the phase separation phenomena can be utilized during the process of membrane manufacture, so as to optimize the performance of the membrane.
[0006] When the organic polymers are hybridized and mixed with the inorganic particles, the inorganic particles are usually high surface energy substance, but the organic polymers are usually low surface energy substance. Thus, the mixture of the organic polymers and the inorganic particles will inevitably form new phase interfaces, so as to form micropores taking advantage of phase separation. The conventional porous membranes have advantages of good flexibility, high permeability and simple preparation process, but the solvent resistance, corrosion resistance and temperature resistance thereof are poor. At the same time, in spite of the high strength, high corrosion resistance and high temperature resistance, the inorganic membrane is fragile and difficult to manufacture and has high cost. Thus, the organic-inorganic hybrid membrane has both the characteristics of organic components and inorganic components and thus has good separation properties and physical and chemical stability.
[0007] Poly-p-phenylene terephthalamide (PPTA) is a typical para-aromatic polyamide which is a rigid macromolecule and an important raw material for manufacturing Kevlar® fiber. Having excellent high temperature resistance and solvent resistance, the PPTA is a satisfying material for manufacturing high-performance porous hollow fiber membrane. However, since the melting point (over 500° C.) of the PPTA is below the decomposition temperature, the PPTA can not be fabricated by melt spinning technique. In addition, since the PPTA rigid macromolecule has a smaller entropy of free energy change than the flexible macromolecule during the dissolution process and thus is difficult to be dissolved in the conventional solvent and only capable of being dissolved in strong acid such as sulfuric acid and chlorosulfonic acid. P. Zschocke et al. produce a PPTA flat membrane and test the flux of the PPTA flat membrane in different types of solvents. Pure water flux of the PPTA flat membrane is only 12.8 L/(m 2 d) (3 MPa). [ Shown as Solvent resistant membranes from poly -(p- phenylene - terephthalamide ), Desalination, 34 (1980):69-751 Katsumori Nakura et al. test the PEG (50000) rejection performance of PPAT flat membrane in different kinds of solvents. Though the rejection rate is high, there is also the problem of low flux.
[0008] During the preparation process of the PPTA spinning solution, stir and deaeration of high viscosity casting solution are two difficult problems to be solved. The dissolved method of PPTA in concentrated sulfuric acid is known to all. However, dissolving high viscosity casting solution in the conventional stirring vessel requires 2-3 hours, and the deaeration time thereof is even longer, which leads to the degradation of PPTA macromolecule, so that the mechanical properties of the hollow fiber membrane are influenced, and that the composite pore-forming agents are modified to cause blackening and deterioration of the casting solution.
SUMMARY OF THE PRESENT INVENTION
[0009] In view of the disadvantages of the conventional arts, the technical problem to be solved by the present invention is to provide a method for preparing an aromatic polyamide porous hollow fiber membrane. In the method, firstly premix PPTA resin, solvent, composite pore-forming agents and inorganic particles in a stirring vessel to form casting solution, secondly inject the casting solution into a double-screw extruder to be fully dissolved under the effect of shear force, finally squeeze the casting solution into a spinneret via a metering pump. The PPTA hollow fiber membranes are prepared by the dry-wet spinning method, which solves the problems that difficult pore-forming and low porosity during the preparation process of PPTA hollow fiber membrane.
[0010] A technical solution to be solved by the present invention is to provide a method for preparing an aromatic polyamide porous hollow fiber membrane, comprising adopting a casting solution and a filming technology;
[0011] wherein components of the casting solution and mass fractions thereof are:
[0012] PPTA resin 1%-20%;
[0013] pore-forming agents 5%-20%;
[0014] solvent 60%-94%; wherein a sum of the mass fractions of the PPTA, pore-forming agents and solvent is 100%;
[0015] inorganic particles 0.05-50% of the weight of PPTA resin;
[0016] wherein logarithmic specific concentration viscosity of the PPTA resin is at a rang of 4.5 dL/g-9.5 dL/g;
[0017] the pore-forming agents is a water-soluble macromolecule and is selected from the group consisting of PEG with an average molecular weight of 1000-20000 and PVP with an average molecular weight of 10000-1000000;
[0018] the solvent is sulfuric acid having a mass concentration at a range of 98%-106%;
[0019] the inorganic particles are at least one member selected from the group consisting of silicon dioxide, calcium oxide and calcium carbonate;
[0020] wherein the method for preparing the aromatic polyamide porous hollow fiber membrane comprises steps of:
[0021] (1) pre-treating
[0022] under 55° C. ultrasonic treatment, adding the PPTA resin in phosphoric acid solution having a mass concentration of 0.5-1% for 15-60 minutes, then drying the PPTA resin and the inorganic particles in vacuum under 100° C.-200° C. for more than 24 hours; and
[0023] (2) preparing PPTA porous hollow fiber membrane
[0024] mixing the PPTA resin, the inorganic particles and the solvent which are pretreated in a sealed stirring vessel, stirring for 1-2 hours under 40-50° C. to obtain transparent yellow thick liquid, then adding the composite pore-forming agents to form casting solution, then injecting the casting solution into a double-screw extruder to be dissolved at 80-90° C. for 1-20 minutes, besides injecting sulfuric acid aqueous solution with a temperature at a range of 0-90° C., a flow velocity at a range of 10-100 ml/min and a volume fraction of 0-50% for serving as spinning bore liquid, while squeeze the casting solution into a hollow spinneret by a metering pump, wherein an extension ratio of a spinning jet is at a range of 1-10 times, finally extrude the casting solution by the hollow spinneret. Thus an air bath is passed through a height range of 10-100 mm, and immersed in sulfuric acid aqueous solution having a volume fraction at a range of 0-50% for serving as coagulation bath to obtain a primary PPTA porous hollow fiber membrane, then winding, water scrubbing and neutralizing with alkaline liquor, extraction eluting in at a room temperature water bath for over 48 hours to obtain the PPTA porous hollow fiber membrane.
[0025] Compared with the conventional art, beneficial effects of the present invention are as follows. The present invention takes advantages of the high shearing stress of the extruder to greatly shorten the dissolved time and the deaeration time, further increase content of PPTA in feed liquid, and improve mechanical properties of the PPTA hollow fiber membrane. The addition of the inorganic particles improves performance and mechanical toughness of the membrane, which enhances pure water flux, hydrophilia and rejection rate.
[0026] The composite pore-forming agents PEG/PVP in the present invention is the key to solve the problem that PPTA is not easily pore-forming. The PPTA porous hollow fiber membrane prepared in the present invention has a small average pore size and a high porosity, this is because when the alcohol ketones are mixed with inorganic salt, the existence of hydroxyl in alcohol ketones make the inorganic ions to have more groups, weaken charge interaction among ions, and thus has a homogenizing effect. Furthermore, the addition of inorganic particle makes the surface of the PPTA become rough and increases the effective filtration area of the membrane. Since the PPTA and the inorganic particle are not capable of dissolving in each other, the forming process of fiber membrane easily generates interface microvoid, in such a manner that the permeability and the mechanical properties of the membrane are significantly improved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is an election microscope of a cross section view of a morphology of an aromatic polyamide hollow fiber membrane prepared according to the method of the present invention.
[0028] FIG. 2 is a partial enlarged view of an area shown in FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] Detailed description of the present invention is illustrated as follows. The preferred examples of the present invention are exemplary only and not intended to be limited.
[0030] A technical solution to be solved by the present invention is to provide a method for preparing an aromatic polyamide porous hollow fiber membrane, comprising adopting a casting solution and a filming technology;
[0031] wherein components of the casting solution and mass fractions thereof are:
[0032] PPTA resin 1%-20%;
[0033] pore-forming agents 5%-20%;
[0034] solvent 60%-94%; wherein a sum of the mass fractions of the PPTA, pore-forming agents and solvent is 100%;
[0035] inorganic particles 0.05-50% of the weight of PPTA resin;
[0036] wherein logarithmic specific concentration viscosity of the PPTA resin is at a rang of 4.5 dL/g-9.5 dL/g;
[0037] the pore-forming agents are water-soluble macromolecule and is selected from the group consisting of PEG with an average molecular weight of 1000-20000 and PVP with an average molecular weight of 10000-1000000;
[0038] the solvent is sulfuric acid having a mass concentration at a range of 98%-106%;
[0039] the inorganic particles are at least one member selected from the group consisting of silicon dioxide, calcium oxide and calcium carbonate with an average particle size of 5 nm-10 μm;
[0040] wherein the method for preparing the aromatic polyamide porous hollow fiber membrane comprises steps of:
[0041] (1) pre-treating
[0042] wherein under ultrasonic processing at 55° C., the PPTA resin is treated for 15-60 minutes in phosphoric acid solution which is a mass concentration of 0.5-1%, then the PPTA resin and the inorganic particles are dried in vacuum at 100° C.-200° C. for more than 24 hours;); and
[0043] (2) preparing PPTA porous hollow fiber membrane
[0044] wherein the wholly pretreated PPTA resin and the inorganic particles are mixed into the solvent in a sealed stirring vessel, stirring for 1-2 hours at 40° C.-50° C. to obtain transparent yellow thick liquid, and the composite pore-forming agents are added to form casting solution,) then injecting the casting solution into a double-screw extruder to be dissolved at 80-90° C. for 1-20 minutes, besides inject sulfuric acid aqueous solution with a temperature at a range of 0-90° C., a flow velocity at a range of 10-100 ml/min and a volume fraction of 0-50% for serving as spinning bore liquid, while squeeze the casting solution into a hollow spinneret by a metering pump, wherein an extension ratio of a spinning jet is at a range of 1-10 times, finally extrude the casting solution by the hollow spinneret. Thus an air bath is passed through a height range of 10-100 mm, and immersed in sulfuric acid aqueous solution having a volume fraction at a range of 0-50% for serving as coagulation bath to obtain a primary PPTA porous hollow fiber membrane, then winding, water scrubbing and neutralizing with alkaline liquor, the PPTA porous hollow fiber membranes are obtained in water bath for over 48 hours at a room temperature.
[0045] The extension ratio of the spinning jet refers to a ratio of winded velocity to extruded velocity.
Example 1
[0046] under ultrasonic processing at 55° C., the PPTA resin is treated for 15-60 minutes in phosphoric acid solution which is a mass concentration of 0.5-1%, then the PPTA resin and the inorganic particles are dried in vacuum at 100° C.-200° C. for more than 24 hours;
[0047] The wholly pretreated 2.0 wt % PPTA resin and 0.5 wt % nano silicon dioxide are mixed into 88 wt % sulfuric acid which is a mass concentration of 98% in a sealed stirring vessel, stirring for 2 hours at 40° C. to obtain transparent yellow thick premixed liquid, and then the 10 wt % composite pore-forming agents PEG (2000) and PVP (58000) are added to form casting solution, wherein a mass ratio of PEG (2000):PVP (58000)=9:1, then inject the casting solution to a double-screw extruder to be dissolved at 80° C. for 10 minutes, besides inject 20° C. pure water at a flow velocity of 20 ml/min for serving as spinning bore liquid, meanwhile squeeze the casting solution into a hollow spinneret after measuring by a metering pump, wherein an extension ratio of a spinning jet 2 times, then extrude the casting solution by the hollow spinneret, thus an air bath is passed through) having a height of 20 mm, and immersed in 20° C. pure water coagulation bath for shaping to obtain a primary PPTA porous hollow fiber membrane, then winding, washing and neutralizing by alkaline liquor, the PPTA porous hollow fiber membranes are obtained in water bath for over 48 hours at a room temperature, in such a manner that the PPTA porous hollow fiber membrane is obtained. After testing, the PPTA porous hollow fiber membrane has an external diameter of 2.0 mm, an internal diameter of 1.2 mm, a breaking strength of 1.5 MPa and an elongation at break of 18%. When the PPTA porous hollow fiber membrane is filtering under 0.1 MPa, a distilled water flux is 218.67 L/(m 2 h), a static contact angle is 36.3°, a breaking strength of 1.5 MPa and an elongation at break of 18%.
Comparation 1
[0048] under ultrasonic processing at 55° C., the PPTA resin is treated for 15-60 minutes in phosphoric acid solution which is a mass concentration of 0.5-1%, then the PPTA resin and the inorganic particles are dried in vacuum at 100° C.-200° C. for more than 24 hours;);
[0049] The wholly pretreated 2.0 wt % PPTA resin is mixed into 88 wt % sulfuric acid which is a mass concentration of 98% in a sealed stirring vessel, stirring for 2 hours at 40° C. to obtain transparent yellow thick premixed liquid, and then the 10 wt % composite pore-forming agents PEG (2000) is added to form casting solution, then inject the casting solution into a double-screw extruder to be dissolved under 80° C. for 10 minutes, besides inject at 20° C. pure water at a flow velocity of 20 ml/min for serving as spinning bore liquid, meanwhile squeeze the casting solution into a hollow spinneret after measuring by a metering pump, wherein an extension ratio of a spinning jet is 2 times, then extrude the casting solution by the hollow spinneret, thus an air bath having a height of 20 mm is passed through, and immersed in 20° C. pure water coagulation bath for shaping to obtain a primary PPTA porous hollow fiber membrane, then winding, washing and neutralizing by alkaline liquor, the PPTA porous hollow fiber membranes are obtained in water bath for over 48 hours at a room temperature, in such a manner that the PPTA porous hollow fiber membrane is obtained. After testing, the PPTA porous hollow fiber membrane has an external diameter of 2.0 mm, an internal diameter of 1.2 mm. When the PPTA porous hollow fiber membrane is filtering under 0.1 MPa, distilled water flux is 102.32 L/(m 2 h), a static contact angle is 72.8°, a breaking strength of 0.62 MPa and an elongation at break of 7%.
Example 2
[0050] As mentioned in the example 1, the wholly pretreated 2.0 wt % PPTA resin and 0.5 wt % nano silicon dioxide are mixed into 88 wt % sulfuric acid which is a mass concentration of 100% in a sealed stirring vessel, stirring for 1 hours at 50° C. to obtain transparent yellow thick premixed liquid, and then the 10 wt % composite pore-forming agents PEG (2000) and PVP (30000) are added to form casting solution, wherein a mass ratio of PEG (2000):PVP (30000)=8:2, then inject the casting solution into a double-screw extruder to be dissolved at 85° C. for 8 minutes, besides inject 40° C. pure water at a flow velocity of 30 ml/min for serving as spinning bore liquid, meanwhile squeeze the casting solution into a hollow spinneret after measuring by a metering pump, wherein an extension ratio of a spinning jet is 2 times, then extrude the casting solution by the hollow spinneret, thus an air bath having a height of 20 mm is passed through, and immersed in 20° C. pure water coagulation bath for shaping to obtain a primary PPTA porous hollow fiber membrane, then winding, washing and neutralizing by alkaline liquor, the PPTA porous hollow fiber membranes are obtained in water bath for over 48 hours at a room temperature, in such a manner that the PPTA porous hollow fiber membrane is obtained (Shown as FIGS. 1 and 2 ). After testing, the PPTA porous hollow fiber membrane obtained has an external diameter of 2.0 mm, an internal diameter of 1.2 mm. When the PPTA porous hollow fiber membrane is filtering under 0.1 MPa, a distilled water flux is 318.34 L/(m 2 h), a static contact angle is 36.3°, a breaking strength of 2.25 MPa and an elongation at break of 53%.
Example 3
[0051] The extension ratio of a spinning jet is changed to be 3 times, the height of the air bath is 10 mm, and other conditions are identical to the example 2. After testing, the PPTA porous hollow fiber membrane obtained has an external diameter of 1.8 mm, an internal diameter of 1.2 mm. Under 0.1 MPa respectively testing permeation fluxes of 90° C. water and 90° C. N,N-dimethylacetamide (DMAc) of the PPTA porous hollow fiber membrane obtained, the testing permeation fluxes thereof are respectively 413.72 L/(m 2 h) and 265.36/(m 2 h). Under 90° C., a breaking strength of the PPTA porous hollow fiber membrane is 1.65 MPa and an elongation at break thereof is 28%.
[0052] Under 65° C. and 0.1 MPa, performing rejection test for 30 min on 1000 ml bovine serum albumin (BSA) having a mass concentration of 1 g/L, respectively testing absorbance of feed and permeate solutions by a double beam UV-vis spectrophotometer, and then calculating rejection rate. A filtration flux is 66.43 L/(m 2 h) and a rejection rate of protein is 92.54%.
Example 4
[0053] The 0.5 wt % silicon dioxide particles are changed to 0.5 wt % composite inorganic particles composed by SiO 2 and CaCl 2 , wherein a mass ratio of SiO 2 :CaCl 2 =1:1. Other conditions are identical to the example 2. After testing, the PPTA porous hollow fiber membrane obtained has an external diameter of 2.0 mm and an internal diameter of 1.2 mm. When the PPTA porous hollow fiber membrane is filtering under 0.1 MPa, a distilled water flux is 120.47 L/(m 2 h).
Example 5
[0054] The 0.5 wt % silicon dioxide particles are changed to 0.5 wt % composite inorganic particles composed by SiO 2 and CaCO 3 , wherein a mass ratio of SiO 2 :CaCO 3 =1:1. Other conditions are identical to the example 2. After testing, the PPTA porous hollow fiber membrane obtained has an external diameter of 2.0 mm and an internal diameter of 1.2 mm. When the PPTA porous hollow fiber membrane is filtering under 0.1 MPa, a distilled water flux is 80.72 L/(m 2 h).
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A method for preparing an aromatic polyamide porous hollow fiber membrane firstly premixes PPTA resin, solvent, composite pore-forming agents and inorganic particles in a stirring vessel to form casting solution, secondly injects the casting solution into a double-screw extruder to be fully dissolved under the effect of shear force and enters a spinneret via a metering pump. The PPTA hollow fiber membranes are prepared by the dry-wet spinning method, which solves the problems that hard pore-forming and low porosity in the preparation process of PPTA porous membrane. Utilization of the double-screw extruder is capable of greatly shortening the dissolved time and the deaeration time. Meanwhile the increase of PPTA in casting solution also improves mechanical properties of the PPTA membrane. The addition of the inorganic particles improves mechanical toughness and enhance pure water flux, hydrophilia and rejection rate.
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BACKGROUND OF THE INVENTION
[0001] This invention relates generally to the field of seed layers for subsequent metallization. In particular, this invention relates to methods for repairing seed layers prior to metallization and to methods for filling of apertures.
[0002] The trend toward smaller microelectronic devices, such as those with sub-micron geometries, has resulted in devices with multiple metallization layers to handle the higher densities. One common metal used for forming metal lines, also referred to as wiring, on a semiconductor wafer is aluminum. Aluminum has the advantage of being relatively inexpensive, having low resistivity, and being relatively easy to etch. Aluminum has also been used to form interconnections in vias to connect the different metal layers. However, as the size of via/contact holes shrinks to the sub-micron region, a step coverage problem appears which in turn can cause reliability problems when using aluminum to form the interconnections between the different metal layers. Such poor step coverage results in high current density and enhances electromigration.
[0003] One approach to providing improved interconnection paths in the vias is to form completely filled plugs by using metals such as tungsten while using aluminum for the metal layers. However, tungsten processes are expensive and complicated, tungsten has high resistivity, and tungsten plugs are susceptible to voids and form poor interfaces with the wiring layers.
[0004] Copper has been proposed as a replacement material for interconnect metallizations. Copper has the advantages of improved electrical properties as compared to tungsten and better electromigration property and lower resistivity than aluminum. The drawbacks to copper are that it is more difficult to etch as compared to aluminum and tungsten and it has a tendency to migrate into the dielectric layer, such as silicon dioxide. To prevent such migration, a barrier layer, such as titanium nitride, tantalum nitride and the like, must be used prior to the depositing of a copper layer.
[0005] Typical techniques for applying a metal layer, such as electrochemical deposition, are only suitable for applying copper to an electrically conductive layer. Thus, an underlying conductive seed layer, typically a metal seed layer such as copper, is generally applied to the substrate prior to electrochemically depositing copper. Such seed layers may be applied by a variety of methods, such as physical vapor deposition (“PVD”) and chemical vapor deposition (“CVD”). Typically, seed layers are thin in comparison to other metal layers, such as from 50 to 1500 angstroms thick.
[0006] U.S. Pat. No. 5,824,599 (Schacham-Diamand et al.) discloses a method of preventing oxide formation on the surface of a copper seed layer by conformally blanket depositing under vacuum a catalytic copper layer over a barrier layer on a wafer and then, without breaking the vacuum, depositing a protective aluminum layer over the catalytic copper layer. Such blanket deposition of a copper layer under vacuum is typical of such procedures used commercially.
[0007] PCT patent application number WO 99/47731 (Chen) discloses a method of providing a seed layer by first vapor depositing an ultra-thin seed layer followed by electrochemically enhancing the ultra-thin seed layer to form final a seed layer. The copper seed layer is enhanced by using an alkaline electrolytic bath., i.e. discontinuities, i.e. areas in the seed layer where coverage of the seed layer is incomplete or lacking, are reduced. Such alkaline plating is conformal. Bottom-up fill of apertures, particularly very small apertures, is not disclosed. Subsequent metal fill of apertures is preferably accomplished by electroplating with an acid copper bath. However, one using this method to enhance a seed layer would have to rinse and neutralize the seed layer before using conventional acidic electrolytic plating baths. Only alkaline copper plating baths containing copper sulfate are disclosed in this patent application.
[0008] International Patent Application WO 01/24239 (Tench et al.) discloses highly complexed copper plating solutions for the electroplating of copper circuitry in trenches and vias in the Damascene process of integrated circuit manufacture. The highly complexing anions for copper include pyrophosphate, cyanide and sulfamate. This patent application discloses the complete fill of features such as vias and trenches, i.e. circuitry formation. This patent application fails to disclose copper pyrophosphate plating solutions in the deposition of a copper seed layer for subsequent plating of copper circuitry.
[0009] Thus, there is a continuing need for methods of repairing seed layers having oxidation and discontinuities, particularly for use in devices having small geometries, such as 0.5 micron and below. Further, there is also a need for bottom-up filling of apertures.
SUMMARY OF THE INVENTION
[0010] It has been surprisingly found that the present alkaline electroplating solutions may be used to repair copper seed layer by providing seed layers substantially free of discontinuities prior to subsequent metallization. It has further been found that the present alkaline copper plating baths provide bottom-up fill of apertures.
[0011] In one aspect, the present invention provides a method of providing a metal seed layer substantially free of discontinuities disposed on a substrate including the steps of contacting a metal seed layer disposed on a substrate with an alkaline copper electroplating bath including copper pyrophosphate.
[0012] In a second aspect, the present invention provides a method of manufacturing an electronic device including the step of contacting a metal seed layer disposed on a substrate with an alkaline copper electroplating bath including copper pyrophosphate.
[0013] In a third aspect, the present invention provides an article of manufacture including an electronic device substrate containing one or more apertures, each aperture containing a seed layer deposit enhanced by contact with an alkaline electroplating composition that includes copper pyrophosphate.
[0014] In a fourth aspect, the present invention provides a method for removing excess material from a semiconductor wafer containing one or more apertures by using a chemical mechanical planarization process which includes contacting the semiconductor wafer with a rotating polishing pad thereby removing the excess material from the semiconductor wafer; wherein the apertures contain a seed layer deposit enhanced by contact with an alkaline electroplating composition that includes copper pyrophosphate.
[0015] In a fifth aspect, the present invention provides a method for removing excess material from a semiconductor wafer containing one or more apertures by using a chemical mechanical planarization process which includes contacting the semiconductor wafer with a rotating polishing pad thereby removing the excess material from the semiconductor wafer; wherein the apertures contain a copper deposit obtained by contact with an alkaline electroplating composition that includes copper pyrophosphate.
[0016] In a sixth aspect, the present invention provides a method of enhancing a copper seed layer including the steps of: contacting a seed layer disposed on a substrate with an alkaline electroplating composition including copper pyrophosphate and subjecting the electroplating composition to a current density sufficient to provide a seed layer substantially free of discontinuities.
DETAILED DESCRIPTION OF THE INVENTION
[0017] As used throughout the specification, the following abbreviations shall have the following meanings, unless the context clearly indicates otherwise: nm=nanometers; g/L=grams per liter; oz/g=ounces per U.S. gallon; pm=micron=micrometer; ASF=amperes per square foot; M=molar; mA/cm 2 =milliamperes per square centimeter; ° C.=degrees Centigrade; ° F.=degrees Fahrenheit; and ppm=parts per million.
[0018] As used throughout the specification, “feature” refers to the geometries on a substrate, such as, but not limited to, trenches and vias. “Apertures” refer to recessed features, such as vias and trenches. The term “small features” refers to features that are one micron or smaller in size. “Very small features” refers to features that are one-half micron or smaller in size. Likewise, “small apertures” refer to apertures that are one micron or smaller in size and “very small apertures” refer to apertures that are one-half micron or smaller in size. As used throughout this specification, the term “plating” refers to metal electroplating, unless the context clearly indicates otherwise. “Deposition” and “plating” are used interchangeably throughout this specification. The term “accelerator” refers to a compound that enhances the plating rate. The term “suppressor” refers to a compound that suppresses the plating rate. “Halide” refers to fluoride, chloride, bromide, and iodide.
[0019] All percentages and ratios are by weight unless otherwise indicated. All ranges are inclusive and combinable.
[0020] The present invention provides certain alkaline copper electroplating baths that are capable of providing seed layers, particularly copper or copper alloy seed layers, that are substantially free of discontinuities or voids. The present electroplating baths are particularly suitable for use in the manufacture of electronic devices, and particularly in the manufacture of integrated circuits.
[0021] Electroplating solutions of the present invention generally include copper pyrophosphate, one or more complexing agents, water, and orthophosphate. The electroplating solutions of the present invention may optionally contain one or more additives, such as halides, accelerators or brighteners, suppressors, levelers, grain refiners, wetting agents, surfactants and the like.
[0022] Copper pyrophosphate is present in the electroplating baths in an amount of from about 2.5 oz/g to about 4 oz/gal. Amounts above and below this range may be used but with less desirable copper deposits.
[0023] The seed layer repairing electroplating baths may also contain amounts of other alloying elements. Thus, the copper electroplating baths useful in the present invention may deposit copper or copper alloy.
[0024] The pH of the present alkaline electroplating baths is typically in the range of from >7 to 11, preferably 7.5 to 9, more preferably 8 to 9, still more preferably 8 to 8.8, and even more preferably 8.1 to 8.5. It is preferred that the pH is <9 as baths having a pH >9 tend to cause roughness and a decrease in current density. Baths having a pH <7 tend to cause orthophosphate buildup and a loss of throwing power. Suitable complexing agents include pyrophosphate salts such as potassium pyrophosphate and sodium pyrophosphate. Typically, the pyrophosphate to copper ratio is in the range of from 5:1 to 9.5:1, preferably 6:1 to 9.5:1, more preferably 7:1 to 9:1 and even more preferably 7.5:1 to 8:1.
[0025] One or more bases may optionally be added to the present electroplating baths. Suitable optional bases include, but are not limited to, ammonium hydroxide and tetra(C 1 -C 4 )alkylammonium hydroxides such as tetramethylammonium hydroxide. The amount of bases may be from 0.05 to 0.5 oz/gal, and preferably from 0.1 to 0.4 oz/g.
[0026] Particularly suitable electroplating baths according to the present invention are those that are substantially free of ammonia, alkali metal or both. In an alternate embodiment, the present copper pyrophosphate plating baths are free of ammonia or alkali metal and more preferably free of both ammonia and alkali metal.
[0027] The present electrolytes may optionally contain one or more halides, and preferably do contain at least one halide. Chloride and bromide are preferred halides, with chloride being more preferred. A wide range of halide ion concentrations (if a halide ion is employed) may be suitably utilized, e.g. from about 0 (where no halide ion employed) to 40 ppm of halide ion in the plating solution. Such halides may be added as the corresponding hydrogen halide acid or as any suitable salt.
[0028] A wide variety of brighteners or accelerators, including known brightener agents, may be employed in the present compositions. Particularly suitable brighteners are mercaptobenzothiazole, such as 2-potassium mercaptobenzothiazole, and 2,5-dimercapto-1,3,4-thiadiazole. Such brighteners may be used alone or in combination. The amount of brighteners or accelerators present in the electroplating baths is in the range of from about 0.1 to about 1000 ppm. Preferably, such compounds are present in an amount of from about 0.5 to about 300 ppm, more preferably from about 1 to about 100 ppm, and still more preferably from about 2 to about 50 ppm.
[0029] Other suitable organic additives that can be added to the present electroplating baths include one or more suppressors, one or more levelers, one or more surfactants, one or more grain refiners and the like. The amount of such suppressors present in the electroplating baths is in the range of from about 0.1 to about 1000 ppm. Preferably, the suppressor compounds are present in an amount of from about 0.5 to about 500 ppm, and more preferably from about 1 to about 200 ppm. Surfactants are typically added to copper electroplating solutions in concentrations ranging from about 1 to 10,000 ppm based on the weight of the bath, more preferably about 5 to 10,000 ppm. Particularly suitable surfactants for plating compositions of the invention are commercially available polyethylene glycol copolymers, including polyethylene glycol copolymers. Such polymers are available from e.g. BASF (sold by BASF under TETRONIC and PLURONIC tradenames), and copolymers from Chemax. Levelers may optionally be added to the present electroplating baths in amounts of from about 0.01 to about 50 ppm.
[0030] Electroplating baths of the present invention are advantageously used to treat or repair copper or copper alloy seed layers to provide seed layers substantially free of discontinuities. It is preferred that the present invention provides a seed layer substantially free of discontinuities and substantially free of seed layer oxidation.
[0031] The present copper electroplating compositions are suitably used in similar manner as conventional more concentrated copper electroplating baths. Plating baths of the invention are preferably employed at a wide range of temperatures from below room temperature to above room temperature, e.g. up to 65° F. and greater. Preferably, the plating baths are operated at a temperature in the range of from 100 to 135° F., and preferably from 115° to 125° F. The plating composition is preferably agitated during use such as by air sparger, work piece agitation, impingement or other suitable method. Plating is preferably conducted at a current ranging from 1 to 40 ASF depending upon substrate characteristics, and preferably 20 to 35 ASF. Plating time may range from about 2 minutes to 1 hour or more, depending on the difficulty of the work piece.
[0032] A wide variety of substrates may be plated with the compositions of the invention, as discussed above. The compositions of the invention are particularly useful to plate difficult work pieces, such as circuit board substrates with small diameter, high aspect ratio microvias and other apertures. The plating compositions of the invention also will be particularly useful for plating integrated circuit devices, such as formed semiconductor devices and the like. The compositions of the invention are particularly suitable for plating high aspect ratio microvias and trenches, such as those having aspect rations of 4:1 or greater.
[0033] As discussed above, aspect ratios of at least 4:1, having diameters of about 200 nm or smaller have been effectively copper plated with no defects (e.g. no voids or inclusions by ion beam examination) using plating solutions of the invention. Apertures with diameters below 150 nm, or even below about 100 nm, and aspect ratios of 5:1, 6:1, 7:1, 10:1 or greater, and even up to about 15:1 or greater can be effectively plated (e.g. no voids or inclusions by ion beam examination) using plating solutions of the invention. The present invention is particularly suitable for repairing seed layers on substrates having 1 μm and smaller apertures, preferably 0.5 μm and smaller apertures, and more preferably 0.18 μm and smaller apertures.
[0034] A wide variety of substrates may be plated with copper according to the present invention. Particularly suitable are substrates used in the manufacture of electronic devices, such as wafers used in the manufacture of integrated circuits, printed wiring board inner layers and outer layers, flexible circuits and the like. It is preferred that the substrate is a wafer.
[0035] Thus, the present invention provides a method of providing a metal seed layer substantially free of discontinuities disposed on a substrate comprising the steps of contacting a metal seed layer disposed on a substrate with an alkaline electroplating bath including copper pyrophosphate. The seed layer-containing substrate is then subjected to a current density in the range of 1 to 40 ASF for a period of time sufficient to enhance the seed layer, i.e. substantially remove or repair the discontinuities to provide a seed layer substantially free of discontinuities.
[0036] The present invention also provides a method of manufacturing an electronic device comprising the step of contacting a metal seed layer disposed on a substrate with an alkaline copper electroplating bath comprising copper pyrophosphate. An advantage of the present invention is that not only is the seed layer enhanced by substantially removing discontinuities, but the present electroplating bath can also be used to substantially metallize or fill the apertures with copper. The present electroplating bath, thus, also provides bottom-up fill or superfill.
[0037] “Superfill” or bottom-up fill occurs when metal plating at the bottom of features, particularly small features, is faster than plating occurring on the top surface of the substrate to be plated. “Conformal plating” occurs when metal plating following the surface topography is occurs at the same rate as metal plating in the bottom of features, such as trenches or vias. At times, conformal plating is desired, while at other times superfill plating is desired. In the manufacture of certain electronic devices, such as wafers used in the manufacture of integrated circuits or semiconductors having small or very small features, superfill plating is desired. Particularly desired is superfill copper electroplating in such electronic device manufacture.
[0038] In general, superfill deposition occurs when the deposition rate at the bottom of the features is greater than the deposition rate at the top surface of the substrate. While not intending to be bound by theory, it is believed that the deposition rate at the surface of the substrate is controlled by mass transport (convection) of the reactants in the plating bath and the magnitude of the current applied. It is further believed, while not intending to be bound by theory, that convection inside the features is unimportant when plating very small features and that the deposition rate inside the features is controlled by mass transport (diffusion).
[0039] Accordingly, the present invention also provides an article of manufacture including an electronic device substrate containing one or more apertures, each aperture containing a seed layer deposit enhanced by contact with an alkaline electroplating composition that comprises copper pyrophosphate. The present invention further provides an article of manufacture including an electronic device substrate containing one or more apertures, each aperture containing a seed layer deposited by contact with an alkaline electroplating composition that comprises copper pyrophosphate.
[0040] In an alternative embodiment, the substrate having an enhanced seed layer may be removed from the plating bath, rinsed with water and contacted with a second copper electroplating bath to metallize or fill the apertures. Such second electroplating bath may be alkaline or acidic. Such plating baths are well known to those skilled in the art. After metallization, i.e. filling of the apertures, the substrate, in the case of a wafer, is preferably subjected to chemical-mechanical planarization (“CMP”). A CMP procedure can be conducted in accordance with the invention as follows.
[0041] The wafer is mounted in a wafer carrier which urges the wafer against the surface of a moving polishing pad. The polishing pad can be a conventional smooth polishing pad or a grooved polishing pad. Examples of a grooved polishing pad are described in U.S. Pat. Nos. 5,177,908; 5,020,283; 5,297,364; 5,216,843; 5,329,734; 5,435,772; 5,394,655; 5,650,039; 5,489,233; 5,578,362; 5,900,164; 5,609,719; 5,628,862; 5,769,699; 5,690,540; 5,778,481; 5,645,469; 5,725,420; 5,842,910; 5,873,772; 5,921,855; 5,888,121; 5,984,769; and European Patent 806267. The polishing pad can be located on a conventional platen can rotate the polishing pad. The polishing pad can be held on the platen by a holding means such as, but not limited to, an adhesive, such as, two faced tape having adhesive on both sides.
[0042] A polishing solution or slurry is fed onto the polishing pad. The wafer carrier can be at a different positions on the polishing pad. The wafer can be held in position by any suitable holding means such as, but is not limited to, a wafer holder, vacuum or liquid tensioning such as, but not limited to a fluid such as, but not limited to water. If the holding means is by vacuum then there is preferably a hollow shaft which is connected to the wafer carrier. Additionally, the hollow shaft could be used to regulate gas pressure, such as, but not limited to air or an inert gas or use a vacuum to initially hold the wafer. The gas or vacuum would flow from the hollow shaft to the carrier. The gas can urge the wafer against the polishing pad for the desired contour. The vacuum can initially hold the wafer into position in the wafer carrier. Once the wafer is located on top of the polishing pad the vacuum can be disengaged and the gas pressure can be engaged to thrust the wafer against the polishing pad. The excess or unwanted copper is then removed. The platen and wafer carrier can be independently rotatable. Therefore, it is possible to rotate the wafer in the same direction as the polishing pad at the same or different speed or rotate the wafer in the opposite direction as the polishing pad.
[0043] Thus, the present invention provides a method for removing excess material from a semiconductor wafer containing one or more apertures by using a chemical mechanical planarization process which includes contacting the semiconductor wafer with a rotating polishing pad thereby removing the excess material from the semiconductor wafer; wherein the apertures contain a seed layer deposit enhanced by contact with an alkaline electroplating composition that includes copper pyrophosphate.
[0044] Also provided is a method for removing excess material from a semiconductor wafer containing one or more apertures by using a chemical mechanical planarization process which includes contacting the semiconductor wafer with a rotating polishing pad thereby removing the excess material from the semiconductor wafer; wherein the apertures contain a copper deposit obtained by contact with an alkaline electroplating composition that includes copper pyrophosphate.
EXAMPLE 1
[0045] A seed layer repair bath is prepared containing copper pyrophosphate at a concentration that gives 20 g/L copper metal and also containing 140 g/L potassium pyrophosphate, ammonia at a concentration which gives a pH of 8.5 and <1 g/L organic additives (such as 2,5-dimercapto-1,3,4-thiadiazole as brightener) in water. A silicon wafer substrate having aspect ratio features of >4:1 and vias of diameter <0.15 μm covered with a copper seed layer (deposited by ion metal plasma physical vapor deposition (“IMP-PVD”)) having a thickness of <100 nm over the surface is contacted with the seed layer repair bath at 45° C. A current density of 3 mA/cm 2 is then applied to the bath for three minutes. Following this, the substrate is removed from the seed layer repair bath, rinsed with de-ionized water and dried in a spin-rinse-dry module. The wafer substrate is then metallized by subjecting the substrate to an electrolytic copper plating bath such as that sold by Shipley Company (Marlborough, Mass.) under the ULTRAFILL 2001 trademark. The wafer substrate is placed in the bath for a sufficient period of time to provide the desired copper layer. The wafer substrate is then removed from the electrolytic plating bath, rinsed with de-ionized water and subjected to further processing.
EXAMPLE 2
[0046] A seed layer repair bath is prepared containing 90 g/L copper pyrophosphate, 220 g/L ammonium pyrophosphate, 55 g/L ammonium phosphate, tetramethylmmonium hydroxide at a concentration that gives a pH of 8.5 and <1 g/L organic additives (such as 2,5-dimercapto-1,3,4-thiadiazole as brioghtener) in water. A silicon wafer substrate having aspect ratio features of >4:1 and vias of diameter <0.15 μm covered with a copper seed layer (deposited by IMP-PVD) having a thickness of <100 nm over the surface is contacted with the seed layer repair bath at 45° C. A current density of 2 mA/cm 2 is then applied to the bath for eight minutes. Following this, the substrate is removed from the seed layer repair bath, rinsed with de-ionized water and dried in a spin-rinse-dry module. The wafer substrate is then metallized by subjecting the substrate to an electrolytic copper plating bath, such as that sold by Shipley Company (Marlborough, Mass.) under the ULTRAFILL 2001 trademark. The wafer substrate is placed in the bath for a sufficient period of time to provide the desired copper layer. The wafer substrate is then removed from the electrolytic plating bath, rinsed with de-ionized water and subjected to further processing.
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Disclosed are electroplating baths for enhancing copper seed layers and for subsequent metallization on the seed layers. Methods of enhancing copper seed layers and depositing metal on such seed layers are also disclosed.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 08/197,011, filed Feb. 15, 1994, pending, which is a file wrapper continuation of application Ser. No. 07/883,667, filed May 15, 1992, abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to fixed cutter rotary drag bits for earth boring and, more particularly, to improvements in bit design for so-called "anti-whirl" bits.
2. State of the Art
Fixed cutter rotary drag bits for subterranean earth boring have been employed for decades. It has been found that increasing the rotational speed of such drill bit has, for a given weight on bit, increased the rate of penetration of the drill string. However, increased rotational speed also has tended to decrease the life of the drill bit due to premature damage to and destruction of cutting elements, commonly polycrystalline diamond compacts (PDC's).
It has recently been recognized that cutting element destruction, particularly at higher rotational speeds, is at least in part attributable to a phenomenon known as "whirl" or "bit whirl." Radially directed centrifugal imbalance forces exist to some extent in every rotating drill bit and drill string. Such forces are in part attributable to mass imbalance and in part to dynamic forces generated by contact of the drill bit with the formation. In the latter instance, aggressive cutter placement and orientation creates a high tangential cutting force relative to the normal force and aggravates the imbalance. In any event, these imbalance forces tend to cause the drill bit to rotate or roll about the bore hole in a direction counter to the normal direction of rotation imparted to the bit during drilling. This counter-rotation is termed "whirl," and is a self-propagating phenomenon, as the side forces on the bit cause its center of rotation to shift to one side, after which there is an immediate tendency to shift again. Since cutting elements are designed to cut and to resist impact received in the normal direction of bit rotation (clockwise, looking down), contact of the cutting elements with the bore hole wall in a counter-clockwise direction due to whirl places stresses on the cutting elements for which they were never designed.
One solution to the problems caused by bit whirl has been to focus or direct the imbalance forces as a resultant side force vector to a particular side of the bit via changes in cutting element placement and orientation and bit mass location, and to cause the bit to ride on a low-friction bearing zone or pad on the gage of that side of the bit, thus substantially reducing the drill bit/bore hole wall tangential forces which induce whirl. This solution is disclosed in numerous permutations and variations in U.S. Pat. Nos. 4,982,802; 4,932,484; 5,010,789 and 5,042,596, all assigned to Amoco Corporation of Chicago, Ill.
The above-referenced patents generally require that the low friction bearing zone or pad on the gage and adjacent bit profile or flank be devoid of cutters, and indeed many alternative bearing zone configurations are disclosed, including wear coatings, diamond stud inserts, diamond pads, rollers, caged ball bearings, etc. It has been suggested that the bearing zone on the bit gage may include cutting elements of different sizes, configurations, depths of cut and/or rake angles than the cutters located in the cutting zone of the bit, which extends over the bit face from the center thereof outwardly to the gage, except in the flank area of the face adjacent the bearing zone. However, it is represented in the prior art that such bearing zone cutters should generate lesser cutting forces than the cutters in the cutting zone of the bit so that the bearing zone will have a relatively lower coefficient of friction. See U.S. Pat. No. 4,982,802, Col. 5, lines 29-36; U.S. Pat. No. 5,042,596, Col. 4, lines 18-25.
While anti-whirl bits have been built according to the aforementioned designs, the use of a cutter-devoid bearing zone and adjacent profile has resulted in excessive wear of the bearing zone as well as of the cutters on the flank of the bit, which shortens bit life even when cutting elements still have significant life remaining. This problem manifests itself most dramatically when the bit has to ream to reach the bottom of the hole.
Therefore, in order to take full advantage of the anti-whirl bit concept, it would be desirable to possess an anti-whirl drill bit having cutters placed on the bit profile adjacent the bearing zone of the bit in such a manner that the reaming capabilities and wear resistance of the bit to high side loads is enhanced without adversely affecting the anti-whirl tendencies of the bit.
BRIEF SUMMARY OF THE INVENTION
The present invention comprises an anti-whirl, fixed cutter drag bit having cutters placed on the profile adjacent the bearing zone of the bit. More specifically, cutters are placed on the flank adjacent the bearing zone so as to protrude or extend from the face or profile of the bit a distance less than that of the remaining cutters on the bit face, i.e., those in the "cutting zone" of the bit. With such a configuration, these "bearing zone flank cutters" on the flank of the bit face only come into contact with the formation when the cutting zone cutters dull and the bit has a reduced tendency to whirl, or when the cutting zone cutters achieve relatively high depths of cut, such as when reaming or under high rates of penetration.
As the cutting zone cutters wear or the bit achieves a high rate of penetration, the bearing zone flank cutters on the profile flank engage the formation, prevent wear of the bearing zone and greatly extend bit life.
Several alternative bearing zone flank cutter placement schemes are contemplated, the first being highly aggressive cutters, such as neutral rake cutters (perpendicular to the bit profile) extending from the profile a lesser distance than the cutting zone cutters. A second alternative comprises bearing zone flank cutters of high backrake relative to the cutting zone cutters, the increased backrake decreasing the distance or height of the cutter edge from the profile.
It is also contemplated that bearing zone flank cutters with grind flats at their top or outer edge might be employed, or penetration limiters such as natural diamonds or diamond-impregnated studs may be placed in front of or behind the bearing zone flank cutters to control the cutting forces generated adjacent the bearing zone. Finally, reduced-height standoffs or wear bumps may be placed on the flank adjacent the bearing zone in lieu of cutters.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a top elevation of an anti-whirl drill bit according to the present invention showing cutter locations;
FIG. 2 is a side sectional elevation of a bit profile of the bit of FIG. 1, depicting the increased backrake and reduced height of a flank cutter adjacent the bearing zone with respect to other cutters on the bit profile;
FIG. 3 is a side sectional elevation of an alternative bit design according to the present invention, wherein a flank cutter perpendicular to the profile adjacent the bearing zone is placed so as to protrude a lesser distance from the profile flank than the cutters in the cutting zone of the bit;
FIG. 4 is a side sectional elevation of a bit profile depicting a flank cutter adjacent the bearing zone and having a grind flat thereon;
FIG. 5 is a side sectional elevation of a bit profile having a flank cutter adjacent the bearing zone with a schematically shown penetration limiter; and
FIG. 6 is a side sectional elevation of a bit profile having a standoff structure on the flank adjacent the bearing zone.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 of the drawings, a top elevation (looking downward through the face of the bit) of drill bit 10 showing cutter locations thereon, it will be appreciated that the bit face adjacent circumferentially extending bearing zone 12 is, in prior art anti-whirl bits, completely devoid of cutters in proximity to gage 14 of the bit. It should be noted that many of the cutters, depicted in FIG. 1 as cylinders with one rounded end, are unnumbered so as to focus on only those cutters primarily required for a description of the preferred embodiments of the invention. While flank cutters 16, 18, 20, 22 and 24 in the cutting zone 26 comprising the remainder of the bit face are located at or near gage 14, no cutters on the profile flank of the bit face adjacent the bearing zone 12 would extend radially outwardly beyond cutters 28, 30 and 32, which are far removed from gage 14, as can be seen in more detail in FIG. 2, which is a side quarter-section elevation of the bit profile as the bit would be oriented during drilling. Thus, in prior art anti-whirl bits, all of the side loading in the bearing zone 12 would be taken by tungsten carbide pads, diamond inserts, or other non-cutting bearing structures located on gage 14, which structures wear significantly under the radially directed forces focused on the bearing zone 12 according to conventional anti-whirl design theory and practice.
The term "cutting zone" and the use of such term in describing the location of cutters disposed thereon is, as implied above, intended to designate the area of the bit face other than the profile flank adjacent bearing zone 12.
It has been found by the inventors herein, however, that bits which have been used to drill an interval of a bore hole and on which the cutters have worn have reduced whirl tendencies. Further, the tendency of a bit to whirl decreases as the depth of cut of the cutters on the bit increases. For example, lowering the speed of bit rotation or increasing weight on bit to increase depth of cut may reduce whirl tendencies. High rates of penetration, which are usually achieved by an increased depth of cut, also demonstrate reduced whirl tendencies, even on standard bits, as rates approach and exceed 100 ft/hr. Stated in another manner, if, for whatever reason, each cutter on the bit engages the rock formation being drilled so as to take a good "bite" of it, then whirl tendencies of the bit are minimized.
The question then arises as to why anti-whirl designs are desirable. In many, if not most, bore holes being drilled, the characteristics of the formations encountered are not uniform and the bit may achieve a high rate of penetration through one interval and an extremely low rate of penetration through the next. In other cases, relatively soft rock may include extremely hard "stringers" which abruptly and markedly slow the rate of penetration. Since the depth of cut decreases in any instance where the rotational speed of the bit remains the same but the rate of penetration decreases, the result is an increased tendency to whirl. It is impractical to pull a bit and replace it with one more suitable each time a new formation is encountered, even if such changes would be predicted with a high enough degree of accuracy, which is not the case. Further, a bit may begin to whirl in a matter of seconds in response to changing formation characteristics and destroy its cutters in a matter of a few minutes. Therefore, a bit which includes the above-described anti-whirl design concept to prevent cutter destruction in select situations may be extremely desirable, but prior art anti-whirl designs have sacrificed longevity and the ability to support a high rate of penetration over a long drilling interval.
As a result of the recognition of these above-described phenomena, it has been made possible, by judicious bit and cutter design, to specifically address the aforementioned bearing zone wear problem in a manner which will not deleteriously affect the anti-whirl tendencies of a bit designed in accordance with the aforementioned Amoco patents. Stated in another manner, the inventors have developed an anti-whirl bit design in several preferred embodiments which will not affect the anti-whirl characteristics of a new bit or one which is not engaged in reaming or subjected to high depths of cut, coming into play only in such instances where cutting forces adjacent the bearing zone will not stimulate whirl.
Drill bit 10 according to the present invention deploys additional cutters (designated 34, 36 and 38 in FIG. 1) on the profile of the bit adjacent bearing zone 12 of gage 14 in a normally cutter-devoid region 40 on the flank of the bit, such cutters 36-38 providing a cutting action and prevent bearing zone gage wear when cutters 16, 18, 20, 22 and 24 wear or dull or when high side loads on bit 10 increase the depth of cut of cutters 16-24.
In the embodiment of FIGS. 1 and 2, cutters 34, 36 and 38 adjacent bearing zone 12 are oriented at a high backrake or negative rake angle to the bit profile 42 so as to maintain these cutters at a reduced height in relation to, for example, cutters 16-24 and out of contact with the formation until cutters 16-24 wear or a high rate of penetration is achieved. Reference in FIG. 2 to traditional cutter placement 36' (if cutter 36 was located in the cutting zone 26) is illustrative of the difference in cutter height and attendant depth of cut.
In the alternative preferred embodiment of FIG. 3, the face of cutter 136 in flank region 40 is oriented at the same backrake angle as the rest of the cutters on the bit face (for example, 20°), but at a location with respect to the bit profile 42 so as to protrude or extend a lesser distance from the bit profile 42 than if these cutters were located in the cutting zone 26, such as cutters 16-24. Again, as with the embodiment of FIGS. 1 and 2, the bearing zone flank cutter 136, illustrative of others not shown in the profile section of FIG. 3, does not come into play until cutter wear occurs in the cutting zone 26 or a high rate of penetration by bit 10 increases the depth of cut of the cutting zone cutters.
It is also contemplated that the cutters on flank region 40 may also be oriented at a lesser backrake angle than those on the cutting zone 26, and may even be at a neutral rake angle, or perpendicular to the bit profile, as long as the cutter height on the flank region 40 is less than that in the cutting zone 26.
Referring to FIG. 4, flank region 40 bearing zone flank cutter 236 includes a grind flat 44 which reduces the height or extent of protrusion of cutter 236 from bit profile 42 in comparison to that of cutting zone cutters 16-24.
It is believed that a height difference of at least forty thousandths of an inch (0.040") between the bearing zone flank cutters and the cutting zone cutters is desirable in a bit according to the present invention, and that a height difference of up to sixty to seventy thousandths inches (0.060-0.070") in new bits is not excessive, as the height difference will initially decrease at a relatively rapid rate due to initial wear of the cutters in the cutting zone.
FIG. 5 depicts a full height cutter 336, of traditional cutter placement and similar backrake to cutters 16-24, (e.g., the same as fictitious cutter 36') but with associated penetration limiter 46 which limits the depth of cut adjacent the cutting zone 26 and hence the forces conducive to whirling.
FIG. 6 depicts yet another alternative embodiment of the present invention in the form of wear knots or standoffs 436 on the flank region 40. Such structures may comprise a tungsten carbide stud or insert, bit matrix material or other suitable material known in the art. The stud, insert or matrix material may carry round natural diamonds thereon, have diamond or other superhard material grit disposed therein or define a dome-shaped clad structure such as might be formed by coating a stud, insert or matrix material with a layer or film of diamond or other superhard material. While such structures would perform little, if any, cutting, their presence at the same or a slightly reduced protrusion or height from the bit flank (relative to cutting zone cutters) will, as with the other disclosed embodiments of the invention, reduce wear on the bearing zone. Such a structure effectively extends the bearing area via the use of non-aggressive wear knots or standoffs without extending or increasing the pad area in the bearing zone on the gage. The use of a non-cutting wear knot or standoff as a bearing structure eliminates the need for reduced height or protrusion thereof vis-a-vis the cutting zone cutting elements, as contact of the wear knots or standoffs with the formation will cause them to wear at the same or greater rate than the cutting elements.
It will be appreciated that the use of reduced-height flank cutters, wear knots or other standoff structures on the flank region 40 adjacent the bearing zone achieves a major advantage over prior art anti-whirl bits, even those disclosed in the aforementioned patents which purport to suggest cutters on the bearing pads. Specifically, the tangential cutting forces generated on the profile of the bit are borne on the same radial plane by the flank cutters, wear knots or other standoff structures of the present invention, thus resisting the tendency of the bit to tilt, cock or wobble in the bore hole. In contrast, the bearing pad cutters suggested by the prior art would not act in the same plane, but above the bit profile (as the bit is oriented in the hole), resulting in a side force at the end of a bending moment arm equal to the longitudinal displacement of the bearing pad cutters from the bit force, which displacement serves to destabilize bit rotation about the longitudinal axis.
Of course, whether or not the bearing pads include cutting structures, the moment arm which resists the side forces generated at the plane of the bit face is detrimental to smooth bit rotation and may cause uneven wear on the bearing pads. The present invention avoids such problems, reduces wear and encourages even wear of the pads in the bearing zone.
Many additions, deletions and modifications to the invention as disclosed and depicted in terms of the preferred and alternative embodiments may be made without departing from the scope of the invention set forth in the following claims. For example, the bearing zone flank cutters may be of reduced height but at the same backrake angle as the cutting zone cutters. On smaller bits, only a single flank cutter adjacent the bearing zone may be employed, or a single wear knot. Wear knots and cutters as described herein may be employed in combination on the flank adjacent the bearing zone.
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An anti-whirl rotary drag bit including one or more cutters, wear knots or other support structures disposed on the flank of a bit profile in a normally cutter-devoid region of the profile adjacent the gage of the bit in the circumferential segment of the gage used as a bearing zone for the bit to ride against the side of the bore hole. Such flank cutters or other structures reduce wear of the bearing zone but, due to their placement, do not come into play except under certain drilling situations such as reaming or high rates of penetration wherein whirl tendencies resulting from cutting forces are not as pronounced.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a National Phase Application based on PCT/GB2003/003570, filed Aug. 14, 2003, and claims the priority of European Patent Application Nos. 02358016.0, filed Aug. 20, 2002, and 03358004.4, filed Mar. 3, 2003, all of which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
The present invention relates to the preparation of polymerisation catalysts, and in particular to the preparation of silicon containing transition metal catalyst components for use in the polymerisation of olefins.
In recent years there have been many advances in the production of polyolefin homopolymers and copolymers due to the introduction of metallocene catalysts. Metallocene catalysts offer the advantage of generally a higher activity than traditional Ziegler catalysts and are usually described as catalysts which are single site in nature.
There have been developed several different families of metallocene complexes. In earlier years catalysts based on bis (cyclopentadienyl) metal complexes were developed, examples of which may be found in EP 129368 or EP 206794. More recently complexes having a single or mono cyclopentadienyl ring have been developed. Such complexes have been referred to as ‘constrained geometry’ complexes and examples of these complexes may be found in EP 416815 or EP 420436. In both of these complexes the metal atom eg. zirconium is in the highest oxidation state.
Other complexes however have been developed in which the metal atom may be in a reduced oxidation state. Examples of both the bis (cyclopentadienyl) and mono (cyclopentadienyl) complexes have been described in WO 96/04290 and WO 95/00526 respectively.
The above metallocene complexes are utilised for polymerisation in the presence of a cocatalyst or activator. Typically activators are aluminoxanes, in particular methyl aluminoxane or compounds based on boron compounds. Examples of the latter are borates such as trialkyl-substituted ammonium tetraphenyl- or tetrafluorophenylborates. Catalyst systems incorporating such borate activators are described in EP 561479, EP 418044 and EP 551277.
The above metallocene complexes may be used for the polymerisation of olefins in solution, slurry or gas phase. When used in the slurry or gas phase the metallocene complex and/or the activator are suitably supported. Typical supports include inorganic oxides eg. silica or polymeric supports may alternatively be used.
Examples of the preparation of supported metallocene catalysts for the polymerisation of olefins may be found in WO 94/26793, WO 95/07939, WO 96/00245, WO 96/04318, WO 97/02297 and EP 642536.
Supported metallocene catalysts may be prepared by use of sol-gel techniques.
Silicate gels are typically prepared by hydrolyzing monomeric tetrafunctional alkoxide precursors utilizing a mineral acid or base as a catalyst. For example the hydrolysis and condensation of tetraethoxysilane in a sol-gel process catalysed by ammonia results in a sol-gel powder which may be used as an organometallic catalyst support.
In J. Applied Polymer Science Vol. 78, 2318-2326 (2000) there is described silica supports for metallocenes prepared by the gelation of a stable colloidal phase of silica using MgCl 2 as initiator. Polymer Bulletin 46, 175-182 (2001) describes the synthesis of metallocene catalysts supported on silica type sol-gel carriers. The silica gels were prepared in a wet sol-gel procedure by hydrolysis and condensation of tetraethoxysilane in a mixture of water, ethyl alcohol and ammonia.
Polymer 42, 2001 pgs 4517-4525 describes the preparation of supported metallocenes by use of xerogels based on the hydroylsis and condensation reactions between tetraethoxysilane and bis(indenyl)diethoxysilane. In all the above preparations the resultant supported catalysts were employed in the polymerisation of ethylene.
Applied Catalysis 230, Pg. 287-302 (2001) describes indenyl-silica xerogels prepared by hydrolysis and polycondensation of bis(indenyl)diethoxysilanes and tetraethoxysilane.
SUMMARY OF THE INVENTION
We have now surprisingly found that sol-gel techniques which utilise a non-hydrolytic procedure may be successfully used in the preparation of silicon containing transition metal compound for the polymerisation of olefins.
Thus according to the present invention there is provided a process for the preparation of a silicon containing transition metal compound, said process comprising the steps of
(a) non-hydrolytic sol-gel condensation of a silane of formula
L x SiQ n
wherein L is a σ-bonded ligand,
Q is an anionic ligand, and x+n=4 with an halogenated silane (or siloxane) and an alkoxysilane,
(b) optionally alkylation,
(c) deprotonation, and
(d) addition of a transition metal compound.
DETAILED DESCRIPTION OF THE INVENTION
L is typically a cyclopentadienyl, indenyl or fluorenyl ligand.
Q is typically a halogen ligand and in particular is chloride
Preferred silanes are bis(cyclopentadienyl) dihalogenated silanes or bis(indenyl)cyclopentadienyl dihalogenated silanes.
The (cyclopentadienyl) dihalogenated silane is typically a dichlorinated compound.
The preferred dihalogenated silanes are those having one or two cyclopentadienyl ligands however bis(cyclopentadienyl) compounds for example bis(cyclopentadienyl)dichlorosilanes or bis(indenyl)dichlorosilanes are most preferred.
The preferred alkoxysilanes are ethoxysilanes for example tetraethoxysilane.
The preferred halogenated silanes are chlorosilanes for example tetrachlorosilane or dimethyldichlorosilane.
Suitable halogenated siloxanes for step (a) include for example dichlorotetramethylsiloxanes.
The non-hydrolytic condensation in step (a) is performed in the presence of a condensation catalyst for example a transition metal compound. A most suitable condensation catalyst is zirconium tetrachloride.
The non-hydrolytic sol-gel condensation has the advantage of allowing the reaction in step (a) to take place without solvent and under mild conditions
The alkylation step, when present, may be carried out by use of well known passivation agents, for example triethylaluminium.
The deprotonation step may be carried out by use of well known deprotonation agents for example n-butyllithium.
The sol-gel condensation products of the present invention may be represented by the following structure:
The transition metal compound used in step (d) is typically a Group IVA metal compound for example zirconium, titanium or hafnium metal compound and is preferably a halogenated compound. Preferred compounds are zirconium tetrachloride or titanium tetrachloride.
Other suitable Group IVA metal compounds for use in the present invention include metal amines for example Zr(NMe 2 ) 4 or similar. The use of a transition metal amine in step (d) has the advantage of grafting the metal directly on the sol-gel thereby avoiding the need for the specific deprotonation agent.
The process according to the present invention may additionally include a final halogenation step for example addition of chlorotrimethylsilane thereby forming the metal dichloride species. This is particularly the case when Zr(NMe 2 ) 4 or similar are used.
Thus according to another aspect of the present invention there is provided a process for the preparation of a silicon containing transition metal compound, said process comprising the steps of
(a) non-hydrolytic sol-gel condensation of a silane of formula
L x SiQ n
wherein L is a σ-bonded ligand,
Q is an anionic ligand x+n=4
with an halogenated silane (or siloxane) and an alkoxysilane,
(b) alkylation, and
(c) addition of a transition metal amine.
The process of the present invention is particularly suitable for the preparation of silicon containing metallocene catalyst components which may contain either a single σ-bonded ligand or two σ-bonded ligands.
The transition metal compound may be used for the polymerisation of olefins in the presence of any suitable activator component well known for use with transition metal catalysts.
These include aluminoxanes such as methyl aluminoxane (MAO), boranes such as tris(pentafluorophenyl)borane and borates.
Aluminoxanes are well known in the art and preferably comprise oligomeric linear and/or cyclic alkyl aluminoxanes. Aluminoxanes may be prepared in a number of ways and preferably are prepared by contacting water and a trialkylaluminium compound, for example trimethylaluminium, in a suitable organic medium such as benzene or an aliphatic hydrocarbon.
A preferred aluminoxane is methyl aluminoxane (MAO).
Other suitable cocatalysts are organoboron compounds in particular triarylboron compounds. A particularly preferred triarylboron compound is tris(pentafluorophenyl) borane.
Other compounds suitable as cocatalysts are compounds which comprise a cation and an anion. The cation is typically a Bronsted acid capable of donating a proton and the anion is typically a compatible non-coordinating bulky species capable of stabilizing the cation.
Such cocatalysts may be represented by the formula:
(L*-H) + d (A d− )
wherein
L* is a neutral Lewis base
(L*-H) + d is a Bronsted acid
A d− is a non-coordinating compatible anion having a charge of d − , and
d is an integer from 1 to 3.
The cation of the ionic compound may be selected from the group consisting of acidic cations, carbonium cations, silylium cations, oxonium cations, organometallic cations and cationic oxidizing agents.
Suitably preferred cations include trihydrocarbyl substituted ammonium cations eg. triethylammonium, tripropylammonium, tri(n-butyl)ammonium and similar. Also suitable are N.N-dialkylanilinium cations such as N,N-dimethylanilinium cations.
The preferred ionic compounds used as cocatalysts are those wherein the cation of the ionic compound comprises a hydrocarbyl substituted ammonium salt and the anion comprises an aryl substituted borate.
Typical borates suitable as ionic compounds include:
triethylammonium tetraphenylborate triethylammonium tetraphenylborate, tripropylammonium tetraphenylborate, tri(n-butyl)ammonium tetraphenylborate, tri(t-butyl)ammonium tetraphenylborate, N,N-dimethylanilinium tetraphenylborate, N,N-diethylanilinium tetraphenylborate, trimethylammonium tetrakis(pentafluorophenyl) borate, triethylammonium tetrakis(pentafluorophenyl) borate, tripropylammonium tetrakis(pentafluorophenyl) borate, tri(n-butyl)ammonium tetrakis(pentafluorophenyl) borate, N,N-dimethylanilinium tetrakis(pentafluorophenyl) borate, N,N-diethylanilinium tetrakis(pentafluorphenyl) borate.
Another type of cocatalyst suitable for use with the transition metal catalyst components of the present invention comprise ionic compounds comprising a cation and an anion wherein the anion has at least one substituent comprising a moiety having an active hydrogen.
Suitable cocatalysts of this type are described in WO 98/27119 the relevant portions of which are incorporated herein by reference.
Thus according to another aspect of the present invention there is provided a catalyst system for the polymerisation of olefins comprising (a) a transition metal compound as hereinbefore described and (b) a cocatalyst.
The transition metal catalysts of the present invention may be suitable for the polymerisation of olefin monomers selected from (a) ethylene, (b) propylene (c) mixtures of ethylene and propylene and (d) mixtures of (a), (b) or (c) with one or more other alpha-olefins.
Thus according to another aspect of the present invention there is provided a process for the polymerisation of olefin monomers selected from (a) ethylene, (b) propylene (c) mixtures of ethylene and propylene and (d) mixtures of (a), (b) or (c) with one or more other alpha-olefins, said process performed in the presence of a silicon containing transition metal catalyst system as hereinbefore described.
Particularly preferred polymerisation processes are those comprising the polymerisation of ethylene or the copolymerisation of ethylene and α-olefins having from 3 to 10 carbon atoms.
The transition metal catalysts of the present invention may be used for the polymerisation of olefins in either the solution, slurry or gas phase.
A slurry process typically uses an inert hydrocarbon diluent and temperatures from about 0° C. up to a temperature just below the temperature at which the resulting polymer becomes substantially soluble in the inert polymerisation medium. Suitable diluents include toluene or alkanes such as hexane, propane or isobutane. Preferred temperatures are from about 30° C. up to about 200° C. but preferably from about 60° C. to 100° C. Loop reactors are widely used in slurry polymerisation processes.
The preferred process for the present invention is the gas phase.
Suitable gas phase processes of the present invention include the polymerisation of olefins, especially for the homopolymerisation and the copolymerisation of ethylene and α-olefins for example 1-butene, 1-hexene, 4-methyl-1-pentene are well known in the art. Particularly preferred gas phase processes are those operating in a fluidised bed. Examples of such processes are described in EP 89691 and EP 699213 the latter being a particularly preferred process for use with the supported catalysts of the present invention.
The present invention will be further described by reference to the following examples:
EXAMPLE 1
Preparation of Support No: 1
In a glove box, zirconium tetrachloride (0.18 mmol) and bis(indenyl)dichlorosilane* (1.01 mmol) were introduced into a Schlenk tube. The tube was connected to a vacuum/N 2 line and dimethyldichlorosilane (4.51 mmol) and tetraethoxysilane (2.83 mmol) were successively added via syringes. The mixture was stirred for 5 minutes and transferred via a syringe to another tube which was then sealed under vacuum. The sealed tube was introduced in a steel envelope and held in an oven at 110-115° C. After 8 days the tube was opened in a glove box under N 2 and the resultant gel dried under vacuum at room temperature for 6 hrs. The chemical composition of the gel was as follows:
Elemental Analysis
C
H
Cl
Si
Zr
O
Mass %
31.96
5.34
2.36
30.75
1.4
28.19
These results indicate a final structure of:
SiZr 0.02 O 1.36 (OEt) 0.0.3 Cl 0.03 Ind 0.2 Me 1.1 .
NB. * prepared according to Organometallics 1993, 12, 4607-4612.
EXAMPLE 2
Preparation of Metallocene Catalyst Component A
1.94 mmol of n-butyl lithium was added dropwise at room temperature to 163 mg. of Support No: 1, prepared in example 1, in suspension of pentane (nBuLi/Indenyl=5.5). The reaction mixture was kept under reflux for 7 hrs. The solvent was removed under vacuum and the solid washed with 3 aliquots of 8 ml. pentane and then dried under vacuum at room temperature for 1 hr.
To the suspension of the resulting solid in 10 ml tetrahydofuran, 0.177 mmol ZrCl 4 .2THF in tetrahydrofuran were added dropwise at room temperature. The mixture was then stirred for 1 hr. The resultant solid was then filtered, washed with 2 aliquots of 10 ml. tetrahydrofuran and dried under vacuum.
EXAMPLE 3
Polymerisation of Component A
In a Schlenk tube were introduced 6.8 mg. of the metallocene catalyst component A, prepared in example 2, (6.3 μmol Ind 2 ZrCl 2 ), 50 ml toluene and 4.2 ml of methyl aluminoxane (Al/Zr=1000). After stirring for 10 min. the system was degassed. The mixture was held at 60° C. and a continuous flow of ethylene (pressure=1 bar) was maintained. After 1 hr. the polymerisation was terminated by adding acidic ethanol. The precipitated polymer was filtered and dried under vacuum for 8 hr. at room temperature. 1.01 g. of polyethylene was obtained corresponding to an activity of 110 gPE/(g catalyst .h..bar).
The polymer was characterised as having Mn=44800, Mw=124100 and MWD=2.8.
EXAMPLE 4
Preparation of Support No: 2
In a glove box, zirconium tetrachloride (0.352 mmol) and bis(indenyl)dichlorosilane* (3.01 mmol) were introduced into a Schlenk tube. The tube was connected to a vacuum/N 2 line and dichlorotetramethylsiloxane (5.093 mmol) and tetraethoxysilane (4.403 mmol) were successively added via syringes. The mixture was stirred for 5 minutes and transferred via a syringe to another tube which was then sealed under vacuum. The sealed tube was introduced in a steel envelope and held in an oven at 110-115° C. After 8 days the tube was opened in a glove box under N 2 and the resultant gel dried under vacuum at room temperature for 6 hrs. The chemical composition of the gel was as follows:
Elemental Analysis
C
H
Cl
Si
Zr
O
Mass %
44.71
5.79
5.35
24.75
1.61
17.79
These results indicate a final structure of:
SiZr 0.02 O 1.12 (OEt) 0.11 Cl 0.11 Ind 0.34 Me 1.16 .
NB. * prepared according to Organometallics 1993, 12, 4607-4612.
EXAMPLE 5
Preparation of Metallocene Catalyst Component B
A suspension of Support No: 2 (120 mg corresponding to 1.12 mmol of Si) in pentane was reacted with triethylaluminium (TEA) (0.67 mmol). The mixture was kept stirring for 6 hours. After stopping the stirring and waiting for the decantation, the supernatant liquid was removed by the use of a canula. The resulting solid was washed with pentane in the same manner and dried under vacuum 1.91 mmol of n-butyl lithium was added dropwise at room temperature to a suspension of the passivated solid in pentane (nBuLi/Indenyl=5). The reaction mixture was kept under reflux overnight. After stopping the stirring and waiting for the decantation, the supernatant liquid was removed by the use of a canula. The solid was washed with pentane in the same manner and dried under vacuum.
To the suspension of the resulting solid in tetrahydofuran, 0.191 mmol ZrCl 4 .2THF in tetrahydrofuran were added dropwise at room temperature. The mixture was then stirred for 1 hr. The solvent was eliminated by vacuum, pentane was added, the suspension was kept stirring for 1 h. After stopping the stirring and waiting for the decantation, the supernatant liquid was removed by the use of a canula. The solid was dried under vacuum.
EXAMPLE 6
Polymerisation of Component B
In a Schlenk tube were introduced 3.9 mg of the metallocene catalyst component A, prepared in example 5, (4.9 μmol Ind 2 ZrCl 2 ), 50 ml toluene and 3.2 ml of methyl aluminoxane (Al/Zr=1000). After stirring for 10 min. the system was degassed. The mixture was held at 60° C. and a continuous flow of ethylene (pressure=1 bar) was maintained. After 1 hr. the polymerisation was terminated by adding acidic ethanol. The precipitated polymer was filtered and dried under vacuum for 8 hr. at room temperature. 0.74 g. of polyethylene was obtained corresponding to an activity of 190 gPE/(g catalyst .h..bar).
The polymer was characterised as having Mn=8700, Mw=168400 and MWD=19.
EXAMPLE 7
Preparation of Support No: 3
In a glove box, zirconium tetrachloride (0.417 mmol) and bis(indenyl)dichlorosilane* (2.1 mmol) were introduced into a Schlenk tube. The tube was connected to a vacuum/N 2 line and dichlorotetramethylsiloxane (6.913 mmol) and tetraethoxysilane (4.923 mmol) were successively added via syringes. The mixture was stirred for 5 minutes and transferred via a syringe to another tube which was then sealed under vacuum. The sealed tube was introduced in a steel envelope and held in an oven at 110-115° C. After 11 days the tube was opened in a glove box under N 2 and the resultant gel dried under vacuum at room temperature for 6 hrs. The chemical composition of the gel was as follows:
Elemental Analysis
C
H
Cl
Mass %
39.28
6.00
3.97
These results indicate a final structure of:
SiZr 0.02 O 1.17 (OEt) 0.11 Cl 0.11 Ind 0.2 Me 1.33 .
NB. * prepared according to Organometallics 1993, 12, 4607-4612.
EXAMPLE 8
Preparation of Metallocene Catalyst Component C
A suspension of Support No: 3 (145.4 mg corresponding to 1.58 mmol of Si) in pentane was reacted with triethylaluminium (TEA) (0.98 mmol). The mixture was kept stirring for 20 hours. After stopping the stirring and waiting for the decantation, the supernatant liquid was removed by the use of a canula. The resulting solid was washed with pentane in the same manner and dried under vacuum.
0.16 mmol of Zr(NMe 2 ) 4 was added at room temperature to support No. 3 (Zr(NMe 2 ) 4 /Indenyl=0.5). Toluene was added and the reaction was stirred overnight at 100° C. The solvent was removed via reduced pressure. Pentane and chlorotrimethylsilane (3.2 mmol) were then added and the reaction was stirred overnight at room temperature. After stopping the stirring and waiting for the decantation, the supernatant liquid was removed by the use of a canula. The solid was washed with THF and pentane in the same manner and dried under vacuum.
EXAMPLE 9
Polymerisation of Component C
In a Schlenk tube were introduced 6 mg. of the metallocene catalyst component C (corresponding to a theoretical amount of 5.5 μmol Ind 2 ZrCl 2 ), 50 ml toluene and methyl aluminoxane (Al/Zr=1000). After stirring for 10 min. the system was degassed. The mixture was held at 60° C. and a continuous flow of ethylene (pressure=1 bar) was maintained. After 1 hr. the polymerisation was terminated by adding acidic ethanol. The precipitated polymer was filtered and dried under vacuum for 8 hr. at room temperature. 0.327 g. of polyethylene was obtained corresponding to an activity of 65 gPE/(g catalyst .h.bar).
The polymer was characterised as having Mw=317 kg/mol and MWD=45.
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A process for the preparation of a silicon containing transition metal compound that includes the steps of (a) non-hydrolytic sol-gel condensation of a silane of formula L x SiQ n wherein L is a σ-bonded ligand, Q is an anionic ligand, and x+n=4 with a halogenated silane (or siloxane) and an alkoxysilane, (b) optionally alkylation, (c) deprotonation and (d) addition of a transition metal compound. The process allows for the preparation of transition metal compounds which may suitably be used with cocatalysts for the polymerization of olefins, in particular for such processes carried out in the gas phase.
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FIELD OF THE INVENTION
This invention relates to apparatus for generating the inverse of a binary number.
BACKGROUND OF THE INVENTION
Those involved with the development of binary arithmetic have required the need for mechanisms for finding the inverse of a number as easily as possible. Finding the inverse or reciprocal of a number has significance in different applications: for example, oftentimes, only the period of the occurrence is known; therefore, to determine the frequency in real time, the reciprocal of the period must be obtained. Methods for obtaining the frequency of an occurrence where only the period of the occurrence is known heretofore has required complex apparatus such as that taught by H. Ling in U. S. Pat. No. 3,633,018, issued Jan. 4, 1972; W. S. Bennett in U.S. Pat. No. 4,047,011, issued Sept. 6, 1977; and W. S. Bennett in U.S. Pat. No. 4,025,773, issued May 24, 1977, respectively. Ling teaches a reciprocal convergence technique for obtaining the reciprocal of a number. This technique requires complex nonmodular hardware to carry out the method. Bennett in his disclosures describes a method of performing division by successive approximations which similarly require complex circuitry.
The above-mentioned disclosures are generally applicable for use in large digital computer systems. Therefore, the inherent complexity of the aforementioned patented methods is a major deterrent to their use. But where the reciprocal of a binary number is needed in a relatively simple application, the previously mentioned methods may be too expensive or complex to implement. For example, the reciprocal of a number may be needed in conjuction with a simple heart rate monitor, or it may be needed for ocean study experiments to determine water velocity or the interaction between waves and the ship. This procedure can be utilized to generate a pseudorandom sequence, useful in the field of broadband communication and elsewhere. The complex circuitry disclosed in the above-mentioned patents would not be compatible with such a use.
The complexity of the circuitry may lend itself to problems which tend to limit the application of the methods described in the previously mentioned patents to a large system. It is known that there are various methods for producing the reciprocal of a binary number and that those methods are generally complex.
It is an object of this invention to provide a simpler apparatus for determining the reciprocal of a binary number than any known to the prior art.
In contrast to the prior art, this invention is adaptable to low-frequency occurrences. This hardware simplification is readily amenable to integrated circuit technology and clearly represents an improvement over the prior art.
SUMMARY OF THE INVENTION
According to one embodiment of my invention, the reciprocal of a number is generated by the use of a mathematical technique similar to long division but with simplifications specific to finding the reciprocal of a binary number. This embodiment comprises the following elements for implementation: three registers, a comparator subtractor, and a clocking device. These components work in combination to produce the reciprocal of the binary number. The first register stores the binary number to be inverted. The second register initially stores a reference binary number. Upon initiation by the clocking device the binary numbers contained within the first and second registers are transferred to the comparator subtractor. The comparator subtractor circuit compares the binary number received from the first register to the binary number received from the second register. The third register stores bit-by bit the quotient value that represents the inverse of the number stored in the first register. The comparator subtractor subtracts the binary number from the first register from the reference binary number received from the second register and sends the difference back to the second register. The contents of the second register are then shifted and inputted back into the comparator subtractor to be compared once again with the binary number stored in the first register. Initially, a logical one is sent to the third register from the comparator subtractor. Then, in successive comparisons the following rules are observed: If the binary number from the second register is larger than that in the first register, a logical one is sent to the third register; if the binary number from the second register is smaller than the binary number from the first register, a logical zero is sent to the third register. In essence, therefore, the third register stores bit-by-bit a quotient value derived from successive remainders. The clocking circuit shifts the binary numbers in the third register over one place and either shifts the binary number located in the second register or loads the difference between the first and second registers into the second register, whichever is appropriate until the last digit in the reference number has been operated on.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be understood from the following description when read with reference to the drawings, in which:
FIG. 1 is a simplified block diagram of the apparatus of this invention for generating the inverse number; and
FIG. 2 is a block diagram of a clock circuit useful in the practice of this invention.
DETAILED DESCRIPTION
FIG. 1 depicts in block diagram form an apparatus for generating the inverse of the binary number. This apparatus comprises registers 1, 2 and 3 for storing, respectively, the number to be reciprocated, the reference numerator and the desired quotient; comparator subtractor 4 interconnecting registers 1, 2 and 3; and clock circuit 5 for regulating the operations of registers 2, and 3 and comparator subtractor 4. Register 1 receives a number to be reciprocated at terminal 7 and provides an output to comparator subtractor 4 on lead 8. Register 2 receives a reference numerator at terminal 16 and exchanges signals with comparator subtractor 4 on leads 9 and 10. Register 3 receives signals from comparator subtractor 4 on lead 13 and provides an output at terminal 15. Comparator subtractor 4 provides outputs to registers 2 and 3 on lead 13. Clock circuit 5 provides outputs to registers 2 and 3 on leads 12 and 11, respectively.
Initially, register 3 is cleared by control lead 14 in response to a start signal at terminal 6. Binary data representing the number to be inverted enters register 1 by way of terminal 7. Register 1 can be represented by two 4 bit registers connected in cascade. Commercially available registers that can be used to represent register 1 are Model No. SN7475, manufactured by Texas Instruments Incorporated. Thereafter, the binary number from register 1 is transferred to comparator subtractor 4 by way of lead 8. Register 2 is supplied with a reference binary number at terminal 16. Register 2 is commercially available as Model No. SN74199, maufactured by Texas Instruments Incorporated. Register 2 interacts with comparator subtractor 4 to produce the inverse of the binary number stored in register 1 at register 3. Comparator subtractor 4 can be implemented by two 4 bit comparator subtractors connected in cascade, such as Texas Instrument Model No. SN7483. Register 3 is commercially available as Texas Instrument Model No. 74164. This interaction will be explained more fully later in the discussion. Clock circuit 5, as before mentioned, initiates the operation on the binary number. It also alternately shifts the binary numbers located in registers 2 and 3 over one digit.
As before mentioned, register 1 transfers the number to be inverted to comparator subtractor 4 on lead 8. Register 2 simultaneously enters a reference binary number into the comparator subtractor 4 over lead 9. This reference number is chosen arbitrarily such that it is larger than the binary number received in the comparator subtractor 4 from register 1 but does not exceed twice the value stored in register 1 to ensure that the result is some positive whole number. It is also scaled so that the complete quotient is an integer, and not a fraction. In a first comparison of the binary numbers in registers 1 and 2, therefore a logical one is loaded into register 3 via control lead 13 from the comparator subtractor 4 to represent the first digit of the quotient value of the inverse of the binary number originally in register 1.
Lead 13 determines whether the difference obtained in comparator subtractor is entered or not entered into register 2 in the following manner. If the number in register 2 is larger than that in register 1, then control lead 13 sends the remainder difference generated in comparator subtractor 4 back to replace the previous number stored in register 2. If the number in register 1 is larger than that in register 2, control lead 13 inhibits the entry of any new number into register 2. The clock circuit 5 also ensures that the number located in register 2 is shifted by one bit.
Initially, comparator subtractor 4 sends the difference between the binary number to be inverted and the reference number into register 2, on data lead 10 as determined by lead 13 from register 3. Clock circuit 5 then alternately shifts the digit located in register 3 over one digit by lead 11 and either loads the difference binary number into register 2 or not, depending upon whether a one or a zero is loaded into register 3 on control lead 13, and shifts the binary number stored in register 2 over one digit by lead 12. Register 2 via lead 9 sends the binary number located within it back to the comparator subtractor 4 to be compared to the binary number from register 1. Therefore, in this embodiment register 1 stores the binary number to be inverted, and register 2 initially stores a reference number provided at terminal 16 chosen such that it is larger than the number located within register 1 but does not exceed twice the value stored in register 1.
The above-described process will repeat itself up to a predetermined number of digits determined by the number of counts preset into clock circuit 5. Once the cycles are complete, a number representing the inverse of the binary number located in register 1 has been built up bit by bit at register 3 in integer form and is available for read out at terminal 15.
FIG. 2 is an expanded block diagram of clock circuit 5 of FIG. 1. Clock circuit 5 comprises presettable counter 17 for determining the number of successive comparisons between registers 1 and 2 of FIG. 1, dual monostable multivibrator 18 which acts as a free-running, two-phase clock to perform operations on registers 2 and 3, respectively, and NAND gates 23 and 24. NAND gates 23 and 24 act to block the outputs of two-phase dual monostable multivibrator 18 (leads 20 and 21) when presettable counter 17 has reached its overflow condition through the other inputs of gates 23 and 24. A binary counter suitable for use in this embodiment can be Model No. SN74161, manufactured by Texas Instruments Incorporated. Also, there are a variety of dual monostable multivibrators available commercially, a typical one appropriate for this application being Model No. SN74123, manufactured by Texas Instruments Incorporated.
When the start cycle is initiated at terminal 6, counter 17 which is at its overflow number is preset to some predetermined number; for instance, 8. Dual monostable 18 then toggles counter 17 for successive comparisons via control lead 19 to count from the predetermined number (in this case, 8) to the overflow number which, for a Model No. SN74161, is 15. This toggling represents the number of operations performed in registers 2 and 3 via control leads 11 and 12, respectively, as well as the number of significant digits in the quotient, i.e., inverse. When the counter 17 reaches the number 15, line 22 will change state, therby causing NAND gates 23 and 24 to block the outputs of dual monostable multivibrator 18 from operating on registers 2 and 3 in FIG. 1 through leads 11 and 12. Control lead 25, upon sensing the change in state in lead 22, disables the counter 17; thereafter, dual monostable multivibrator 18 will be inhibited from toggling the counter 17.
This invention adapts mathematical techniques of long division to find the reciprocal of a prescaled positive number. As an aid in understanding the concept of this invention, let us restrict ourselves to integer arithmetic and consider the reciprocal of the decimal number 22. The reciprocal of this number is less than one and thus cannot be an integer. Therefore, the quotient will be a prescaled version of the reciprocal 1/22·2 n . For the purposes of the example, let n=9 and assume the use of 6 bit registers. The number 22 is written in its binary form 010110, and the operation is performed in binary notation. Table 1 below summarizes the operation of the system of FIG. 1. The divisor column represents the contents of register 1, the dividend column represents the contents of register 2, the column represents the contents of register 3, and the remainder represents the contents of comparator subtractor 4.
In initial step A, registers 1, 2 and 3 and comparator subtractor 4 are cleared to contain all zeros, as shown in Table 1. In step B, a binary number, in this case, the binary representation 010110 of decimal 22, is inputted into register 1. The reference number in register 2 is a one followed at the right with as many zeros as there are digits required in the quotient. In this example 9 zeros are used.
Binary division involves a series of subtractions of the divisor from the original dividend initially and from successive remainders thereafter. If subtraction is possible with a non-negative remainder then replaces the dividend, and a new subtraction follows after the next dividend digit is brought down to the remainder. In taking a reciprocal, however, the next dividend digit is always a 0. Bringing down the next dividend digit is then equivalent to moving the remainder one place to the left. If subtraction with a non-negative remainder is not possible, then a 0 is entered in the quotient, the remainder is shifted to the left, and the subtraction is repeated. Each shift to the left is accompanied by the entry of a 0 in the quotient.
In step 1, divisor 010110 is compared with dividend 100000 and found to be smaller. It is contained once in the dividend, and a 1 is placed at the right in the quotient. The remainder obtained from the subtraction of the divisor from the dividend is 001010, as shown in the rightmost column.
In step 2 the divisor is undisturbed, but the previous remainder is left-shifted one digit and substituted in column 2 for the original dividend. When divisor and dividend are compared in step 2, it is found that the dividend is smaller than the divisor; therefore, subtraction is impossible and 0 is added to the quotient. The remainder is numerically the same as in step 1, but it is now left-shifted to add a 0 on the right.
In step 3 the dividend is clearly larger than the divisor. Consequently, another 1 is placed in the quotient column, the subtraction is carried out and the remainder is entered in the last column.
In step 4, the remainder from step 3 is left-shifted and placed with an added 0 in the dividend column. The new dividend is again larger than the divisor. Another 1 is theerfore added to the quotient and the remainder is obtained.
In step 5 finally, the remainder from step 4 is left-shifted and placed with an added 0 in the dividend column. Since the new dividend is larger than the divisor, a 1 is added to the quotient. Therefore, after reconverting the binary numbers back to decimal, it is seen that the divisor register contains the decimal number 22, the quotient register contains 23 and the remainder register contains 6. Thus, where n=9, it is observed that 2 9/22=23 with a remainder of 6.
TABLE 1______________________________________ Dividend Quotient RemainderDivisor Register Register ComparatorRegister 1 2 3 4______________________________________Step A 000 000 000 000 000 000 000 000Step B 010 110 100 000 (0000) 000 000 000 000Step 1 010 110 100 000 (0000) 000 001 001 010Shift &CompareStep 2 010 110 010 100 (000) 000 010 010 100Shift &CompareStep 3 010 110 101 000 (00) 000 101 010 010Shift &CompareStep 4 010 110 100 100 (0) 001 011 001 110Shift &CompareStep 5 010 110 011 100 010 111 000 110Shift &Compare______________________________________
The number initially within the dividend is some reference number which represents "1"to obtain in this particular instance some positive whole number. Those skilled in the art can readily see that the method is easily adaptable to a reference number which would allow for a positive or negative fractional or whole number in the quotient register.
Those skilled in the art also recognize that the principles of this invention in the before-mentioned example could be applied to number systems other than binary and the decimal number 22 is arbitrarily chosen for exemplary purposes only.
This circuit can be implemented in integrated circuit technology, and all of the circuit elements are realizable in TTL logic, or the like, circuits. This invention will find use in applications where low-frequency data pulses are encountered. For example, this invention can be used in ocean experiments to study water velocity, wave height and interaction of waves with ships and submarines. These marine experiments are generally low-frequency occurrences and therefore can be analyzed by use of the above-mentioned embodiment because the pulse frequency is simply defined as the reciprocal of the time between data pulses. This calculation can be performed by the before-described apparatus in real time. Furthermore, this invention can find use in such varied apparatus as heart rate monitors or automotive monitoring devices, devices in which low-frequency pulses are to be measured. Also, this invention can find use as pseudorandom sequence generator useful in broadband communication and other fields.
While this invention has been disclosed by means of specific illustrative embodiments, the principles thereof are capable of a wide range of modification by those skilled in the art within the scope of the following claims.
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Apparatus for generating the inverse or reciprocal of a binary number simplifies the implementation of previous methods. A plurality of registers, a comparator subtractor and a clock circuit are used in combination to modify a long division operation to generate the desired inverse number expeditiously.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/318,844, filed on Mar. 30, 2010, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to tuning a radio-frequency (RF) front-end circuit having an embedded antenna, and in particular to a method for tuning the RF front-end circuit over a desired RF band by using an on-chip negative transconductance circuit to make an oscillator.
[0004] 2. Description of the Prior Art
[0005] Radio frequency (RF) receivers are used in a wide variety of applications such as television, cellular telephones, pagers, global positioning system (GPS) receivers, cable modems, cordless phones, radios and other devices that receive RF signals. For example, with respect to frequency modulation (FM) audio broadcasts, within the United States FM audio signals are broadcast in the frequency band from 76 MHz to 108 MHz.
[0006] In conventional systems that receive terrestrial audio broadcasts, filter circuitry is often used to filter out unwanted parts of a signal spectrum that is received through an antenna. This filter circuit, therefore, acts to tune, at least in part, the incoming signal to a desired channel or portion of the RF signal spectrum. For example, with respect to FM terrestrial audio broadcasts, this filter will help tune the receiver to the desired FM channel.
[0007] FM receivers typically use headphone wires as a main long antenna. A problem with this is there is no signal reception after the headphones are disconnected from the receiver. As a result, customers now demand that receivers come with embedded antennas that provide support for receiving FM signals.
[0008] Similarly, in some applications customers demand to have an FM transmitter circuit that can take the music from a digital library device and transmit it on FM band to be played back on the car radio while driving for example. Such FM transmitters also use embedded antennas for transmission.
[0009] FIG. 1 illustrates an embedded antenna 12 formed on a printed circuit board (PCB) 10 . The embedded antenna 12 can be formed in many different ways, for example as a PCB trace with no ground layer beneath. The embedded antenna 12 can also be formed as a simple wire that is wound around the housing of a device, such as a mobile phone. The embedded antenna 12 is used as an antenna for FM and other broadcast applications. The equivalent circuit model for this embedded antenna 12 , which has a length that is much less than the signal wave length of the signal being received over the embedded antenna 12 , is simply a capacitor, referred to here as C ANT . The equivalent capacitor C ANT of the embedded antenna 12 can have a range from 1-10 pF for example.
[0010] The reception of the embedded antenna 12 is several tens of dB lower than that of a conventional long antenna used for FM reception. In order to boost the signal level at the antenna output, a shunt inductor can be used to resonate with the equivalent capacitance of the embedded antenna 12 to form a high resonance (high-Q) resulting in voltage gain. Since the desired bandwidth of the receive band is generally wideband, tank resonance frequency must be tuned. In the prior art, tunable on-chip capacitor arrays have been used, consisting of a number of capacitor branches connected in parallel via switches are used to shift the resonance frequency. However, a problem that remains in the prior art is how the tank's resonance frequency can be measured automatically and accurately in order to be tuned to the right value.
[0011] Therefore, there is a need for an improved method of tuning an embedded antenna system.
SUMMARY OF THE INVENTION
[0012] According to one embodiment, a radio-frequency (RF) front-end circuit includes a tunable filter, a negative transconductance circuit coupled with the tunable filter to produce a tuning oscillation signal, and a counter arranged to determine a frequency of the tuning oscillation signal. The RF front-end circuit also includes a control circuit arranged to shift the frequency of the tuning oscillation signal by adjusting the tunable filter until the frequency of the tuning oscillation signal falls within an acceptable frequency range corresponding to a desired channel frequency band.
[0013] According to another embodiment, a filter calibration system for a radio-frequency (RF) front-end circuit includes a tunable filter configured to be tuned to a desired channel by adjusting a tuning control signal, the tunable filter being tunable across a frequency spectrum including a plurality of channels. The filter calibration system also includes a negative transconductance circuit coupled with the tunable filter to produce a tuning oscillation signal in a calibration mode of operation. A control circuit is used to receive a feedback signal based on the tuning oscillation signal and accordingly shift a frequency of the tuning oscillation signal by adjusting the tuning control signal to shift until the frequency of the tuning oscillation signal falls within an acceptable frequency range corresponding to a desired channel frequency band. The negative transconductance circuit and the control circuit are integrated on a same integrated circuit of the RF front-end circuit.
[0014] According to yet another embodiment, a method of tuning a radio-frequency (RF) front-end circuit includes producing a tuning oscillation signal with a negative transconductance circuit coupled with a tunable filter, determining a frequency of the tuning oscillation signal, and shifting the frequency of the tuning oscillation signal by adjusting the tunable filter until the frequency of the tuning oscillation signal falls within an acceptable frequency range corresponding to a desired channel frequency band.
[0015] These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 illustrates an embedded antenna formed on a printed circuit board (PCB).
[0017] FIG. 2 illustrates a functional block diagram of a RF front-end circuit.
[0018] FIG. 3 is a flowchart summarizing the frequency tuning method performed by the RF front-end circuit illustrated in FIG. 2 .
[0019] FIG. 4 illustrates a detailed block diagram of an RF transceiver front-end circuit.
[0020] FIG. 5 is an equivalent circuit diagram modeling parts of the RF transceiver front-end circuit and their effect on an oscillation frequency of the resulting resonance tank.
[0021] FIG. 6 illustrates a block diagram of an RF receiver front-end circuit.
[0022] FIG. 7 illustrates a block diagram of an RF transmitter front-end circuit.
DETAILED DESCRIPTION
[0023] A radio-frequency (RF) front-end circuit with enhanced tuning method is proposed. FIG. 2 illustrates a functional block diagram of a RF front-end circuit 100 . The RF front-end circuit 100 contains a tunable filter 102 that is controlled by a tuning control signal 124 output by a control circuit 112 . A negative transconductance circuit 104 is connected to the tunable filter 102 . At resonance the negative transconductance of the negative transconductance circuit 104 cancels the tank loss of the other elements in the RF front-end circuit 100 in order to sustain oscillation and produce a tuning oscillation signal 122 .
[0024] A counter 110 measures the oscillation frequency of the tuning oscillation signal 122 to calculate a counting value. During the tuning process, the counter 110 counts the received number of pulses of the tuning oscillation signal 122 during a counting period to calculate the counting value. Meanwhile, with the aid of an on-chip precision clock, the control circuit 112 calculates an expected number of pulses of the tuning oscillation signal 122 that should be received during the counting period if the RF front-end circuit 100 is properly tuned to the correct frequency, which is a desired channel frequency band. The counter 110 then outputs the counting value to the control circuit 112 in order for the control circuit 112 to compare the counting value with the expected number of pulses. If the counting value is not within the predetermined range of the expected value, the control circuit 112 changes the value of the tuning control signal 124 to adjust the tunable filter 102 , thereby adjusting the oscillation frequency of the tuning oscillation signal 122 . Once the tuning oscillation signal 122 is within an acceptable range of the desired channel frequency band, the control circuit 112 latches the desired value of the tuning control signal 124 and then the negative transconductance circuit 104 is disabled for normal mode operation. Using a feedback loop created by the tunable filter 102 , the negative transconductance circuit 104 , the counter 110 , and the control circuit 112 , the frequency of the RF front-end circuit 100 can be tuned quickly, accurately, and automatically.
[0025] FIG. 3 is a flowchart summarizing the frequency tuning method performed by the RF front-end circuit 100 illustrated in FIG. 2 . In step 150 , a desired tuning frequency is selected for the RF front-end circuit 100 . In step 152 , the tuning oscillation signal 122 is produced with the combination of the negative transconductance circuit 104 and the tunable filter 102 . Next, the frequency of the tuning oscillation signal 122 is counted by the counter 110 in step 154 . The control circuit 112 then determines in step 156 if the frequency of the tuning oscillation signal 122 is within an acceptable frequency range for the desired tuning frequency. If so, the step 160 is executed. Otherwise, step 158 is executed. In step 158 , the control circuit 112 adjusts the tunable filter 102 with the tuning control signal 124 in order to shift the frequency of the tuning oscillation signal 122 . The tuning method ends in step 160 .
[0026] FIG. 4 illustrates a detailed block diagram of an RF transceiver front-end circuit 300 according to one embodiment of the present invention. FIG. 5 is an equivalent circuit diagram modeling parts of the RF transceiver front-end circuit 300 and their effect on an oscillation frequency of the resulting resonance tank. A shunt inductor 306 resonates with the sum of all capacitance connected to the RF port and the resulting resonance frequency equals the desired channel frequency band. The tunable capacitance circuit 308 is controlled to tune (shift) this resonance frequency for different desired RF channels.
[0027] In the embodiment illustrated by FIG. 4 , a negative transconductance circuit 304 of FIG. 4 corresponds to the negative transconductance circuit 104 of FIG. 2 , the shunt inductor 306 and the tunable capacitance circuit 308 of FIG. 4 correspond to the tunable filter 102 of FIG. 2 , a digital counter 310 of FIG. 4 corresponds to the counter 110 of FIG. 2 , and a digital signal processor (DSP) 312 of FIG. 4 corresponds to the control circuit 112 of FIG. 2 .
[0028] An embedded antenna 302 is used to transmit or receive RF signals, and the embedded antenna 302 can be modeled as an equivalent capacitance C ANT in series with an equivalent resistance R ANT . One application of the RF transceiver front-end circuit 300 is supporting reception and transmission of RF signals within the frequency modulation (FM) broadcast frequency band of 76 MHz to 108 MHz.
[0029] It will be appreciated that the RF transceiver front-end circuit 300 satisfies the objective of automatically tuning the embedded antenna 302 for a desired FM channel within the FM frequency band of 76 MHz to 108 MHz. The tuning flexibility offered by the RF transceiver front-end circuit 300 also allows for a wide range of embedded antenna configurations to be used, allowing the circuit to be used in a variety of different products.
[0030] In an embodiment, an integrated circuit 325 is used for integrating several elements of the RF transceiver front-end circuit 300 . In the description below, elements referred to as being “on-chip” are located on the integrated circuit 325 , whereas those elements referred to being “off-chip” are not located on the integrated circuit 325 . In an embodiment, all off-chip elements, along with the integrated circuit 325 , are disposed on a PCB 305 for an example, and the PCB has its own equivalent capacitance C PCB .
[0031] In an embodiment, the shunt inductor 306 is located off-chip, and is used to resonate with the capacitance C ANT of the embedded antenna 302 . The shunt inductor 306 is realized as an equivalent inductance L SH . The tunable capacitance circuit 308 is a variable on-chip capacitance circuit that can be discrete or continuous depending on the application and is controlled by a tuning control signal 324 output by the DSP 312 located on-chip. The tunable capacitance circuit 308 is realized as a variable capacitor C VAR . The on-chip negative transconductance circuit 304 is used to provide a negative transconductance and oscillating with the resonance tank. The negative transconductance circuit 304 is modeled as an equivalent capacitance C −gm in parallel with an equivalent resistance R −gm . At resonance the negative transconductance of the negative transconductance circuit 304 cancels the tank loss of the other elements in the RF transceiver front-end circuit 300 in order to sustain oscillation and produce a tuning oscillation signal 322 .
[0032] In an embodiment, the tunable capacitance circuit 308 comprises a capacitor array, and can be located either on-chip or off-chip. The capacitance values of the tunable capacitance circuit 308 can be either discrete or continuous, and the tunable capacitance circuit 308 is digitally or analog or mixed analog and digitally controlled with the tuning control signal 324 .
[0033] In an embodiment, the tunable capacitance circuit 308 is a tunable capacitance array, and both the tunable capacitance circuit 308 and the shunt inductor 306 are connected to the signal path using a shunt configuration. In yet another embodiment, as shown in FIG. 5 , the embedded antenna 302 and the shunt inductor 306 are located off-chip, whereas the negative transconductance circuit and the tunable capacitance circuit 308 are located on-chip.
[0034] During calibration mode, the negative transconductance circuit 304 is enabled, and the digital counter 310 measures the oscillation frequency of the tuning oscillation signal 322 with respect to a reference clock CLKref. The reference clock CLKref is a substantially constant clock frequency that can be used as a reference for counting other signals. For instance the reference clock CLKref can be a 26 MHz clock produced by a crystal. The digital counter 310 and the reference clock CLKref can both be integrated on-chip. The digital counter 310 aids in the tuning process by counting pulses of the tuning oscillation signal 322 during a counting period indicated by the reference clock CLKref in order to calculate a counting value.
[0035] During the tuning process, the digital counter 310 counts the received number of pulses of the tuning oscillation signal 322 during the counting period to calculate the counting value. Meanwhile, the DSP 312 calculates an expected number of pulses of the tuning oscillation signal 322 that should be received during the counting period if the RF transceiver front-end circuit 300 is properly tuned to the correct frequency. The digital counter 310 then outputs the counting value to the DSP 312 in order for the DSP 312 to compare the counting value with the expected number of pulses. If the counting value received from the digital counter 310 is close enough, or within a predetermined range, of the expected value calculated by the DSP 312 , then the RF transceiver front-end circuit 300 is considered to be properly tuned. If the counting value is not within the predetermined range of the expected value, the DSP 312 changes the value of the tuning control signal 324 to adjust the variable capacitance C VAR of the tunable capacitance circuit 308 , thereby adjusting the oscillation frequency of the tuning oscillation signal 322 . Once the tuning oscillation signal 322 is within an acceptable range, the DSP 312 latches the desired value of the tuning control signal 324 and then the negative transconductance circuit 304 is disabled for normal mode operation. Thus, using the above tuning method, the negative transconductance circuit 304 produces the tuning oscillation signal 322 that is used to adjust or tune the frequency of the RF transceiver front-end circuit 300 . The digital counter 310 counts the oscillation frequency of the tuning oscillation signal 322 and provides this counting value to the DSP 312 as feedback. Using the feedback loop, the frequency of the RF transceiver front-end circuit 300 can be tuned quickly and automatically.
[0036] Please continue to refer to FIG. 4 . The RF transceiver front-end circuit 300 has the functions of both transmitting RF signals and receiving RF signals. For receiving RF signals, a low noise amplifier (LNA) 314 located on-chip is used for amplifying received RF signals that are received through the embedded antenna 302 to produce amplified received RF signals. A receiving mixer 316 located on-chip is used for frequency down converting the amplified received RF signals for further processing. The input impedance of the LNA 314 can be modeled as an equivalent capacitance C LNA joined in parallel with an equivalent resistance R LNA .
[0037] For transmitting RF signals, a power amplifier 318 located on-chip is used for amplifying RF signals to be transmitted to produce amplified output transmission RF signals for transmission through the embedded antenna 302 . The power amplifier 318 can be realized as an equivalent current source I PA joined in parallel with both an equivalent capacitance C PA and an equivalent resistance Rp A .
[0038] FIG. 6 illustrates a block diagram of an RF receiver front-end circuit 400 . Differing from the RF transceiver front-end circuit 300 shown in FIG. 4 , the RF receiver front-end circuit 400 only receives RF signals and does not contain a transmitter function. Therefore, the power amplifier 318 used for transmitting RF signals are not included in the RF receiver front-end circuit 400 . For all other elements in the RF receiver front-end circuit 400 , their functions are the same as described above with respect to the RF transceiver front-end circuit 300 .
[0039] FIG. 7 illustrates a block diagram of an RF transmitter front-end circuit 500 . Differing from the RF transceiver front-end circuit 300 shown in FIG. 4 , the RF transmitter front-end circuit 500 only transmits RF signals and does not contain a receiver function. Therefore, the LNA 314 and the receiving mixer 316 used for receiving RF signals are not included in the RF transmitter front-end circuit 500 . For all other elements in the RF transmitter front-end circuit 500 , their functions are the same as described above with respect to the RF transceiver front-end circuit 300 .
[0040] The RF transceiver front-end circuit 300 , the RF receiver front-end circuit 400 , and the RF transmitter front-end circuit 500 are well suited for receiving or transmitting FM radio signals. The embedded antenna 302 can have a length of less than λ/4, and even much less than λ/10, where the wave length λ is related to the desired tuning frequency of the RF front-end circuit used to transmit or receive signals.
[0041] In addition to the simplicity of the proposed tuning method, another main advantage of using the proposed solution is that the tuning algorithm is very similar to that used for the tuning of an on-chip voltage controlled oscillator (VCO) used in a synthesizer of local oscillator (LO) generation used for a receiver or a transmitter. Therefore, the same digital hardware can be re-used for both the VCO and embedded antenna tuning. As a result, no extra digital hardware is needed.
[0042] Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.
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A radio-frequency (RF) front-end circuit includes a tunable filter, a negative transconductance circuit coupled with the tunable filter to produce a tuning oscillation signal, and a counter arranged to determine a frequency of the tuning oscillation signal. The RF front-end circuit also includes a control circuit arranged to shift the frequency of the tuning oscillation signal by adjusting the tunable filter until the frequency of the tuning oscillation signal falls within an acceptable frequency range corresponding to a desired channel frequency band.
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BACKGROUND OF THE INVENTION
The present invention relates to a complex of novel, sulfur-containing antibiotic compounds demonstrating activity against transplanted tumors designated CL-1577A and CL-1577B and their congeners, to pharmaceutically acceptable derivatives thereof, to a process for the production of said compounds, and to a purified isolate of an actinomycete capable of producing these compounds.
More particularly, the process of producing the CL-1577 complex of antibiotic compounds relates to an aerobic fermentation process using a purified isolate of an actinomycete ATCC 39363.
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention, there is provided a purified isolate of an actinomycete having the identifying characteristics of ATCC 39363 which is capable of producing the antibiotic complex CL-1577, particularly the compounds CL-1577A, CL-1577B and their congeners.
In another aspect of the invention, there is provided a process for producing CL-1577 complex, CL-1577A, CL-1577B, and their congeners by cultivating the actinomycete isolate identified as ATCC 39363 under aerobic conditions in a medium containing assimilable sources of carbon and nitrogen until a substantial quantity of the CL-1577 complex is produced, and subsequently isolating the complex, or CL-1577A and CL-1577B compounds.
In accordance with another aspect of the invention there are provided the antibiotic compounds CL-1577A, CL-1577B and their pharmaceutically acceptable derivatives, which compounds exhibit both antibiotic and antitumor properties.
In another aspect of the present invention, there are supported pharmaceutical compositions comprising at least one CL-1577A and CL-1577B compound, their pharmaceutically acceptable derivatives and, optionally, additional antibiotic compounds together with a pharmaceutically acceptable carrier.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1a, 1b, and 1c are the ultraviolet, infrared, and 200 MHz proton magnetic resonance spectra, respectively, of the compound designated CL-1577A.
FIGS. 2a, 2b, and 2c are the ultraviolet, infrared, and 200 MHz proton magnetic resonance spectra, respectively, of the compound designated CL-1577B.
DETAILED DESCRIPTION
In accordance with the present invention, the CL-1577 complex of antibiotic compounds is produced by cultivating a selected isolate of actinomycete, ATCC 39363, under artificial conditions until a substantial quantity of CL-1577 complex (especially CL-1577A and CL-1577B) is formed, and subsequently isolating one or more of the compounds.
The actinomycete isolate suitable for the purpose of this invention was found in a soil sample collected in Tennessee, USA. This microorganism was isolated from the soil sample using a suitable agar plating medium, one containing salts such as potassium phosphate, potassium chloride, magnesium sulfate, and ferrous sulfate, and carbon sources such as glycerol and asparagine. To isolate the microorganism, the soil sample is pretreated with calcium carbonate before being plated onto the agar medium and, once plated, is incubated at a favorable temperature, particularly 33° C., to allow for the development of the soil microorganisms.
The CL-1577 complex producing organism that was isolated from the soil sample by the agar plating technique is an unidentified actinomycete and has been deposited with the American Type Culture Collection, Rockville, Md. 20852, where it is being maintained in their permanent culture collection as ATCC 39363. This organism, designated as culture WP-444, which produces CL-1577A, CL-1577B and their congeners, is also being maintained as a dormant culture in lyophile tubes, cryogenic vials, and in soil tubes in the Warner-Lambert/Parke-Davis Culture Collection, 2800 Plymouth Road, Ann Arbor, Mich. 48105.
The compounds CL-1577A, CL-1577B, and their closely related congeners, which demonstrate both antibiotic and antitumor properties, are produced by isolate ATCC 39363 during aerobic fermentation under controlled conditions. The fermentation medium consists of sources of carbon, nitrogen, minerals, and growth factors. Examples of carbon sources are glycerol and various simple sugars, such as glucose, mannose, fructose, xylose, ribose, or other carbohydrate-containing compounds such as dextrin, starch, cornmeal, and whey. The normal quantity of carbon source materials in the fermentation medium varies from about 0.1 to about 10 weight percent.
Nitrogen sources in the fermentation medium are organic, inorganic, or mixed organic-inorganic material. Examples of such materials are cottonseed meal, soybean meal, corn germ flour, corn steep liquor, distillers dried solubles, peanut meal, peptonized milk, and various ammonium salts.
The addition of minerals and growth factors are also helpful in the production of the CL-1577 complex of compounds. Examples of fermentation medium mineral additives include potassium chloride, sodium chloride, ferrous sulfate, calcium carbonate, cobaltous chloride, and zinc sulfate. Sources of growth factors include various yeast and milk products.
The preferred method for producing the CL-1577 complex of compounds is by submerged culture fermentation. According to this embodiment of the invention, the fermentation ingredients are prepared in solution or suspension and the mixture subsequently sterilized by autoclaving or steam heating. The pH of the aqueous medium is adjusted to preferably between about pH 4 and about pH 8 and the mixture cooled following sterilization to a temperature between about 16° C. to about 45° C. The cooled, sterile fermentation medium is inoculated with the organism and thereafter fermentation is carried out with aeration and agitation.
In the submerged culture method, fermentation is carried out in shake-flasks or in stationary tank fermentors. In shake-flasks, aeration is achieved by agitation of the flasks to bring about mixing of the medium with air. In stationary tank fermentors, agitation is provided by impellers which may take the form of disc turbines, vaned discs, open turbine or marine propellers. Aeration is accomplished by injecting air or oxygen into the agitated mixture.
Adequate production of the CL-1577 complex of compounds is normally achieved under these conditions after a period of about two to ten days.
In an alternative embodiment, the CL-1577 complex of compounds may also be produced by solid state fermentation of the microorganism.
The following examples are provided to enable one skilled in the art to practice the present invention and are merely illustrative thereof. They are not to be viewed as limiting the scope of the invention as defined by the appended claims.
FERMENTATIVE PRODUCTION OF CL-1577 COMPLEX
Example 1
The culture of Streptomyces sp. (ATCC 39363) of the present invention, following its isolation from the agar plate, was transferred to an agar slant employing CIM 23 medium and incubated at 28° C. for 7 to 14 days.
TABLE I______________________________________ Formulation of CIM 23 Medium______________________________________Amidex corn starch 1.0%N--Z amine, type A 0.2%Beef Extract (Difco) 0.1%Yeast Extract (Difco) 0.1%Cobalt chloride pentahydrate 0.002%Agar 2.0%______________________________________
Example 2
A portion of the microbial growth from the agar slant was used to inoculate an 18-mm×150-mm seed tube containing 5 ml of ARM 1550 seed medium. The inoculated seed was shaken at 33° C. for three days.
TABLE II______________________________________ Formulation of ARM 1550 Seed Medium______________________________________Bacto-Yeast extract (Difco) 0.5%Glucose monohydrate 0.1%Soluble starch (Difco) 2.4%Bacto-tryptone (Difco) 0.5%Bacto-Beef extract (Difco) 0.3%Calcium carbonate 0.2%______________________________________ Note: pH is adjusted to 7.5 with NaOH prior to adding the calcium carbonate.
Example 3
A 1-ml portion of the microbial growth from the seed tube was transferred to a 300-ml baffled shake-flask containing 50 ml of SM-13 production medium.
TABLE III______________________________________ Formulation of SM-13 Production Medium______________________________________Dextrin-Amidex B411 (American Maize) 1.5%Lactose (Mallinckrodt) 1.0%Pharmamedia (Traders) 0.65%Fish meal (Zapata Haynie) 0.35%Torula yeast (St. Regis) 0.25%______________________________________
The inoculated flask contents were incubated at 33° C. for four days with shaking (170 rpm gyratory shaker, 5 cm throw.) After a five day period, the fermentation beer was tan in color, the mycelia was granular in appearance, and the pH of the beer was about 6.4.
The antitumor activity of this fermentation broth was assayed at a dilution of 1:100 versus L1210 mouse leukemia cells grown in tissue culture. The assay technique is fully described in Cancer Chemotherapy Reports, Part 3, Vol. 3, No. 2 (1972), Deran, Greenberg, MacDonald, Schumacher and Abbott. A broth which gave L1210 leukemia cell growth rates of 0 to 35%, compared with the growth of these cells under control conditions, was considered active, 0%, most active. The observed activities of the fermentation broth of Example 3 are given in Table IV.
TABLE IV______________________________________Antitumor Activity of Fermentation Broth fromExample 3 (As Measured Against L1210 MouseLeukemia Cells) % L1210 Cell Growth Freeze-DriedFlask Number Supernate Ethanol Extract______________________________________I -- 8II 10 31______________________________________
The crude fermentation broth was also tested for anti-bacterial activity against various organisms using the agar-disc method. The crude broth was found to be active against Alcaligenes viscolactis, Bacillus subtilis, Micrococcus luteus, Branhamella catarrhalis, and Staphylococcus aureus.
Example 4
A cryogenic vial containing approximately 1 ml of a suspension of the culture was used to inoculate 600 ml of SD-05 seed medium contained in a 2-liter baffled shake-flask. The inoculated flask contents were incubated for 76 hours at 33° C. on a gyratory shaker at 130 rpm.
TABLE V______________________________________ Formulation of SD-05 Seed Medium______________________________________Amberex 1003 (Amber Laboratories) 0.5%Glucose monohydrate (Cerelose, Corn Products) 0.1%Dextrin-Amidex B 411 (American Maize) 2.4%N--Z Case (Humko Sheffield) 0.5%Spray-dried meat solubles (Daylin Labs) 0.3%Calcium carbonate 0.2%______________________________________
After 76 hours, the contents of the seed flask were transferred aseptically to a 30-liter stainless steel fermentator containing 16 liters of SD-05 seed medium. The inoculated fermentor contents were incubated at 33° C. for 24 hours while being stirred at 300 rpm and sparged with air at a rate of 1 vol/vol/min.
Example 5
The microbial growth from Example 4 was used to inoculate 75 gallons (284 liters) of SD-05 seed medium contained in a 200-gallon (757-liter) stainless steel fermentor. The medium was sterilized by steam heating at 121° C. for 40 minutes. The fermentor and contents were cooled to 33° C. and then inoculated with about 16 liters of the broth from Example 4. The resulting mixture was incubated at 33° C. for about 20 hours with stirring at 155 rpm, and sparged with air at a rate of 0.75 vol/vol/min.
Example 6
The microbial growth from Example 5 was used to inoculate about 1300 gallons (4921 liters) of SM-121 medium contained in a 2000 gallon (7571 liter) stainless steel fermentor. The medium was sterilized prior to inoculation by heating with steam for 40 minutes at 121° C. After sterilization, the fermentor and contents were cooled to 33° C., inoculated, and incubated for five days with stirring at 125 rpm and air sparging at a rate of 0.75 vol/vol/min.
The SM-121 medium consisted of 1.75% by weight of a feed grade mixture composed of soybean meal, ground yellow corn, ground wheat, corn gluten meal, wheat middlings, dried milk products, animal fat preserved with BHA, ground beet pump, calcium carbonate, sucrose, dehydrated alfalfa meal, dicalcium phosphate, brewers' dried yeast, salt, vitamin B 12 supplement, riboflavin supplement, calcium pantothenate, niacin, choline chloride, menadione sodium bisulfite (source of vitamin K activity), folic acid, pyridoxine hydrochloride, thiamin, ascorbic acid, vitamin A supplement, D activated animal sterol (source of vitamin D 3 ), vitamin E supplement, iron carbonate, iron sulfate, calcium iodate, manganous oxide, copper oxide, cobalt carbonate, zinc oxide.
The production of CL-1577 complex was monitored throughout the fermentation cycle by in vitro assay against L1210 mouse leukemia cells and by antimicrobial activity against Micrococcus luteus. In addition, such fermentation parameters as pH and percent sedimentation were recorded throughout the fermentation cycle. The data are presented in Table VI.
TABLE VI__________________________________________________________________________ Observed Bioactivity Inhibition of Growth Percent Growth of L1210 of Micrococcus luteus Mouse Leukemia CellsFermentation Time Percent Sedimentation Inhibition Zone Dia. at Given Dilution(Hours) pH (Growth) (mm) 1:500 1:2500 1:5000 1:10,000 1:30,000 1:100,000__________________________________________________________________________0 6.65 0 0 NA* -- NA* -- -- --24 8.10 10.0 0 NA* -- NA* -- -- --46 7.40 29.3 17 5.1 -- 13.9 -- -- --75 7.30 25.4 21 -- 2.3 -- 7.6 15.7 29.296 7.90 20.0 22 -- 2.8 -- 5.8 12.1 17.1116 8.20 25.4 22.5 -- 1.6 -- 4.7 11.2 30.4__________________________________________________________________________ *NA = Not active.
After 116 hours of fermentation, the 1140 gallons (4315 liters) of fermentation beer were harvested and the CL-1577 complex of compounds isolated as described below.
CHEMICAL ISOLATION OF CL-1577 COMPLEX
Example 7
The pH of the fermentation beer from Example 6 was adjusted to 6.2 and stirred for about two hours with 3000 liters of ethyl acetate. The mixture was treated with 68 kg of Celite 545 filter aid and then filtered through a 79-cm plate-and-frame filter press. The filtrate was allowed to stand and the lower aqueous layer which separated was removed and extracted with an additional 2070 liters of ethyl acetate. The organic solutions were combined and concentrated in vacuo to a final volume of 20 liters. Upon standing at 5° C. overnight, a lower layer of approximately 900 ml separated. This layer was found to contain only trace amounts of CL-1577 complex and was discarded.
The upper layer of approximately 19 liters was filtered through Celite 545 filter aid to remove insoluble materials and then washed with 2 liters of water. To the ethyl acetate solution were added with stirring, 15 liters of a 50:50 water-methanol mixture and then 45 liters of petroleum ether (bp 30°-60° C.). The resulting two-phase mixture was allowed to stand and the upper organic layer was removed and extracted a second time with 15 liters of a 50:50 water-methanol mixture. The aqueous methanol extracts were combined and concentrated in a vacuum evaporator to a volume of three liters. The oily residue which remained on the inside walls of the evaporator was dissolved in 5 liters of ethyl acetate. The 3 liter concentrate was thrice extracted with 1.5-liter portions of ethyl acetate and the four ethyl acetate solutions combined and dried over about 3 kg of anhydrous sodium sulfate. The drying agent was filtered off and washed with 3 liters of ethyl acetate. The filtrate and drying agent wash were combined and the resulting solution was passed through a chromatographic column (15-cm i.d.) containing 2.5 kg of 40 μm aminopropyl-silica gel (Analytichem International, Inc., Harbor City, CA) which had been prewashed with methanol and equilibrated with ethyl acetate.
The first 4 liters of eluate were found to contain no CL-1577 complex and were discarded. The material adsorbed on the chromatographic column was eluted with a total volume of 36.1 liters of ethyl acetate and the eluate was concentrated to a volume of about 600 ml. A small amount of insoluble material in the eluate was filtered off and the filtrate was treated with 5 liters of petroleum ether (bp 30°-60° C.) to precipitate 12.75 g of CL-1577 complex.
The solid was triturated with 300 ml of methanol and the insoluble material was removed by filtration. The filtrate was diluted with 130 ml of water and the trace of insoluble material was filtered off to produce a filtrate designated "filtrate A."
A 7-cm (i.d.) stainless steel chromatographic column was dry-packed with 1.9 kg of 40 μg C 18 -silica gel (Analytichem International, Inc., Harbor City, CA) and then sequentially washed with methanol, 50:50 methanol-water, 20:10:70 methanol-acetonitrile-0.05M sodium acetate buffer (pH 5.1), and finally 75:25 methanol-water. Filtrate A was charged to this column and eluted with 17 liters of 75:25 methanol-water followed by 1.3 liters of methanol. CL-1577A and CL-1577B were collected in the final 1.3 liter methanol eluate fraction.
The methanol fraction was concentrated in vacuo to an oily residue which was taken up in 30 ml of ethyl acetate. The ethyl acetate solution was treated with 300 ml of petroleum ether (bp 30°-60° C.) to precipitate 3.4 g of a mixture containing CL-1577A and CL-1577B.
CHEMICAL ISOLATION OF CL-1577A
Example 8
The product (3.4 gm) of CL-1577A, and CL-1577B from example 7 was dissolved in 40 ml of methanol. The resulting solution was diluted with 10 ml of water and chromatographed on the 7 cm (i.d.) C 18 silica gel column described above using 80:20 methanol-0.05M ammonium acetate buffer (pH 6.8) as the eluent. The flow rate was adjusted to about 200 ml/min and the eluate monitored by measuring its ultraviolet absorption at 254 nm.
The first major UV-absorbing fraction was eluted at a k' value of 2.5 (1.8 liters) and was designated "solution A." (The value of k' is given by the expression k'=(Ve-Vo)/Vo where Vo is the void volume, 2.0 liters, and Ve is the volume eluted at maximum ultraviolet absorption.)
Solution A was concentrated in vacuo to a volume of 100 ml and the concentrate extracted with two successive 40-ml portions of chloroform. The chloroform extracts were combined, dried over anhydrous sodium sulfate, and concentrated to a volume of 25 ml. Addition of 300 ml of petroleum ether (bp 30°-60° C.) caused the precipitation of a solid product designated CL-1577A.
This material was dissolved in 3 ml of 65:35 methanol-water and rechromatographed using a Prep 500 LC Apparatus (Waters Instruments, Inc., Milford, MA) fitted with a PrepPAK-500™ C-18 column employing 55:20:25 methanol-acetonitrile-0.05M ammonium acetate buffer (pH 6.8) as the eluent.
The eluate was monitored by measuring its refractive index. The fraction containing CL-1577A was eluted at k'=4.5. This fraction was concentrated to 85 ml and extracted with three 30 ml portions of chloroform which were combined and dried over anhydrous sodium sulfate. Addition of 250 ml of n-haxane to the dried and filtered solution precipitated 0.242 g of CL-1577A which was found to be 95% pure by high pressure liquid chromatographic analysis.
The chemical and physical properties of CL-1577A appear in Table VII and the ultraviolet, infrared, and 200 MHz proton magnetic resonance spectra of the compound appear as FIGS. 1a, 1b, and 1c, respectively.
CHEMICAL ISOLATION OF CL-1577B
Example 9
The second major ultraviolet-absorbing fraction eluted from the chromatographic column described in Example 8 was eluted at a k' of 3.5 (2.0 liters) and was designated "solution B."
Solution B was concentrated in vacuo and the concentrate was extracted with two successive 40 ml portions of chloroform. The chloroform extracts were combined, dried over anhydrous sodium sulfate, and filtered. The dried solution was concentrated to 25 ml and upon the addition of 300 ml of petroleum ether (bp 30°-60° C.), 0.456 g of CL-1577B precipitated.
A portion (0.43 g) of this material was dissolved in 3 ml of 65:35 methanol-water and chromatographed on the column described in Example 8 employing 55:20:25 methanol-acetonitrile-0.05M ammonium acetate buffer (pH 6.8) as the eluent. The eluate was monitored by measuring its refractive index. The CL-1577B compound was eluted at k'=7.5 in a 1.85 liter fraction. This solution was concentrated to 100 ml and extracted with three 35 ml portions of chloroform. The chloroform extracts were combined, dried, and concentrated to 20 ml. Addition of 300 ml of cyclohexane precipitated 0.30 g of CL-1577B which was found to be 95% pure by high liquid chromatographic analysis.
The chemical and physical properties of CL-1577B appear in Table VII and the ultraviolet, infrared and 200 MHz proton magnetic resonance spectra of the compound appear as FIGS. 2a, 2b, and 2c, respectively.
TABLE VII__________________________________________________________________________Physical Properties of CL-1577A and CL-1577BProperty CL-1577A CL-1577B__________________________________________________________________________Ultraviolet absorption spectrum λmax = 215 nm, a = 27.4 λmax = 215 nm, a = 26.8in methanol λmax = 252 nm, a = 28.2 λmax = 252 nm, a = 26.5 λmax = 282 nm, a = 16.7 λmax = 282 nm, a = 16.1 λmax = 318 nm, a = 11.6 λmax = 325 nm, a = 11.9Infrared absorption spectrum Principal absorption peaks at Principal absorption peaks at 3450,(KBr pellet; values given in 3450, 2970, 2930, 1690, 1630, 1610, 2970, 2930, 1690, 1630, 1610, 1600,reciprocal centimeters) 1600, 1525, 1465, 1450, 1410, 1370, 1525, 1465, 1450, 1410, 1370, 1310, 1310, 1250, 1210, 1155, 1075, 1020, 1250, 1210, 1155, 1075, 1020, 945, 990, 905, 880, 855, 795, and 750. 905, 880, 855, 795, 780, and 750.200 MHz Proton magnetic 1.11 (d), 1.3 (d), 1.35 (d), 1.41 (d), 1.11 (d), 1.12 (d), 1.24 (d), 1.35 (d),resonance spectrum in CDCl.sub.3 1.56 (m), 1.95 (d), 2.12 (m), 2.13 (s), 1.41 (d), 1.43 (s), 1.46 (m), 2.00 (m),(values given in ppm relative 2.22 (m), 2.30(m), 2.52 (dd), 2.53 (s), 2.13 (s), 2.14 (m), 2.31 (m), 2.52 (s),to tetramethylsilane; s = 2.75 (m), 3.42 (s), 3.4-4.2 (m), 2.53 (m), 2.75 (m), 3.42 (s), 3.4-singlet, d = doublet, dd = 3.81 (s), 3.89 (s), 3.98 (s), 4.21 (s), 4.2 (m), 3.79 (s), 3.89 (s), 3.99 (s),doublet of doublets, t = 4.57 (d), 4.67 (m), 4.97 (d), 5.40 (m), 4.19 (s), 4.49 (m), 4.56 (d), 4.66 (d),triplet, q = quartet, m = 5.49 (d), 5.50 (m), 5.70 (d), 5.82 (d), 4.77 (m), 4.97 (d), 5.35 (broad s),multiplet) 6.00 (d), 6.15 (broad s), 6.26 (s), 5.47 (m), 5.72 (d), 5.83 (d), 5.93 (d), 6.60 (dd), 7.49 (s), 8.60 (s), 11.71 6.21 (m), 6.24 (s), 6.59 (dd), 7.61 (s), 8.64 (s), 11.58 (s).Optical rotation [α].sub.D = -198° (c 1.25, [α].sub.D = -189° (c 0.63, CHCl.sub.3)Melting point 185° - 195° C. with prior 170° -195° with prior browning beginning at about 140° C. beginning at about 140° C.Elemental analysis 53.26% C; 6.04% H; 3.82% N; 8.98% S 54.81% C; 6.33% H; 3.86% N; 8.96% SRetention volume, HPLC (μBondpak™ 12.02 ml 26.26 mlC.sub.18 silica gel, 3.9 mm i.d.× 30 cm; eluent 55:20:25methanol-acetonitrile-0.05Mammonium acetate buffer(pH 6.8))R.sub.f Value 0.5 0.43(Thin-layer chromatography;solvent: 9:1 methanol-0.1 Mammonium acetate buffer(pH 6.8); C.sub.18 silica gel,200 μm thickness; Whatman KC.sub.18 F™reversed phase TLC)Molecular weight (FAB mass 1248 --spectrometry__________________________________________________________________________
BIOLOGICAL ACTIVITY OF CL-1577A AND CL-1577B
Example 10
The antimicrobial activity of CL-1577A and CL-1577B were evaluated by saturating 12.7 mm paper discs with a 500 μg/ml solution of either CL-1577A or CL-1577B, placing each saturated paper disc on a bioassay tray containing an agar medium seeded with a particular organism, incubating for 16 hours at 37° C. and measuring the diameter of the resulting growth inhibition zone, if any. The data for these tests appear in Table VIII.
TABLE VIII__________________________________________________________________________Antimicrobial Activity of CL-1577A and CL-1577B Growth Inhibition Zone Diameter (mm)Microorganism Culture Number* Medium CL-1577A CL-1577B__________________________________________________________________________Agrobacterium tumefaciens PD 05037 Mycin 23 23Alcaligenes viscolactis ATCC 21698 TSA 34 31Bacillus subtillis PD 04555 Mycin 28 27Bacillus subtillis PD 04555 AM-21 32 33Bacillus subtillis PD 04555 AM-22 34 28Bacillus subtillis PD H17 AM-19 21 25Bacillus subtillis PD M45 AM-19 30 30Escherichia coli PD 04524 AM-18 17 20Escherichia coli ATCC 25947 AM-18 17 17Escherichia coli PD 04863 AM-23 23 22Escherichia coli PD 04863 AM-24 22 22Micrococcus luteus PD 05064 PAS 30 29Penicillium avellaneum PD M2988 H & B 31 24Streptococcus faecalis PD 05045 AM-9 27 26Streptococcus faecalis PD 05045 AM-10 24 24Streptococcus faecalis PD 05045 TSA 18 17Streptococcus faecalis PD 05045 AM-11 26 26Streptococcus faecalis PD 05045 AM-12 25 24Streptococcus faecalis PD 05045 AM-13 25 22Streptococcus faecalis PD 05045 AM-14 23 21Turalopis albida PD M1390 102 17 17__________________________________________________________________________ *ATCC = American Type Culture Collection, Rockville, Maryland 20852 PD = WarnerLambert/Parke-Davis Culture Collection, 2800 Plymouth Road, An Arbor, Michigan 48105
Example 11
The antitumor activities of CL-1577A and CL-1577B against B16 melanocarcinoma in mice were evaluated using the test described in Cancer Chemotherapy Reports, Part 3, Vol. 3, 1-87, 1972. The data from these tests appear in Table IX. In each case, the mice were infected intraperitoneally on Day 0 and then given the indicated doses of CL-1577A or CL-1577B on Days 1, 5, and 9 of the test. The data are presented in terms of T/C values where: ##EQU1##
TABLE IX______________________________________In Vivo Antitumor Activity of CL-1577A and CL-1577B(As Measured Against B16 Melanocarcinoma in Mice) T/C (× 100)Dose (μg/kg of body weight) CL-1577A CL-1577B______________________________________10 Toxic 2065 196 1602.5 201 1721.25 198 144______________________________________
Example 12
The antitumor activities of CL-1577A and CL-1577B against P388 lymphocytic leukemia in mice were evaluated using the test described in Cancer Chemotherapy Reports, Part 3, Vol. 3, 1-87, 1972. The data from these tests appear in Table X. The mice were infected intraperitoneally on Day 0 and then given the indicated doses of CL-1577A or CL-1577B on Days 1, 5, and 9 of the test.
TABLE X______________________________________In Vivo Antitumor Activity of CL-1577A and CL-1577B(As Measured Against P388 LymphocyticLeukemia in Mice) T/C (× 100)Dose (μg/kg of body weight) CL-1577A CL-1577B______________________________________16 Toxic --10 -- Toxic8 163 --5 -- 1604 192 --2.5 -- 1721.3 -- 144______________________________________
The antibiotic compounds CL-1577A and CL-1577B and their congeners can be used for their anti-microbial and antitumor activity in the form of pharmaceutical compositions in combination with a compatible pharmaceutically acceptable carrier. These compositions may also contain other antimicrobial agents. The compositions may be made up in any pharmaceutically appropriate form for the desired route of administration. Examples of such forms include solid forms for oral administration as tablets, capsules, pills, powders and granules, liquid forms for topical or oral administration as solutions, suspensions, syrups, and elixirs, and forms suitable for parenteral administration such as sterile solutions, suspensions, or emulsions.
For use as antimicrobial agents, the compositions are administered so that the concentration of the active ingredient or ingredients of the composition exceeds that required for the minimal inhibition of the particular microorganism sought to be controlled.
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A purified isolate of an actinomycete identified as ATCC 39363 is capable of producing a complex of sulfur-containing antibiotic compounds having activity against transplanted tumors.
Antibiotic compounds CL-1577A and CL-1577B and their closely related congeners are produced by cultivating isolate ATCC 39363 under aerobic conditions in a culture medium containing assimilable sources of carbon and nitrogen until a substantial quantity of the CL-1577 complex is produced, and subsequently isolating the complex or one or more of the compounds.
The antibiotic compounds CL-1577A, CL-1577B, their congeners, and pharmaceutical compositions comprising these substances together with a suitable carrier are also disclosed.
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BACKGROUND OF THE INVENTION
The invention relates to a method for open-end rotor spinning, wherein the fibers to be spun are conveyed via a fiber guide channel into the rotor, are collected in its rotor groove of the largest interior diameter, are tied while being twisted into the yarn end in the area of a so-called tie-in zone by means of the rotor rotation and are drawn off as finished yarn through a draw-off nozzle, which is arranged centered and substantially on one level with the rotor groove.
The development of rotor spinning goes back a very long time, wherein the industrial use of this method only started on a larger scale in the sixties. A multitude of inventions was created not only in peripheral areas, i.e. from the sliver feed, the opening up into individual fibers and feeding of the individual fibers to the spinning rotor, as well as the drawing-off and winding-up of the yarn, but also in the core area of yarn formation, i.e. inside the rotor, only a small portion of which has entered into the present-day, very efficient automatic rotor spinning machines, which produce a yarn of high quality.
All methods have essentially in common that fibers from a sliver, which have been opened into individual fibers by means of an opening cylinder, are conducted together by means of a vacuum air flow to the rotor and are conveyed against a circumferential wall by means of the air flow and/or centrifugal force. As a rule, the shape of the inner rotor wall permits the collection of these fibers by forming an almost closed fiber ring. These collected fibers are continuously tied-up into a yarn end, wherein the yarn performs a true twist with every revolution of the rotor. The yarn rotation wanders opposite the yarn draw-off direction from the draw-off nozzle in the direction toward the yarn collection and, by the twisting of the doubled yarn, makes its continuous spinning on the open yarn end possible. The area where this piecing of the fibers to the yarn end takes place, is located between the detachment point of the yarn being created from the rotor wall, and the transition from the twisted yarn into the untwisted small sliver. It is called the tie-in zone.
Normally a yarn end for a piecing, which is fed into the rotor by the draw-off nozzle, is taken along in the direction of the rotor rotation by the air flow formed by the rotor rotation, at the latest when reaching the rotor groove. This curvature of the yarn end in the direction of rotor rotation is then maintained during the entire spinning process.
As can be seen from JP-OS 49-54 639, a malfunction can be caused by intensive soiling in the rotor, large bundlings of fibers, or the loss of the vacuum supply. The flipping of the curvature of the yarn end caused by this is quite undesirable, as stated in this Japanese laid-open document, since the yarn created in the course of this is said to show considerable disadvantages in respect to strength and evenness in comparison with a yarn, whose yarn end is curved in the direction of the rotor rotation. To prevent this flipping of the curvature opposite the rotor rotation direction, it is proposed in JP-OS 49-54 639 to arrange appropriate yarn contact elements on the draw-off nozzle and the rotor bottom, which are intended to stabilize the desired direction of curvature.
Within the scope of the further developments of the open-end spinning methods it was possible to definitely improve the processes, so that it is normally possible to avoid large collections of fibers, soiling or the failure of a vacuum. Accordingly, modern open-end spinning machine in principle are operated without additional aids for maintaining the curvature of the yarn end in the direction of rotation of the rotor.
A rotor spinning arrangement is described in “Breakspinning”, report of the Shirley Institute, Manchester, England, 1968, pages 76 to 79, wherein a funnel-shaped false twist element is arranged inside of the actual spinning rotor, which itself has the shape of a pan. This false twist element extends directly up to the fiber collection surface of the rotor. The rotor and the false twist element are separately seated and can also be separately driven. This means that the false twist element can be arranged in a stationary manner, as well as being driven in the direction of the rotor rotation, or opposite the direction of rotor rotation. Openings are arranged in the area of the collecting surface, by means of which a suction flow is created because of the centrifugal force of the rotor rotation. The fibers are fed in the radial direction on the collecting surface, which has the approximate shape of a cylinder surface. The yarn is drawn off through the rotor shaft, i.e. at the location opposite the fiber feed-in.
As described there, the relative direction of rotation of the yarn leg can be changed in relation to the rotor rotation as a function of the direction of rotation of the false twist arrangement. It is stated in conclusion that this relative rotation direction of the yarn leg clearly affects the yarn quality. Thus, in the positive direction, i.e. with the yarn leg running faster than the rotor, the yarn quality is said to be better by approximately 18% than with the oppositely directed relative speed of the yarn leg in relation to the rotor rotation.
A problem, which reduces the employment options of the rotor yarn produced on modern open-end rotor spinning machines, which otherwise has very even and good physical textile properties, resides in the formation of cover yarn, the so-called “belly bands”, which are wound in alternating directions of rotation either loosely, but partially very tightly, around the yarn periphery. The yarn structure, or the fiber orientation and fiber stretching, suffers because of this, with the result that the range of application of open-end rotor yarns becomes limited.
SUMMARY OF THE INVENTION
It is therefore the object of the invention to propose a method which limits the creation of cover yarn at least noticeably.
In accordance with the invention, this object is attained by providing a method for open-end rotor spinning, wherein the fibers to be spun are conveyed via a fiber guide channel into the rotor, are collected in its rotor groove of the largest interior diameter, are tied while being twisted into the yarn end in the area of a so-called tie-in zone by means of the rotor rotation and are drawn off as finished yarn through a draw-off nozzle which is arranged centered and substantially on one level with the rotor groove. The fiber flow exiting from a fiber guide channel has a directional component in the direction of rotation of the rotor, and the yarn leg extending from the draw-off nozzle to the rotor groove is curved, at least in the vicinity of the rotor groove, opposite the direction of rotation of the rotor during the spinning process.
The invention is advantageously further developed in a preferred embodiment of the method wherein the fiber flow is essentially fed to a fiber slide surface located between the rotor opening and the rotor groove. The direction of curvature of the yarn leg is created during the piecing process. In a first phase of the piecing process, a rotary flow directed tangentially opposite the direction of rotation of the rotor during its operation is caused to act on the yarn end introduced into the rotor for piecing, which flow is sufficient for creating the intended direction of curvature of the yarn leg. In such first phase of the piecing process, the rotor is initially driven opposite the direction of rotation of the rotor during its operation in such a way that the intended direction of curvature of the yarn leg occurs, and that the direction of rotation of the rotor during its operation does not exceed an angular acceleration which could lead to the flipping of the direction of curvature.
The method in accordance with the invention is based on the knowledge that, with a curvature direction of the yarn end in the direction of rotation of the rotor, fibers which, coming from the fiber slide face, directly reach the tie-in zone of the yarn end are initially tied to the twisting yarn in a direction which is opposite the normal yarn twisting direction, wherein in the course of the continued draw-off of the yarn, along with a simultaneous twisting thereof around its own axis, the direction of twisting of this fiber changes to the main yarn twisting direction. In those cases in particular in which the fiber reaches the tie-in zone first with its end located at the front in the direction of rotation of the rotor, several locally concentrated wraps can be created when the direction of rotation is changed. The yarn is constricted at this point with the result, that the yarn is uneven and the twist propagation is braked, which results in a loss of strength of the yarn in turn.
The setting in accordance with the invention of the curvature of the yarn opposite the direction of rotation of the rotor results in single fibers, which reach the yarn end in the tie-in zone, are immediately tied on, or in, in the normal twisting direction of the yarn and therefore do not cause any interference with the yarn production, nor a lack of quality arising therefrom.
Because of the detachment of the yarn end from the rotor groove, the angular speed of the detachment point, or of the tie-in zone, differs from the angular speed of the rotor. In the case of a curvature of the yarn end in the direction of rotation of the rotor, the angular speed of the tie-in zone is greater than that of the rotor, the tie-in zone runs ahead of the rotor. In the case of the present invention, with a curvature of the yarn end opposite the direction of rotation of the rotor, the tie-in zone trails behind the rotor. Because of this trailing of the tie-in zone, the fibers are drawn out of the rotor groove under an increased tensile stress. This results in additional stretching, which leads to an improved orientation of the fibers and makes possible an increased use of the strength of the fiber substance. In contrast to yarn which was produced with a leading tie-in zone, yarn produced in this way has a distinctive yarn core of stretched fibers.
The fact that with a trailing tie-in zone the fibers are tied to the yarn end with the same orientation with which they were conducted through the fiber guide channel to the rotor, also has an advantageous effect on the yarn structure. Here, the tangential alignment of the fiber flow in the direction of rotation of the rotor also assures the stretching of the fibers, because the inner surface of the rotor, i.e. the fiber slide surface, has a greater speed than the fiber flow impinging on it. This continuous maintenance of the stretching direction additionally furthers the stretched deposition of the fibers in the yarn structure.
By feeding the fiber flow onto a fiber slide surface, the fiber flow exiting the fiber guide channel is prevented from directly hitting the tie-in zone or the yarn end.
In accordance with the invention it is necessary to establish the trailing of the tie-in zone already in the course of the piecing procedure, in particular for obtaining an even yarn quality during the entire spinning process.
If no appropriate precautions are taken during the piecing procedure, leading of the tie-in zone automatically occurs because of the air flow which rotates along with the rotor. This orientation of the yarn leg is additionally aided by the rotation flow being created because of the tangential junction of the fiber guide channel and of the vacuum prevailing in the rotor housing. In the course of introducing the yarn end it is accordingly necessary to see to it that an opposite curvature is being formed.
This can be accomplished for one by generating a rotary flow opposite the direction of rotation of the rotor while the rotor still stands still, or does not yet rotate very fast, which acts on the yarn end being conducted from the draw-off nozzle to the rotor groove and which impresses the desired curvature on the yarn end. During this time the suction of the rotor housing can be maintained, since it aids the active air supply in the direction opposite to the rotation, which is in contrast to the passive suction of the fiber guide channel.
After the yarn end with the direction of curvature opposite the direction of rotation of the rotor has reached the rotor groove, this state is stabilized with the increasing number of rotor revolutions and therefore also the centrifugal force, and then remains as stable as in the state with a leading tie-in zone. In this connection the fact should be taken into consideration that the interferences mentioned in the prior art, which could cause a curvature change, are no longer relevant because of the command of the spinning process, as well as because of keeping the rotor clean.
The means used for generating the rotary flow can also be used for the so-called rotor flushing if it is necessary to remove the fibers which have reached the rotor in the course of a so-called fiber tuft equalization prior to the actual piecing (for example, see DE 197 09 747 A1).
Alternatively there is also the possibility of turning the rotor opposite its normal direction of rotation prior to the piecing procedure in order to cause in this way a deposition of the yarn end in this direction of rotation, which is opposite to the direction of rotation during its operation. In this case the suction of the rotor housing should be switched off in order not to endanger the desired deposition of the yarn leg by the suction flow, which causes a rotary flow in the direction of rotation of the rotor because of the tangential orientation of the fiber guide channel.
Following this, the rotor should be switched into the operating direction of rotation, but this process must not take place so abruptly that the direction of curvature of the yarn end flips again. Here, too, a stable curvature of the yarn end opposite the direction of rotation of the rotor is assured after the rotor has been run up. In addition, a slight twisting open of the yarn end during the rotation of the rotor opposite the normal operating direction also is advantageous for the piecing process. This yarn end, which has been opened further, is then better suited for a piecing process.
Besides the variations for creating the direction of curvature of the yarn end opposite the direction of rotation of the rotor described up to now, there are alternatively options of forming a fiber ring prior to introducing the yarn end into the rotor, or to switch the fiber flow into full strength after the yarn end has reach the rotor groove and the rotor has the number of rotor revolutions necessary for the process.
A further possibility for achieving the curvature in accordance with the invention of the yarn leg, or of the trailing thereof, consists in generating a yarn loop during the piecing procedure. In the course of this the yarn end is conveyed in the customary manner through the yarn draw-off tube into the rotor. Thereafter, a suction flow is generated in a radially spaced apart suction channel, while the spinning vacuum is shut off. Because of this the yarn end wanders from the draw-off nozzle into this suction channel. The feed length is regulated by the controlled feeding of the yarn through the yarn draw-off tube. At the end of feeding, the yarn end is clamped in the suction channel. Thereafter, a spinning vacuum is again generated and the rotor is started. Because of a continued return feed of the yarn, a larger size loop is formed between the draw-off tube and the suction channel. The air rotation caused by the rotor rotation pulls the loop in the direction of rotation of the rotor. After the loop has been sufficiently aligned in this way, the clamping is released, so that the yarn end can be deposited in the rotor groove opposite the direction of rotation of the rotor. Thereafter yarn draw-off is very rapidly accelerated, and the previously stepped yarn feed is restarted. In the process the yarn end is tied to the fibers. As in the already mentioned cases, the curvature of the yarn leg is stabilized by means of the centrifugal force then applied. With this process variation it is only necessary to see to it that no early feeding of fibers into the spinning rotor takes place in order to prevent the flipping of the yarn leg into the other direction of rotation in a phase which has not yet been stabilized by centrifugal force.
Stopping the yarn feed prior to the piecing process is not tied to a particular method here. For example, the fed-in fiber tuft can be deflected as long as is required by means of suction air directly downstream of the feed table. On the other hand, it is also possible to displace this point of the fiber flow deflection into the area of the fiber feed channel (for example, see DE 31 18 382 A1). It is only important that the fiber feed is completely stopped in the piecing phase in which the curvature of the yarn is formed.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in greater detail in what follows by means of exemplary embodiments. The associated drawings show in
FIGS. 1 a and 1 b , various variations of the generation of cover yarn in the course of spinning with a leading tie-in zone,
FIGS. 2 a and 2 b , various variations of the generation of cover yarn in the course of spinning with a trailing tie-in zone,
FIG. 3, a channel plate adapter with air outlet openings arranged around the draw-off nozzle for creating a rotating air flow,
FIG. 4, a lateral view of FIG. 3, showing the rotor in addition,
FIGS. 5 a to 5 c , various movement phases of the rotor during the piecing process for creating a trailing tie-in zone,
FIG. 6, the chronological sequence of the winding speed of the rotor in the phases in accordance with FIGS. 5 a to 5 c ,
FIG. 7, a front view of the essential spinning elements of a rotor spinning arrangement,
FIG. 8, a lateral view of the working element of a spinning box,
FIG. 9, a sequence of the yarn return for creating a trailing tie-in zone,
FIG. 10, a lateral view of the working elements of a spinning box, partially modified for the execution of the sequence represented in FIG. 9,
FIG. 11, a lateral view essentially showing the spinning chamber, as well as a piecing cart arranged in front of the spinning box, respectively in partial views, and
FIG. 12, a front view of the essential spinning elements of a rotor spinning arrangement, with a suction device for the temporary deflection of the sliver.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The phases of the tie-in of a single fiber 4 during spinning with a leading tie-zone, i.e. alignment of the yarn leg 3 in the direction of rotation of the rotor, are represented in FIG. 1 a , wherein this single fiber 4 reaches the rotor groove 1 from the fiber slide surface 2 at a time when its front end is grasped in the tie-in zone 5 of the yarn leg 3 (phase 1 ). It can be easily seen that the fiber twist direction in the yarn leg 3 is Z-twist. In contrast to this, the fiber 4 , whose tip has been grasped, is initially wound in S-turns around the yarn surface, as can be seen in phase 2 . In the course of the further yarn draw-off VL, the tip of the fiber 4 nears the point at which further portions of the fiber 4 are wound around the yarn surface at that instant. A change in the direction of twist from S to Z takes place in phase 4 , in the course of which several concentrated wraps can be created. These wraps as a whole tie the yarn together and form so-called belly bands, which can be in the way in the later processing stage and as a whole reduce the quality of the yarn. In phase 5 it can also be seen that the remainder of the fiber 4 is wound up in a Z-twist, i.e. the same twisting as the remaining yarn.
If the end of the fiber 4 is initially spun onto the tie-in zone 5 (FIG. 1 b ). the following sequence results: in phase 1 , the fiber meets the tie-in zone and is grasped in phase 2 by the yarn leg 3 in the area of the tie-in zone 5 . The fiber tip of the fiber 4 follows the direction of rotation ω G of the yarn around its own axis and is drawn off in a Z-twist until it is completely drawn out of the rotor groove 1 and is wound around the yarn core (phases 3 to 5 ), while the fiber end is wound in an S-twist around the fiber core. The fiber is not solidly bound into the yarn core, but rests loosely around the yarn surface.
But in FIGS. 2 a and 2 b it is shown how the tie-in of an individual fiber 4 to the yarn leg 3 takes place within the tie-in zone 5 if spinning is performed with a trailing tie-in zone 5 , i.e. with a curvature of the yarn leg opposite the direction of rotation of the rotor.
FIG. 2 a shows in phases 1 to 5 how a fiber 4 , coming from the fiber slide surface 2 , reaches the tie-in zone 5 with its tip and is wound around the yarn surface. It can be seen here that from the start the fiber 4 is tied to the yarn leg 3 in the same twisting direction as all other fibers. Only the pitch of the twist differs slightly from the other fibers. The same occurs in accordance with FIG. 2 b if the fiber initially meets the tie-in zone 5 with its end.
Therefore the yarns produced in this manner do no longer contain fibers with a twisting direction different from the normal yarn twisting direction. Above all, wraps are no longer created because of a change in the twisting direction, which would affect the yarn quality, and therefore the possibilities of use of the spun yarn.
Since in the course of a normal piecing process a curvature in the direction of the rotation of the rotor inevitably results because of the air flow rotating along with the rotor, it is necessary to take measures for creating the opposite direction of curvature of the yarn leg.
A first variation for the creating in accordance with the invention of a trailing tie-in zone is represented in FIGS. 3 and 4 and will be described in greater detail in what follows.
A channel plate adapter 10 , which can be inserted into a channel plate, supports a draw-off nozzle 11 with a nozzle opening 13 , as well as radial notches 12 , known per se, which are used for increasing the spinning dependability. Air outlets 14 which, as indicated by the arrows 15 , have a tangential direction component, terminate radially outside the draw-off nozzle 11 . Furthermore, a fiber guide channel terminates axially and radially offset, of which the mouth opening 16 ′ can be seen. The arrow 17 indicates that this fiber guide channel, too, has a tangential orientation, which can be seen more clearly in FIG. 7 . The tangential direction components 15 and 17 are oppositely directed.
The air outlets 14 are supplied via an annular channel 19 , which itself is connected to a compressed air source, not represented, via a compressed air supply device 20 and a valve 21 .
The compressed air supply device 20 can also be connected to a so-called piecing aid which, by means of an air feed, causes a rotor flushing of the rotor prior to the actual piecing process after fibers had been pre-fed for fiber tuft equalization which are not to be made available for the piecing process. A device as described in DE 197 09 747 A1, for example, would be suitable for this. Therefore it is not necessary to address further details here.
As can be seen in FIG. 4, the annular channel 19 is created by an appropriate shaping of the base body of the channel plate adapter 10 , together with a cap 22 which has the air outlets 14 . The nozzle opening 13 terminates in a yarn draw-off tube 18 , through which the yarn end is introduced for piecing and, after piecing, is continuously drawn off during the spinning process.
The tangential direction of the fiber flow indicated by 17 , which is caused by the orientation of the fiber guide channel 16 , corresponds to the direction of rotation of the rotor during its operation. In contrast to this, the air rotation direction (see arrows 15 ), which can be achieved by feeding compressed air through the air outlets 14 , is directed opposite the direction of rotation of the rotor. The air supply is limited to a first piecing phase by means of the valve 21 , during which the yarn end is introduced into the rotor through the yarn draw-off tube 18 and the nozzle opening 13 . When the yarn end reaches the rotor groove 1 , this rotating air flow must assure that the yarn end is curved opposite the direction of rotation of the rotor. After rotor revolutions which apply sufficient centrifugal forces to the yarn end have been reached, flipping of the direction of deposit of the yarn end is no longer to be expected. The further spinning process can be solidly performed with a trailing tie-in zone.
A further variation for obtaining an appropriate curvature of the yarn leg 3 is represented in FIGS. 5 a to 5 c and 6 .
FIG. 5 a shows a rotor 6 , whose direction of rotation, or angular speed ω R <0, i.e. has been set opposite the direction of rotation of the rotor during its operation. The yarn leg 3 , introduced into the rotor 6 through the draw-off nozzle 7 , is accordingly deflected into this direction of rotation of the rotor when it reaches the rotor groove. In this case the vacuum supply to the rotor housing should be turned off, in order not to create an opposite rotational flow because of the tangential termination of the fiber guide channel.
FIG. 5 b shows the stopped rotor (ω R =0) while the yarn leg 3 remains in the position it has reached in accordance with FIG. 5 a . FIG. 5 c then shows the run-up of the rotor in the direction of rotation during its operation (ω R <0). In the course of this the direction of curvature of the yarn leg 3 is maintained. The acceleration must be limited in such a way that flipping of the direction of curvature of the yarn leg 3 into the direction of rotation of the rotor is prevented.
FIG. 6 shows the sequence of movements of the rotor in the first phase of the piecing process, in which the curve 8 shows a variation in which the direction of rotation of the rotor is switched directly from reverse running to forward running. But the curve 9 shown in dashed lines shows a dwell time )t of the stopped rotor. These sequences of movement are primarily a function of the drive mechanisms used. Different variations of such drive mechanisms will be discussed in greater detail below.
In FIG. 7 it is shown how a sliver 28 , which is guided between a clamping spot between a feed roller 26 and a clamping table 27 , comes into the area of the teeth of an opening cylinder 24 , which rotates in the interior of an opening cylinder housing 23 . When the sliver leaves the clamping spot between the feed roller 26 and the clamping table 27 , it is opened into individual fibers by means of the opening cylinder 24 , and dirt particles are removed through a dirt removal opening, 25 . The fibers, which have been combed out by means of the opening cylinder 24 , then reach a fiber guide channel 16 , through which they are aspirated by means of the vacuum prevailing in the rotor housing and are further accelerated. By means of the increasing taper of the fiber guide channel 16 , the fiber flow 29 is accelerated and the fibers are further stretched in the process. The fiber guide channel 16 opens at a fiber guide channel opening 16 ′ into the rotor in such a way that the fibers meet the fiber slide surface 2 of the rotor 6 tangentially and are further accelerated by the rapidly rotating rotor 6 and are stretched.
Because of the trailing tie-in zone, the direction of orientation of the fibers is not again changed even in the course of the yarn formation, because the yarn end is oriented toward the mouth 16 ′ of the fiber guide channel 16 , as can be seen in FIG. 7, and therefore the fiber tips are first tied to the yarn end. In contrast to this, with a leading tie-in zone the fiber ends are first tied to the yarn end.
FIG. 8 shows the components 30 of a spinning box which are part of the spinning process. The rotor shaft 6 ′ of the rotor 6 is radially seated in a support ring bearing 40 , i.e. between the nips of support rings 41 , 42 arranged in pairs. An axial bearing 43 of the rotor is arranged at the end of the rotor shaft 6 ′, which radially fixes the rotor in place in both directions. This can be a magnetic radial rotor bearing here, such as described and represented in DE 198 19 767 A1, for example.
The rotor 6 is arranged in a rotor housing 33 , which is connected via a suction line 46 with a vacuum source 47 , so that a permanent spinning vacuum prevails in the rotor housing 33 . This spinning vacuum primarily provides that the fibers are aspirated through the fiber guide channel 16 into the rotor 6 .
A channel plate 32 is arranged in a pivotable cover element 34 and supports a channel plate adapter 31 . The cover element 34 can be pivoted around the pivot shaft 35 , by means of which the rotor housing 33 is opened. In this state the rotor 6 can be cleaned or removed, for example. Accordingly, this cover element 34 is opened prior to the piecing process by a service unit, which customarily can be displaced along the rotor spinning machine in order to perform the cleaning of the rotor.
The opening cylinder 25 is also seated by means of a bearing bracket 39 in the pivotable cover element 34 and is driven via a wharve 38 by means of a tangential belt 37 . A driveshaft 36 drives the feed roller 26 by means of a worm drive, not represented here. On its front end, the feed roller has a crown 26 ′, on which a drive mechanism of the piecing cart can be placed in order to be able to perform the driving of the feed roller 26 , controlled by the piecing cart, during the piecing process.
The rotor 6 is driven via its rotor shaft 6 ′ by means of a tangential belt 48 , which during its operation is maintained in frictional contact with the rotor shaft 6 ′ by means of a pressure roller 49 . Customarily this tangential belt extends over the entire length of the rotor spinning machine, so that it drives all rotors on a side of the machine.
A drive motor 44 is additionally provided which, by means of a friction wheel 45 , acts on one of the support rings 41 as soon as it has been brought into contact with it. For this purpose this drive mechanism is arranged to be moved toward or away from the support ring 41 , as indicated by the two-headed arrow, by means of a lifting device, not represented. This additional drive mechanism 44 , 45 is employed during the first phase of the piecing process in order to create an oppositely-extending direction of rotation of the rotor when the contact roller 49 is lifted off, and with it also the tangential belt 48 , such as explained in the course of the description of FIGS. 5 a to 5 c . Since this drive mechanism does not have to provide high numbers of revolutions, it can be of very small size.
It would also be alternatively conceivable to arrange the drive mechanism on the service unit and to introduce it into the spinning box through the rotatable cover element 34 .
The reversal of the direction of rotation of the rotor could also be accomplished in that a second tangential belt is extended over the entire length of the machine, whose direction of movement is opposite that of the tangential belt 48 . Then this second tangential belt would be temporarily pressed against the rotor shaft 6 ′ by means of a second contact roller during the first phase of the piecing process.
Alternatively to the generation of the opposite direction of rotation it would also be conceivable to employ individual drive mechanisms for rotors, whose direction of rotation can be easily reversed. Such an individual drive mechanism is described by way of example in DE 198 19 767 A1. It is therefore not necessary to provide a detailed description of such a drive mechanism at this point.
A further method for forming the curvature of the yarn 3 opposite to direction of rotation of the rotor is represented in six phases in FIG. 9 . The first phase shows the customary feeding of the yarn through the yarn draw-off tube into the spinning chamber, or the rotor, by means of the effects of the vacuum (spinning vacuum) prevailing in the spinning chamber.
In a second phase the yarn 3 is deflected around the draw-off nozzle 7 into a suction channel 51 (see FIGS. 10 and 11 ). This takes place in that the spinning vacuum is switched off and an auxiliary air flow is generated in the suction channel 51 . After the end of the yarn 3 has been aspirated sufficiently far into the suction channel 51 , it is clamped by means of a clamping device 50 (only schematically indicated in FIG. 9) in the suction channel 51 (phase 3 ).
In phase 4 , additional yarn is fed in through the yarn draw-off tube while the spinning vacuum is again applied and the rotor is started in its customary running direction. By means of this a loop is formed in the yarn 3 , which extends in the direction of the rotor rotation.
In phase 5 the clamping by the clamping device 50 is released after sufficient yarn has been introduced into the rotor 6 , so that the deposition of the yarn end 3 opposite the direction of rotation of the rotor is assured.
Phase 6 shows that the yarn end coming out of the suction channel 51 is deposited in the rotor groove 1 .
It is shown in phase 7 that in the course of the continued run-up of the rotor the yarn is drawn-off the rotor as rapidly as possible, in particular to avoid a larger overlap between the yarn and the further fed-in fibers. While no fibers must be supplied to the rotor in phases 1 to 6 in order to avoid the flipping of the yarn end in the direction of rotation of the rotor, the full fiber flow must be available suddenly in phase 7 in order to have a sufficient amount of fibers available in the rotor collecting groove 1 , which can be tied to the yarn end. It is assured in this way that the cross section and the solidity of the so-called piecer approach that of the normal yarn as closely as possible.
FIG. 10 shows a suction/clamping device 53 in the suction channel 51 . If it is possible to set the fed-in length of the yarn by means of a yarn feeding device 60 (FIG. 11) exactly in such a way that an exactly predetermined length of the yarn is aspirated in the suction channel, it is merely necessary to provide a clamping device. A more detailed representation of such a clamping device has been omitted here, since only the blade is omitted there.
But if the yarn is to be cut to size in the suction channel 51 , it is necessary to provide a suction/clamping device 53 . An actuating switch 54 is coupled with the suction/clamping device 53 and can switch the latter on and off. As shown in FIG. 11 in connection with this, an actuating rod 55 is arranged on the piecing cart 58 , which can act on the actuating switch 54 in a controlled manner. The piecing cart 58 moreover contains a suction tube 56 , which can be connected by means of a sealing element 57 to the suction channel 51 . By means of this the auxiliary air flow can be generated, chronologically controlled, in the suction channel 51 for forming the yarn loop in the end.
A support of the piecing cart 58 can also be seen and has a roller which supports it along the spinning machine against the respective boxes in the course of the displacement of the piecing cart 58 .
The switching processes, as well as the supply of the auxiliary air flow, can also be performed by the spinning station itself. The same vacuum source which provides the spinning vacuum can be used for this. In this case in particular the cutting to size of the yarn 3 by means of the clamping/cutting device 52 is advantageous.
A variation is represented in FIG. 12, which shows a possibility for deflecting the fiber flow. A suction connector 61 is connected via a valve 63 with a suction air source 62 . This suction air source 62 can again be arranged on the piecing cart or on the spinning station itself. If suction is applied to the suction connector 61 , the sliver fed in by means of the feed roller 26 over the clamping table is kept away from the fittings of the opening cylinder 24 and is therefore not further combed out. After a short running time of the opening cylinder with a supply of sliver, no fibers are present anymore on the opening cylinder 24 . The shut-off of the suction air at the suction connector 61 by means of the valve 63 takes place early enough so that, when the phase 7 from FIG. 9 has been reached, the fiber flow is fully available again in the rotor. However, other arrangements of the suction connector 61 along the running direction of the opening cylinder 24 , or even in the fiber guide channel 16 , are also conceivable.
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It is the object of the invention to propose a method for open-end rotor spinning, wherein the formation of cover yarn, in particular the so-called “belly bands”, is at least appreciably reduced.
In accordance with the invention, the fiber flow exiting a fiber guide channel has a directional component in the direction of rotation of the rotor, while the yarn leg ( 3 ) extending, from the draw-off nozzle to the rotor groove, is curved opposite the direction of rotation of the rotor, at least near the rotor groove ( 1 ), during the spinning process. The creation of this direction of curvature of the yarn leg ( 3 ) takes place during the piecing process.
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FIELD OF THE INVENTION
This invention relates generally to paper making machines and more particularly to the dryer section of such a paper making machine and, still more particularly, to apparatus for use with such a dryer section for enhancing the removel of moisture and thereby enhance the drying of the paper being dried in said dryer section.
BACKGROUND OF THE INVENTION
It is known that in the dry or drying end section or portion of a paper making machine the moisture-bearing paper web is directed along a serpentine path in wrapping relation with drying cylinders or drums arranged in tiers and having the cylinders in one tier staggered with respect to the cylinders or drums in the other tier. The dryer drums are heated, as by steam, and the traveling paper web is urged against the heated drums as by a porous, air-permeable endless support band which may be a felt generally woven from cotton or a plastic wire fabric belt. Generally, each tier of drying cylinders has such a support band or felt associated therewith. That is, the upper support band or felt presses the paper web against the drying cylinders of the upper tier while the lower support band or felt presses the paper web against the drying cylinders of the lower tier. As is known in the art, the respective support bands run between pairs of drying cylinders over a deflecting means such as, for example, a guide roller. In its travel as from an upper to a lower situated drying cylinder, or vice-versa, the paper web runs freely, that is, without in any way being supported by one of the support bands. As a consequence of such an arrangement a pocket is created and defined as between the lengths of run-on and run-off of paper web (as between succeeding drying cylinders), the uncovered portion of a drying cylinder and the juxtaposed portion of the support band, of the other tier of drying cylinders, juxtaposed to said uncovered portion of said drying cylinder. As is known and as should be apparent, usually there are a plurality of such pockets in the drying end section of the paper making machine. The moisture evaporating from such run-on and run-off portions of the paper web collects within such pockets and creates a condition of high humidity therein and interferes with the maintenance of a desired drying temperature.
In the prior art, such moisture or vapor within the pockets is attempted to be removed therefrom as by causing the vapor to flow through the porous support belt or felt, or, generally laterally across and beyond the porous support felt and free running paper web.
U.S. Pat. No. 3,110,575 teaches the use of blast air blown through the support band or felt on one side of the related guide roll while, on the other side of such guide roll, a suction box is provided serving to receive vapors or moist air again passing out of the pocket and through the support band. In such an arrangement, of course, there is an attendant relatively high cost of construction and additional operating energy must be provided for the operation of the pumping means, for supplying the air blast, and for the operation of the suction boxes.
U.S. Pat. No. 3,427,727 discloses the use of an air blast box to provide air stream against and through the support band or felt. The air stream created is, in turn, peripherally contained or confined by a rectangular "air curtain" produced by a rectangular generally continuous slot or blow orifice. According to the patentee in said U.S. Pat. No. 3,427,727, the "air curtain" serves the purpose of permitting the blast of air to pass through the support band or felt with as little as possible attendant swirling of such air. However, a plurality of blow or air blast orifices 74--74 are provided in each of face of discharge plates 52 and 54 and such orifices 74 or more specifically, pairs of such orifices 74, within the blow zone between the box 28 and the support band, will create a plurality of respective swirl zones resulting in a loss of flow through the support band or felt. As a consequence high energy usage and losses are experienced in the creation of the air stream in the arrangement of said U.S. Pat. No. 3,427,727. Further, the box or apparatus 28 (of U.S. Pat. No. 3,427,727) supplies such air to both sides of the related guide roll 20. Consequently, the moisture laden air within the pocket can move out of such pocket only by moving laterally, with respect to such support band and paper web. This type of flow, in turn, causes the edges of the paper web to flutter (much as the free end of a flag in a strong wind) thereby increasing the danger of having the paper web tear.
The invention as herein disclosed and described is primarily directed to the solution of the foregoing as well as other related and attendant problems of the prior art.
SUMMARY OF THE INVENTION
According to the invention, an air blast apparatus for a dryer section of a paper making machine having a plurality of drying cylinders comprising an upper tier and a lower tier for having a paper web trained therethrough, an endless gas-permeable support band urged against the paper web while the paper web is trained over the drying cylinders in the upper and lower tiers, a pocket formed generally by run-off and run-on portions of said paper web as said paper web passes from a first drying cylinder of one of said tiers to a drying cylinder of the other of said tiers and from said drying cylinder of said other of said tiers to a second drying cylinder of said one of said tiers, guide roller means situated generally between said first and second drying cylinders, said pocket being also formed by said endless support band as it passes from said first drying cylinder about said guide roller means and to said second drying cylinder, said air blast apparatus comprising air blast housing means situated as to extend transversely to the running direction of said endless support band, blow orifice means carried by said air blast housing means, said blow orifice means comprising a continuous ring slot orifice, said continuous ring slot orifice circumscribing a generally centrally situated land portion, said continuous ring slot orifice comprising first and second longitudinal slots extending generally transversely of the running direction of said endless support band, said first longitudinal slot being the first of said longitudinal slots traversed by said support band in the running direction of said support band, said second longitudinal slot being the second of said longitudinal slots traversed by said support band in the running direction of said support band, the blow direction of said first longitudinal slot being generally normal to the running direction of the support band running therepast, and the blow direction of said second longitudinal slot being at an obtuse angle with respect to the running direction of the support band running therepast.
Various general and specific objects, advantages and aspects of the invention will become apparent when reference is made to the following detailed description considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings wherein for purposes of clarity certain details and/or elements may be omitted from one or more views:
FIG. 1 is a schematic view of a portion of the dryer section of a paper making machine illustrating an air blast apparatus employing teachings of the invention;
FIG. 2 is a view of the air blast apparatus of FIG. 1 taken generally in the direction of arrow II of FIG. 1;
FIG. 3 is a fragmentary cross-sectional view, in relatively enlarged scale, taken generally on the plane of line III--III of FIG. 2 and looking in the direction of the arrows; and
FIG. 4 is a fragmentary cross-sectional view, in relatively enlarged scale, taken generally on the plane of line IV--IV of FIG. 2 and looking in the direction of the arrows.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now in greater detail to the drawings, FIG. 1 illustrates the usual arrangement of two tiers of drying cylinders or drums with the upper tier being comprised of drying cylinders 11 and 13 and the lower tier being comprised of drying cylinders of which the one at 12 is typical. The paper web 10 to be dried runs or passes alternately over an upper tier cylinder, such as at 11, and lower tier drying cylinder, such as at 12, and then again over an upper tier cylinder, such as at 13. While the paper web 10 passes over the upper tier drying cylinders 11 and 13, such paper web is pressed against the upper drying cylinders 11 and 13 by an upper situated endless air-permeable support belt or band 14 running in synchronous speed with the paper web 10. The lower situated endless air-permeable support band, functionally equivalent to support band 14, associated with drying cylinder or rollers means 12 has been omitted from the drawings. Between pairs of drying cylinders, as depicted by cylinders 11 and 13, the support band 14 passes over and generally about guide roller means 15. As a consequence, and as generally previously discussed, a so-called pocket 16 is formed and defined as by the lower drying cylinder 12, the paper web 10 run-off from drying cylinder 11 onto the lower drying cylinder 12, the paper web run-off from drying cylinder 12 onto drying cylinder 13 and the support band 14 portion generally spanning the distance between adjacent drying cylinders 11 and 13. As should be apparent, especially in view of the prior art herein specifically referred-to, a plurality of such pockets are usually formed and, with respect to FIG. 1, similar pockets could be formed to either side of lower drying cylinder 12 with, in such cases, drying cylinders 11 and 13 forming respective one ends of such pockets.
An air blast box or apparatus 20, embodying teachings of the invention, is disposed generally between drying cylinders 11 and 13 and is situated relatively closer to drying cylinder 11 from which the support band or felt 14 runs-off toward guide roller means 15. It is precisely in this run-off zone of the support band 14 that the air blast box means 20 has blow orifices so that hot air, provided by the air blast box means and associated blow orifices, passes through the support band 14, in such run-off zone, and into the pocket 16. There is a natural tendency for the vapors within the pocket 16 to experience a generally clockwise flow, about guide roller means 15 as generally depicted by the arrows in FIG. 1. Such vapor flow, caused by the pumping action resulting from the running of the support band 14, results in a vapor flow out of the pocket 16 through support band 14 generally in the area between guide roller means 15 and drying cylinder 13; such may be considered as being generally at the back side of the air blast box 20. Such pumping action and air or vapor flow leaving pocket 16, brought about by the pumping effect of running support band 14, is intensified and enhanced by the air blast box means 20.
Referring to FIG. 2, it can be seen that the air blast box means 20 comprises a plurality of slot type air blast orifices 21 which, effectively, surround respective field or plate portions 25. In the preferred arrangement, the field or plate portions 25 are each of a parallelogram outer configuration and the orifices 21 are endless "ring slots" with each ring slot 21 comprising two longitudinal slot portions 22 and 23 and two transverse slot portions 24--24. It is to be understood that the term or expressions, ring slots, or ring slot, is intended to encompass all possible forms or configurations of endless slot blow orifices, respectively surrounding a certain area or body portion, and not merely a configuration of a circular ring.
Referring to FIG. 3, it can be seen that the blow direction, of what in the running direction of the support band 14 is the first longitudinal slot 22 forms a substantially right angle "a" with the running direction of the support band 14. However, it has been determined that acceptable results are achieved when the magnitude of the direction angle "a" is in the order of 70° to 110°. In the preferred embodiment, the air blowing direction, of what in relation to the running direction of the band 14, is the second longitudinal slot 23, is inclined with respect to the running direction of the support band 14. That is, the direction of air blow through and from slot portion 23, preferably, forms an obtuse angle "b", of a magnitude in the order of 100° to 140°, with the running direction of support belt or band 14. As possibly best illustrated in FIG. 4, the transverse slot portions or section 24 of a single ring slot 21 may be so formed or inclined as to cause the direction of the air blow therefrom to be directed generally toward each other. However, in another embodiment of the invention not shown in the drawing, the blow direction of such transverse slot segments may form a substantially right angle with the plane of the wall members 25.
From FIGS. 3 and 4 it can be seen that in the preferred embodiment the medially situated wall or land portion 25, defining the inner boundary of the continuous slot 21, is operatively secured to the adjacent wall or support structure as by a plurality of bridging bracket means 26.
Preferably, the interior of the air blast box means 20 is divided into several chambers or compartments as by means of transverse walls 27 in such a manner as to have a ring slot 21 for each such chamber or compartment. Even though only a single air feed channel means 28 is illustrated as supplying all of such plurality of chambers (leading to respective ring slots 21) it should be understood that separate air feed passages may be employed with respective ones thereof communicating with respective ones of such chambers or compartments (leading or feeding respective ring slots 21).
With the invention, the use of circular blow orifices as at 74--74 of U.S. Pat. No. 3,247,727 for the creation of the air stream is no longer necessary. It has, in fact, been discovered that with ring slots of the invention it is possible to create one or more annular-like air curtains and thereby create a very effective air stream through the support band with even a very low expenditure of energy. This is believed due to the fact that the two longitudinal slots 22, 23 form very concentrated, laminar air jets which pass through the support band without any appreciable disturbance to flow. Further, the air being blown through the continuous ring slot 21 of the invention forms a continuous and peripherally endless air curtain the interior of which experiences an air pressure cushion which continually exists as between the air blast box 20 and the juxtaposed portion of the support band means 14 thereby assuring a high volume of air flow, in such region, through the support band means 14.
The ring slots 21 of the invention may have varying forms or configurations, especially when and if several ring slots 21 are arranged in a row, or in two rows lying side-by-side. Very successful results have been obtained when the ring slots 21 of the invention have been made in the form of slender parallelograms or trapeziums. By doing so the paper web 10, as in the run-off and run-on portions, is pressurized as uniformly as possible by the air stream so that local overheating or moist stripes in such paper web are avoided. Further, it has been discovered that the ring slots 21 of the invention may also be triangular and/or arcuate segments. In an arrangement of two adjacent rows, ring slots 21 of pentagonal configuration are possible. Where transverse slot portions are provided, it is advantageous to incline their air blowing direction toward a generally medial or central location with respect to the ring slot.
Further, the air blast box 20 of the invention can be arranged or situated at a relatively great distance from the nearest drying cylinder, as cylinder 11. As a consequence of that, there is no danger, when waste occurs, as is never quite avoidable (as in the case of so-called packing or jamming of the drying cylinder 11), that the support band or felt 14 might come into contact with the air blast box means 20. Further, in such an arrangement, sufficient space exists between the drying cylinder 11 and the air blast box 20 to pass through a pull-in rod when inserting a new support band 14.
In order to positively assure that virtually the entire flow of air issuing from air blast box 20 passes through the support band 14 into pocket 16, a suitable sealing strip 30 is provided as between air blast box 20 and guide roll means 15. Such sealing means 30 may operatively engage or come into close but spaced relationship with guide roll means 15.
Also, it should be pointed-out that the above-described air flow, which passes into and through pocket 16 and from pocket 16 upwardly through the support band 14 at the back of air blast box 20, is totally sufficient for increasing the capacity of the overall drying end section and for the removal of moist air. Therefore, the provision of suction means as disclosed in U.S. Pat. No. 3,110,575 may be omitted.
In said U.S. Pat. No. 3,110,575 the patentee attempts to control the so-called moisture profile of the paper web by varying the air streams in adjacent air blast zones. That is, it is desirable that the finished paper web has a residual moisture content, over its entire width, which is as uniform as possible. Structures employing the teachings of said U.S. Pat. No. 3,110,575 have not been successful in achieving the desired uniformity. However, it has been discovered that air blast boxes according to the invention provide surprisingly uniformity in residual moisture content in the paper web. Even though the reasons are not, for certain, known, it is believed that such uniformity of residual moisture is achieved because the air blast issuing from a selected ring slot 21 does not spread in transverse or lateral directions (relative to the paper making machine), or does so only very slightly, before it impinges on the paper web.
As should be apparent, air blast boxes 20 may also be provided as between successive drying cylinders of the lower tier, of which cylinder 12 may be one, in the manner as disclosed with reference to the upper tier.
Although only a preferred embodiment and selected modifications of the invention have been disclosed and described, it is apparent that other embodiments and modifications of the invention are possible within the scope of the appended claims.
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In the dryer section of a paper making machine, the paper web is pressed against the drying cylinders by means of an air-permeable endless support band. An air blast apparatus extends transversely of the paper making machine and creates an air flow which is directed generally across and through the support band and onto the paper web. The air blast apparatus has at least one blow orifice in the form of a ring slot with two longitudinal slots extending generally longitudinally of the air blast box or housing of the air blast apparatus, and at least generally transversely of the paper web and the support band. The blowing directions of the two longitudinal slots may be at different angles with respect to the running direction of the support band.
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TECHNICAL FIELD
[0001] The present invention relates to an improved snap-ring retaining device for use within a vehicle transmission.
BACKGROUND OF THE INVENTION
[0002] A circlip or snap-ring is a substantially circular or annular retaining device having a break or opening which divides the ring into two interconnected curvilinear members. The members may be deflected or flexed to facilitate insertion into a mating groove. Snap-rings are typically formed, stamped, or otherwise constructed from a relatively thin layer of metal which directs a retaining or clamping force along the circumference or periphery of the snap-clip when properly inserted into the groove. The directional force is most commonly used to retain or clamp together various mating components.
[0003] The force vector imparted by the snap-ring varies with the type or style of snap-ring that is used and the location of the ring relative to the parts retained or mated. Two main styles of snap-ring are available: an internal snap-ring positioned within a mating internal groove and used for applying outwardly-directed clamping force, and an outer snap-ring positioned within a mating external groove for applying inwardly-directed clamping force. Of these two main types of snap-ring, internal snap-rings are of particular beneficial use within an automatic vehicle transmission.
[0004] With an internal snap-ring, the ring is compressed or contracted by deflecting the curvilinear beams or members of the ring and then inserted or “snapped” into a continuous groove cut into an inner circumferential surface of a drum, shaft, cylinder, or other component having an approximately circular cross section. Once inserted into the groove, the snap-ring is then released or retracted into its installed position, directing circumferential clamping force along the groove wall within the relatively restricted space of the groove. In this manner a snap-ring may restrict or minimize any undesirable lateral or axial motion between two or more mating parts, such as within a flange or flanges of a clutch hub and a mating drum within a transmission clutch assembly.
[0005] The insertion and removal of a snap-ring during the transmission assembly or build process may be relatively time or material intensive due to the difficulty of accessing various confined areas within the housing. For instance, a person installing a snap-ring must often insert or place the ring into an area having limited accessibility or installation clearance, while simultaneously exerting a substantial amount of force on the curvilinear beams of the snap-ring in order to open or close the ring. The space and force limitations may be considerable enough to necessitate the use of special-purpose capital equipment, potentially adding substantial cost to the assembly process. Additionally, the requisite strength or rigidity for higher-load applications may require a snap-ring formed from a proportionately thicker layer of material, which in turn may lead to an undesirable increase in overall axial space within a transmission case or other housing, resulting in the need for a larger case and/or the re-arrangement of other components within the system.
SUMMARY OF THE INVENTION
[0006] Accordingly, an improved retaining device is provided having a primary or main loop, a variable-width or compressible opening dividing the main loop into adjoining curvilinear beams or portions operable to exert a circumferential force when inserted into a mating groove or channel, and an additional minor or secondary loop connecting the curvilinear portions, and operable to modify the deflection or compressive force required to compress or deflect the curvilinear portions.
[0007] In one aspect of the invention, the opening comprises a plurality of generally parallel tabular extensions, each extension having sufficient surface area for applying compressive force to the main loop for flexing or bending of the curvilinear portions to facilitate installation of the retaining device. The tabular extensions are further configured to prevent rotation of the snap-ring within the mating circumferential groove.
[0008] In another aspect of the invention, a retaining device having an improved compressive or deflection force is provided in which an externally-projecting secondary loop reduces the compressive force required to compress or deflect the curvilinear portions of the main loop, thereby facilitating the installation of the retaining device.
[0009] In another aspect of the invention, a retaining device having improved rigidity is provided in which an internally-projecting secondary loop increases the compressive or deflection force required to compress or deflect the curvilinear portions of the main loop, thereby providing increased rigidity to the main loop.
[0010] In another aspect of the invention, a circular flange assembly is provided for use within a vehicle transmission, in which a substantially annular retaining device having a main loop and a minor secondary loop is inserted into continuous circumferential or peripheral groove in a flange wall, the main loop having a plurality of tabular extensions configured to prevent rotation of the main loop within the circumferential or peripheral groove.
[0011] In another aspect of the invention, a clutch assembly is provided for use within a vehicle transmission, in which an improved snap-ring retaining device is insertable in the mating grooves of a dual-flanged clutch hub and mating clutch drum to thereby retain the clutch hub and drum.
[0012] The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1A is a plan view of an improved snap-ring according to the invention having an outwardly-projecting secondary loop;
[0014] FIG. 1B is a plan view of an improved snap-ring according to the invention having an inwardly-projecting secondary loop;
[0015] FIG. 2A is a plan view of a clutch drum in combination with an improved internal snap-ring;
[0016] FIG. 2B is a side view of a double-flange clutch hub in combination with an improved snap-ring;
[0017] FIG. 3A is a schematic illustration showing a load deflection of a simplified straight or linear beam;
[0018] FIG. 3B is a schematic illustration showing an exemplary load deflection of a modified straight beam having the secondary outer loop of this invention; and
[0019] FIG. 3C is a schematic illustration showing a load deflection of a modified straight beam having a secondary inner loop.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Referring to the drawings wherein like reference numbers correspond to like or similar components throughout the several figures, there is shown in FIG. 1A a substantially annular or circular snap-ring 10 a comprising a primary or main loop 20 having a width 11 and configured by a main radius 44 drawn from a main center point 32 . An outwardly-projecting minor or secondary extend loop 22 a , preferably circular in shape, is configured by a secondary radius 46 a drawn from a secondary center point 30 a , the extend loop 22 a projecting radially outward from the circular periphery of main loop 20 . A pair of tabular extensions or tabs 24 a , 24 b , preferably aligned in a substantially parallel manner and positioned approximately 180° opposite secondary loop 22 a , define a normal unflexed or “free state” break or opening 26 a in main loop 20 . The unflexed opening 26 a is represented by the phantom or dotted-line profile in FIG. 1A . Center points 30 a , 32 are preferably aligned along a main loop axis 38 bisecting main loop 20 and secondary extend loop 22 a . Thus, main loop 20 has a first and second curvilinear beam portion 40 , 42 being at least partially flexible, compressible, or deflectable, by actuating tabs 24 a , 24 b disposed at the end of portions 40 , 42 , respectively. When curvilinear portions 40 , 42 are deflected by the application of a contracting clamping force to tabs 24 a , 24 b , a reduced-width or compressed opening 26 b results, as shown by the solid line in FIG. 1A .
[0021] In a preferred embodiment, main radius 44 and secondary radius 46 a are proportionately related by a ratio of approximately 25:1, with compressed opening 26 b , when substantially flexed or compressed, having a width approximately 0 to 5% of main radius 44 . When curvilinear portions 40 , 42 are in a “free state”, i.e. undeflected or unflexed, tabs 24 a , 24 b preferably form an unflexed opening 26 a , as shown by the phantom line in FIG. 1A , with a relative angle of approximately 40° between tabs 24 a , 24 b , although those skilled in the art will recognize that other deflection angles and loop ratios may be adapted and modified as necessary depending on the application. Tabs 24 a , 24 b are further preferably configured with a notch or series of notches 25 being sized and/or shaped to fit a ring compression tool (not shown), such as a pair of pliers, for assisting in compressing and inserting ring 10 a into, for example, a flange groove in the wall of a clutch housing.
[0022] Turning to FIG. 2A , a circular drum 54 , depicted herein as a representative clutch drum, is shown with a captive snap-ring 10 a as described hereinabove. Snap-ring 10 a is inserted into a channel or peripheral flange groove 50 positioned along the inner circumferential or peripheral surface 52 of the drum 54 , the groove represented in FIG. 2A as a dotted line. A first window or slot 55 a is positioned at one end of drum 54 generally opposite secondary loop 22 a , slot 55 a being appropriately sized to accept the elastically-deflectable tabs 24 a , 24 b of snap-ring 10 a to prevent relative rotation or spin of the snap-ring 10 a within the flange groove 50 . To obtain the rotational balance as well as to accommodate insertion and flexing of secondary outer loop 22 a , the bottom or opposite end of the drum 54 likewise has a substantially similar and preferably identical slot 55 b positioned approximately 180° opposite slot 55 a . Once compressed or deflected and inserted into flange groove 50 , and subsequently released, snap-ring 10 a returns to a position short of “free state” or unflexed opening 26 a (See FIG. 1A ), and so exerts a continuous outward circumferential clamping force along the surface of groove 50 , thereby providing axial support and noise reduction between the mating parts, such as, for example, between clutch drum 54 of FIG. 2A and mating clutch hub 62 of FIG. 2B .
[0023] Clutch hub 62 of FIG. 2B has a continuous outer circumferential channel or hub groove 60 disposed between a first and second flange 63 a , 63 b . Snap-ring 10 a is inserted into groove 60 between flanges 63 a , 63 b and compressed at tabular extensions 24 a , 24 b (see FIG. 1A ) as described previously herewithin. While holding snap-ring 10 a in a compressed position, hub 62 is inserted into mating clutch drum 54 (see FIG. 2A ). Tabular extensions 24 a , 24 b are held in compressed position until hub 62 is fully inserted into clutch drum 54 . Once the snap ring 10 a is aligned with flange groove 50 , the tabular extensions 24 a , 24 b of snap-ring 10 a are released, and the snap-ring 10 a partially opens or decompresses to at least partially fill mating flange groove 50 (see FIG. 2A ) while remaining at least partially within hub groove 60 . Tabular extensions 24 a , 24 b snap into place within slot 55 a , thereby preventing relative rotation of the snap ring 10 a within grooves 50 , 60 . For example, in the case of clutch hub 62 of FIG. 2B , the snap-ring 10 a would thereby retain the hub and drum, as would any splines on the mating surfaces of clutch drum 54 and hub 62 . For simplicity, mating splines are not shown on surface 52 of clutch drum 54 of FIG. 2A or on flanges 63 a , 63 b of hub 62 of FIG. 2B , which are the respective mating surfaces on which splines could be employed. By utilizing the described double-flange design, the contact area or power density between snap-ring 10 a and flanges 63 a , 63 b is thereby doubled, which may permit the amount and/or type of metal strengthening support components within the transmission component, such as splining, to be reduced in number and/or otherwise modified in appearance.
[0024] In an alternative embodiment of FIG. 1B , a snap-ring 10 b has an inwardly-projecting minor or secondary inner loop 22 b having a center point 30 b and a secondary radius 46 b . The primary advantages of a secondary inner loop are twofold. First, by positioning a secondary inner loop 22 b on the inside of main loop 20 , the outer dimension or periphery of snap-ring 10 b may be completely hidden within a groove positioned within a circular wall of, for example, a clutch hub. Additionally, in some circumstances installation space may be restricted or limited, and consequentially, a secondary extend loop of the type shown in FIG. 1A may not fit properly within the flange. Second, a secondary inner loop 22 b may be used to enhance the rigidity of a snap-ring 10 b , as an inwardly-disposed secondary loop requires greater force to achieve a given amount of annular deflection than does an outer-loop design, as discussed hereinbelow.
[0025] The deflection effect on a main surface due to the addition of a secondary surface of various size and position may be explained by using the simplified linear-beam profile of FIG. 3A in which a straight beam 70 a having a length L 1 is attached to ground 74 and subjected to an applied load P. In this example, load P imparts to beam 70 a a deflection δ, in which δ=P*(L 1 ) 3 /(3*E*I). In this deflection equation, variable E is Young's Modulus, commonly referred to as the modulus of elasticity, with variable I being the moment of inertia. Those skilled in the art will recognize that Young's Modulus E is a material-specific quantity, with a stiffer material providing a reduced magnitude of deflection, while the moment of inertia I varies with the shape of the beam profile.
[0026] FIG. 3B modifies the single-beam design by adding an outwardly-disposed minor beam 72 a having a length L 2 . Under this modified configuration, the force-deflection equation is modified to δ=P*(L 1 +L 2 ) 3 /(3*E*I). That is, the addition of an outwardly-disposed minor-beam 72 a increases deflection 6 for a given load P. In designing a snap ring according to the invention, deflection can therefore be customized by adapting a specific size and shape for the inner and outer loops, by changing ring material, or by modifying the shape of the ring, as indicated by the force-deflection equations.
[0027] By contrast, FIG. 3C shows an inwardly-disposed minor beam 72 b having a length L 2 equal to length L 2 of FIG. 3B . In this example, deflection 6 =P*(L 1 −L 2 ) 3 /(3*E*I). The addition of minor-beam 72 b therefore decreases deflection 6 for a given load P, that is, 72 b imparts stiffness or rigidity to the beam as described previously herewithin. When this deflection effect is applied to a curved beam or a beam of another non-linear shape, such as a snap-ring, the corresponding force-deflection equations consider the radii of the inner and outer loops in determining beam length and linear deflection. Note, however, that the general relationship of inverse proportionality between deflection and both moment of inertia and Young's Modulus, as illustrated in the simplified designs of FIGS. 3A-C , holds true independent of beam shape and can be used by those skilled in the art to design a snap-ring for a given application, in accordance with the teachings of this invention. While the minor beams (secondary loop 22 a , 22 b of FIGS. 1A , 1 B) are preferably circular, they may also take another suitable shape such as an oval or a parabola to further increase or reduce the moment of inertia in the aforementioned manner.
[0028] While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims.
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A retaining device or snap-ring for retaining a mating hub and drum within a transmission is provided. The device is insertable into a groove along the inner circumference of a circular flange and includes a main outer loop, an opening for dividing the snap-ring into two deflectable curvilinear portions and at least partially defined by a tabular extension projecting from each curvilinear member. The tabular extensions provide sufficient surface area for applying deflective or compressive force to the snap-ring and are contoured to facilitate use of a deflection tool. The snap-ring further comprises an externally-projecting secondary loop for reducing deflection force, or an internally-projecting secondary loop for increasing deflection force. The snap-ring may be used within a double-flange hub having a plurality of slots for facilitating insertion of the secondary loop and the tabular extensions within the flange groove.
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TECHNICAL FIELD
[0001] The present invention is related to the production of ultra-clean surfaces and more particularly for a method of cleaning flexible webs.
BACKGROUND
[0002] It is known that in modern industry there are some production processes, e.g. the manufacture of silicon wafers for microprocessors, where the tiniest speck of debris may be damaging. Certain techniques are known for the removal of even ultra-fine particles from such hard surfaces. However, more recently with increased industry movement to lighter, thinner devices both optical and electronic, the requirement for ultra-clean materials has spread to high-volume roll-to-roll production using webs of materials. While webs of hard materials, e.g. stainless steel, have been seen in this expanding market, more often polymeric materials are desired for their flexibility and optical transparency. In the same way that tiny debris can be damaging to silicon wafers, tiny debris can be a significant problem in the roll-to-roll processing of webs with the additional complications of their being many times the area needing to be cleaned, and usually, the presence of much softer surfaces. Still, webs of hard and opaque materials can benefit from cleaning of small particles from the surface.
SUMMARY
[0003] The present invention provides a method of cleaning a web of material, particularly relatively soft polymeric webs, without using dipping baths or ultrasonic energy. In one aspect, the method includes: supporting the web with a backup roller; spraying a first surface of the web with a high pressure liquid while a second opposing surface of the web is in contact with the backup roller; and directing a gas curtain at the first surface, after spraying, while the opposing second surface is supported by the backup roller. A number of fluids are considered suitable for the spraying, but ultra pure water, de-ionized water, water containing a surface-active agent, organic solvents, and high specific gravity fluids, are considered particularly convenient depending on the type of web to be cleaned. It is particularly convenient to pre-filter the fluid being used in connection with the present invention.
[0004] In another embodiment, the web of material is contacted with a cleaning roll while the web is in contact with the backup roller. A cleaning roll having a porous, knobby surface has been found useful, and is conveniently made from polyvinyl alcohol (PVA) or its variants. The knobby roll can have cylindrical mesas or other patterned mesas. It is typical for the cleaning roll to be fed internally with fluid transferred radially out through the pores as it rubs against the web in a direction opposite to the web's direction of movement. The knobby roller is compressed typically from 0.5 to about 2.5 mm measured radially as it is nipped against the web and backup roller. The method may optionally include wetting the web material prior to contacting it with the cleaning roll. This method may optionally include utilizing wetting agents or surfactants in the flow of the fluid through the knobby roller or as a dripped concentrate over the rotating surface of the roller.
[0005] In another embodiment, it is useful to perform parts or all of the method while retaining the web of material in a clean room having a particle-controlled atmosphere while cleaning the web. The web of material can be located in a clean room meeting the limits of Federal Standard 209 “Airborne Particulate Cleanliness Classes in Cleanrooms and Clean Zones.” In particular, the clean room can meet the conditions for Class 10,000, or Class 1,000, or Class 100, or Class 10 under Federal Standard 209.
[0006] In another aspect, the apparatus for cleaning a web of material includes: a backup roller positioned to wrap the web at least partially about the backup roll; a source of high pressure liquid connected to at least one nozzle for spraying the web while the web is supported by the backup roll; and a source of gas connected to an exit gas curtain located after the at least one nozzle, the gas curtain orientated crosswise to the direction of the web's travel and positioned for removing liquid from the web while the web is supported by the backup roll.
DESCRIPTION OF THE DRAWINGS
[0007] It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention, which broader aspects are embodied in the exemplary construction.
[0008] FIG. 1 illustrates a side view of a web cleaning apparatus according to the present invention.
[0009] FIG. 2 illustrates a side view of another embodiment of a web cleaning apparatus according to the present invention.
[0010] FIG. 3 illustrates a side view of another embodiment of a web cleaning apparatus according to the present invention.
[0011] FIG. 4 illustrates a side view of a web cleaning line.
[0012] Repeated use of reference characters in the specification and drawings (not drawn to scale) is intended to represent the same or analogous features or elements of the invention.
DEFINITIONS
[0013] As used herein, forms of the words “comprise”, “have”, and “include” are legally equivalent and open-ended. Therefore, additional non-recited elements, functions, steps or limitations may be present in addition to the recited elements, functions, steps, or limitations.
[0014] As used herein, “high pressure” is defined as about 500 psi (3.45 MPascal) to about 3000 psi (20.68 MPascal) with about 1000 psi (6.89 MPascal) to about 2500 psi (17.24 MPascal) being considered particularly convenient.
DETAILED DESCRIPTION
[0015] Referring now to FIG. 1 , a first embodiment of a web cleaning apparatus 10 according to the present invention is illustrated acting on a web 12 moving in direction D 1 . The flexible web 12 typically has a length significantly greater than its width. The flexible web's length can be indefinite for a polymeric web that is continuously formed and then cleaned, or it can be a predetermined length for previously formed flexible webs that are wound into a roll and then unwound for web cleaning. In various embodiments of the invention, the length of flexible web 12 can be greater than 10 feet (3.0 meters), or greater than 100 feet (30.4 meters), or greater than 1,000 feet (304.8 meters).
[0016] The flexible web 12 is supported by a backup roll 14 , which may be a driven or non-driven roll. The flexible web can be tangent to the backup roll (0 degrees wrap) or the flexible web can wrap a significant portion of the circumference of the backup roll for the necessary support. Suitable flexible web wraps can be between 0 degrees to about 270 degrees, or between 10 degrees to about 180 degrees. Particularly suitable wrap angles include 0 degrees, 90 degrees, or 225 degrees. Larger wrap angles can allow for multiple spray nozzles, multiple cleaning rolls, gas deflectors and other apparatus to be located about the periphery of the backup roll. While being supported by the backup roll, a first side 16 of the flexible web 12 is subjected to a high pressure liquid spray 18 to clean the first surface.
[0017] By stabilizing the flexible web on the backup roll 14 , several advantages occur when contacting the flexible web with the high pressure liquid spray. First, a precise high pressure spray can be employed since the flexible web is prevented from moving or displacing in response to the high pressure spray. The angle of the high pressure spray relative to the flexible web's surface can be precisely set and maintained. The distance between a spray nozzle 42 and the flexible web's surface can be precisely set and maintained. These process variables can be adjusted based on the spray pressure and the type of flexible web being cleaned. Secondly, less damage to the flexible web 12 can result. If an unsupported flexible web 12 was subjected to a high pressure spray 18 , the liquid impact can reposition, move or displace the web and is likely to cause web flutter. The web flutter can lead to web wrinkling and/or damage of the web's surface and inconsistent cleaning of the web's surface. For wide flexible webs, any cross-direction (CD) non-uniformity of the high pressure spray can cause twisting or fluttering of an unsupported span leading to non-uniform cleaning and severe web handling problems. Finally, an unsupported flexible web can require a greater machine direction (MD) tension to resist the spray's impact. A higher MD tension can permanently distort the flexible web, which is undesirable for some applications.
[0018] In general, the backup roll 14 can have a smooth, uniform surface to prevent damaging a second side 20 of the flexible web in contact with the backup roll. Additionally, it can have conductive properties to assist in controlling static charge generated by the flexible web leaving the roll. Suitable backup rolls can include metal rolls such as aluminum or steel, deformable rolls, rubber rolls, compressive cover rolls, graphite or non-conductive rolls, rolls having durable hard coatings, anodized rolls, rolls with conductive coatings, or other suitable web processing rolls.
[0019] The choice of backup roll material can be influenced by the selection of the high pressure fluid used in order to prevent corrosion issues. The backup roll should not be susceptible to shedding particles or coatings onto the second side 20 . The backup roll diameter can be determined based on deflection considerations and space considerations when designing the web cleaning apparatus
[0020] Additional equipment included in the web cleaning apparatus 10 include, a spray chamber 22 , an optional entry gas curtain 24 , an exit gas curtain 26 , an optional cleaning roller 28 , an optional drip bar 30 , and optional static neutralizers 31 . The spray chamber 22 is mostly enclosed and may closely conform to at least a portion of the backup roll's circumference. Suitable materials for constructing the spray chamber 22 include plastic and metal materials known to those of skill in the art. At the entrance and exit of the spray chamber 22 , the gaps between the spray chamber and the backup roll 14 are minimized to allow the flexible web 12 sufficient clearances to enter and exit the spray chamber without hitting the spray chamber. Alternatively, retractable flaps or doors, air knifes, and/or rollers can be provided that open for threading or splices and then close during normal operation. The spray chamber's CD width can closely conform to maximum CD width of the flexible web and the spray chamber's CD ends can closely conform to the backup roll's diameter. If desired, end seals can be used to seal the spray chamber's CD ends to the surface of the backup roll.
[0021] The spray chamber 22 includes a drain 32 and a bottom 34 of the spray chamber can be sloped to move liquid towards the drain. In some embodiments, the liquid is filtered and cleaned for additional use. The spray chamber 22 also includes at least one exhaust duct 35 . The exhaust duct 35 can be fitted with a demisting mesh 36 to reduce mist intake into the exhaust duct. Alternatively or in combination, a mist separator or aerosol filter can be used to remove the liquid from the exhaust gas. In one embodiment, the exhaust duct 35 sloped upwardly away from the spray chamber to drain liquid into the spray chamber. In another embodiment, the exhaust duct 35 is operated to induce a negative gas pressure in the spray chamber 22 or to reduce the gas pressure inside the spray chamber resulting from the high pressure spray and gas curtains. A low or negative spray chamber air pressure minimizes or eliminates mist from exiting the spray chamber and can be set to minimize the draw of ambient air into the spray chamber 22 at any open draft areas between the spray chamber, the backup roll 14 , and the web 12 . Suitable air pressures inside the spray chamber can be between about between about −0.001 inches of water gage to about −0.50 inches of water gage, or between about −0.001 inches of water to about −0.1 inches of water gage. In some embodiments, −0.032 inches of water gage and −0.05 inches of water gage are used.
[0022] The optional entry gas curtain 24 and the exit gas curtain 26 can be used to further contain any mist within the spray chamber. The gas curtains may be located either inside or outside of the spray chamber. Suitable gas curtains can include air knifes, air bars, or air nozzles that can provide a substantially homogenous line of gas across the CD width of the flexible web or spray chamber. In one embodiment, air knifes such as the Standard Air Knife or the Super Air Knife manufactured by Exair Corporation located in Cincinnati, Ohio have been used successfully. In another embodiment, regenerative blowers and sheet metal nozzles can be used to provide the entry and exit gas curtains.
[0023] The CD uniformity of the entry gas curtain 24 is less critical since its main function is to prevent liquid and mist from exiting the spray chamber 22 . With sufficient exhaust air flow or for an apparatus located where misting is less of a concern, the entry gas curtain 24 can be eliminated.
[0024] The exit gas curtain 26 is used to strip away the majority of any liquid film adhering to the first surface 16 of the flexible web 12 and then assist in drying any remaining liquid film by evaporation. Desirably, the liquid film is uniformly removed to prevent streaking, water spotting, or leaving excess moisture that may attract or concentrate dirt particles. The backup roll 14 assists the exit gas curtain 26 by stabilizing the flexible web 12 allowing for the precise placement and orientation of the exit gas curtain. In one embodiment, an Exair model 2012SS air knife is located such that the highest pressure line of the air curtain is located approximately 0.010 inch (0.254 mm) to about 0.030 inch (0.635 mm) from the first surface 16 of the flexible web 12 while the web is supported by the backup roll 14 . The gas curtain impinges the first surface 16 at an angle between 0 degrees to about 90 degrees, or between 70 degrees to about 90 degrees relative to the web's surface. In one embodiment, an angle of approximately 80 degrees was used. In general, the entry and exit gas curtains are adjusted such that the majority of the gas supplied by the gas curtain traverses in a direction opposite to the direction of the web's travel.
[0025] A source of gas 37 that is fed to optional entry gas curtain 24 and the exit gas curtain 26 can be filtered by an oil coalescing filter 48 and dewatered using filtration equipment known to those of skill in the art. In some embodiments, the gas is compressed to a pressure between about 5 psi and about 100 psi to increase the flow from the gas curtains. Useful gases can include air, nitrogen, or other suitable gases. In particular, the supplied gas should be clean and substantially free of moisture or other liquid contaminants. In one embodiment, compressed air is filtered of all particles having a size greater than 0.01 micron absolute and then supplied to the air curtains. In one embodiment, the gas 37 supplied to the exit gas curtain 26 is heated to assist with evaporative drying of any remaining moisture on the web. The gas 37 being fed to the exit gas curtain 26 can have a temperature between about 60 degrees F. (15.5 degrees C.) and about 500 degrees F. (260 degrees C.). The temperature of the compressed gas can be determined based on the sensitivity of the flexible web material to heat and the dwell time during which the flexible web material is subjected to the gas curtain. Additional drying equipment such as infrared radiation, microwave, convection, or conduction drying can be used to evaporate any remaining moisture if needed. Additional drying equipment such as PVA sponge rollers can be used to first remove most of the moisture before air knives or other remedial measures are employed downstream.
[0026] To further assist with cleaning the first surface 16 , the first surface can be run though a nip between an optional cleaning roller 28 and the backup roll 14 . Suitable cleaning rollers 28 can include brush rolls and sponge covered rolls. The surface of the cleaning roller 28 can be bristle, ribbed, textured, dimpled, or knobby. Desirably, the cleaning roller 28 is made of a porous material such that a first cleaning fluid 38 can be supplied to the interior of the cleaning roller for application to the first surface 16 . The first cleaning fluid 38 can be the same liquid supplied to the high pressure spray 18 or different depending on the flexible web material being cleaned. Suitable cleaning fluids include de-ionized water, ultra pure water, or filtered water with surface acting agents. Typically, ammonium hydroxide in a ratio of approximately 0.10 to 2% concentration by weight is included in the fluid to assist in particle neutralization for ease of removal. Desirably, the cleaning roller 28 is readily deformable such that it can yield and conform to the first surface 16 as it rubs against that surface. In one embodiment, the surface of the cleaning roller 28 is compressed between about 0.5 mm (0.02 inch) to about 2.5 mm (0.1 inch) when in contact with the first surface.
[0027] To further enhance cleaning of the first surface 16 , the cleaning roller 28 can be run at a surface velocity differential to the surface velocity of the first surface. The velocity differential can be in the same direction at a different surface speed, in an opposing direction at the same surface speed, or in an opposing direction at a different surface speed as the first surface 16 . In one embodiment, the cleaning roller is rotated in an opposing direction to the rotation of the backup roller 14 and at a surface speed faster than the speed of the first surface 16 . Suitable surface speed differentials can be between about plus 1000% and minus 1000%.
[0028] In one embodiment, a knobby cleaning roller is used having a plurality of small protrusions or mesas on its outer surface that readily compress. The knobby protrusions not only assist with cleaning the first surface, but reduce drag of a counter rotating, compressed knobby cleaning roller. A particularly suitable cleaning roller 28 is a TEXWIPE model TX 5580 nodule cleaning brush, commercially available from ITW Texwipe of Mahwah, N.J. This cleaning roller has an apparent density of approximately 0.12 g/cm 3 , an effective porosity of 89%, an equivalent pore diameter of 528 um, and a 30% compressive strength of 71.5 g/cm 2 . Typical knobby rollers are available that are made from polyvinyl acetal (PVA) or polyvinyl alcohol (PVA) or polyvinyl-formal (PVF).
[0029] To further assist in cleaning the first surface, the drip bar 30 can apply a surfactant solution 40 to the periphery of the cleaning roller 28 or to the first surface 16 of the flexible web 12 . Suitable surfactant solutions include ammonium hydroxide (NH 4 OH) and other cationic, anionic, or non-ionic surfactants. In one embodiment, a 0.1% solution of ammonia hydroxide is supplied at a flow rate of approx 30 ml/min to a drip bar having a plurality of 0.03 inch (0.76 mm) diameter holes spaced at 1 inch (2.54 mm) along the length of the tube with the bar positioned to drip onto the surface of the cleaning roller 28 . Ammonium hydroxide can assist with cleaning the first surface 16 by equalizing the zeta potential between the dirt particles and the first surface. This reduces the attraction and allows them to be more easily removed via mechanical disturbance.
[0030] After the optional cleaning roller 28 , the first surface 16 is subjected to the high pressure spray 18 . The high pressure spray 18 is provided by one or more spray nozzles 42 attached to a CD spray manifold 44 that direct the high pressure spray 18 onto the first surface 16 . The web cleaning apparatus can include multiple CD spray manifolds located about the periphery of the backup roll thereby creating more than one high pressure spray zone as shown in FIGS. 2 and 3 . Suitable spray nozzles can include nozzles designed for fan spray patterns to concentrate spray forces into a line across the surface. One suitable nozzle is Spraying Systems Co., Wheaton, Ill., model number TPU150017. In general, the orifice of the spray nozzles can be between about 0.011 inch (0.279 mm) to about 0.015 inch (0.381 mm) equivalent diameter and the spray fan can be between about 5 degrees to about 20 degrees. The spray from the spray nozzles is directed to impinge the first surface 16 at an angle from about 45 degrees to about 90 degrees, such as from about 70 degrees to about 90 degrees relative to the web's surface.
[0031] When more than one spray nozzle is attached to the CD spray manifold 44 , each individual spray nozzle can be rotated relative to the CD direction such that the spray fan is between an angle of about 1 degree to about 10 degrees relative to the CD direction. Rotation of the spray nozzles can prevent the impingement of adjacent spray fans with each other and provides a more uniform spray across the entire first surface 16 . Spray nozzles are spaced along the spray manifold to ensure that the first surface is uniformly subjected to the high pressure spray without missing any areas and while allowing slight overlap between adjacent spray nozzles. Suitable deflectors or valves can be used to selective clean the web's surface or to run narrower web's though the web cleaning apparatus.
[0032] A source of high pressure liquid 46 is provided to the spray manifold 44 . Suitable liquids for the high pressure spray 18 include ultra pure water, de-ionized water, and water containing a surface-active agent, organic solvents, and high specific gravity fluids. High specific gravity fluids can include HFE (hydrogen fluorinated ethers) or similar high specific gravity low surface tension fluids. An absolute filter 48 is provided to remove most particles exceeding approximately 0.2 microns diameter and larger from the liquid before it is applied to the first surface.
[0033] In one embodiment, water was supplied by filtering the water to remove particles exceeding approximately 0.2 microns, de-ionizing, and then re-ionizing the water. In another embodiment, the water is filtered and de-ionized. Re-ionization is preferentially performed by passing de-ionized water across a membrane with carbon dioxide (CO 2 ) on the opposite side. The CO 2 is transferred across the membrane into the water. As a result of the process of purifying water, de-ionized water possesses a polar character that causes it to naturally disassociate into an ionic state of a low concentration of oxonium H 3 O + and hydroxyl ions —OH. Metals in contact with highly de-ionized water can show localized ionization and actual structural damage at the surface. The ferrous metals can then shed ions to be deposited as impurities on the web being cleaned. Additionally, high velocity sprays of de-ionized water can generate a corona and subsequent high static charge. Such charges imparted to dielectric polymer webs are detrimental in that static charges can cause particles to be highly attracted to the web. However, in the reaction that results from mixing de-ionized water and CO 2 , the water acquires new ions that effectively neutralize its ionic character. Thus, re-ionization can prevent ionic damage to metals in the pressurized piping system and minimize static buildup on the web. Also, using CO 2 restores neutral ions without adding ions that could be a source of impurities.
[0034] The apparatus in FIG. 1 is shown with a single backup roll for supporting the flexible web 12 while being subjected to the gas curtains, cleaning roller, and high pressure spray. However, it is possible to use more than one backup roll 14 within the spray chamber 22 to support the web as it is processed. For example, a first backup roll can be used in conjunction with the entry gas curtain 24 and the knobby roller 28 ; a second backup roller can be used in conjunction with the high pressure spray 18 ; and a third backup roll used in conjunction with the exit gas curtain 26 . One or more backup rolls can be used to support the web during each process operation.
[0035] Referring now to FIG. 2 , a second embodiment of the web cleaning apparatus 100 is shown. The apparatus includes a spray chamber 22 , an optional entry gas curtain 24 , two spray manifolds 44 each having a plurality of spray nozzles 42 thereby creating a first high pressure spray zone 50 and a second high pressure spray zone 52 along the periphery of the backup roll 14 , an exit gas curtain 26 , a first inspection system 54 , and a second inspection system 56 . The inspection system can include a camera and lighting to detect debris on the surface of the web.
[0036] In the web cleaning apparatus of FIG. 2 , the flexible web 12 wrapped the backup roll 14 approximately 100 degrees. The gas curtains ( 24 , 26 ) were located outside of the spray chamber 22 as shown. Locating the air curtains outside the spray chamber, can further enhance containment of mist within the spray chamber. In other embodiments, the air curtains can be located inside the spray chamber as shown.
[0037] Using the inspection systems ( 54 , 56 ), it is possible to measure the number of particulates on the first surface 16 prior to being subjected to the high pressure spray and then measure the number of particulates on the first surface after cleaning. The inspection systems are mounted in a fixed CD position to insure the same CD position of the flexible web is inspected by both the first and the second inspection systems ( 54 , 56 ).
[0038] Referring now to FIG. 3 , a third embodiment of the web cleaning apparatus 150 is shown. The web cleaning apparatus includes in the direction, D 1 , of web travel around the backup roll 14 : an optional entry gas curtain 24 , a first cleaning roller 28 , a first high pressure spray 50 , a second cleaning roller 51 , a second, a third, and a fourth high pressure spray ( 52 , 58 , 60 ), a first air deflector 62 , a first exit gas curtain 26 , a second air deflector 64 , and a second exit gas curtain 66 . The web cleaning components are housed in a spray chamber 22 . For clarity, liquid and gas connections to the individual components have been eliminated.
[0039] The individual components operate in the same manner as described for the web cleaning apparatus 10 of FIG. 1 . The optional entry and exit gas curtains are mounted on adjustable carriages, which allow for the orientation of the gas curtain (distance to the web and impingement angle) to be adjusted. Similarly, the cleaning rollers are mounted on adjustable carriages, which allow for the degree of compression of the cleaning roller to be adjusted. The cleaning rollers are all driven, with the rotation of the cleaning rollers reversed, relative to the direction of the web 12 to increase the velocity differential.
[0040] The first and the second air deflectors ( 62 , 64 ) are designed to scoop and deflect the mix of air and liquid particles (aerosol spray). As such, the leading edge of each air deflector is closely positioned just above the first surface 16 . The first air deflector 62 is designed to divert the aerosol mist away from the exit of the spray chamber. It can be porous with holes allowing some transfer of the aerosol to the demister 36 . The second air deflector 64 is designed to channel any remaining aerosol and flow from the exit gas curtain 26 towards the exhaust duct 35 . Removal of any residual liquid droplets at the second exit gas curtain 66 assists in mist containment and drying of the first surface.
[0041] Referring to FIG. 4 , a web cleaning line 200 is shown. The web cleaning line can be located in a clean room environment to prevent contaminating the web with particles after cleaning. The web cleaning line 200 includes an unwind 210 for feeding the flexible web 12 to a first inspection station 220 having a first inspection system 230 focused on the first side 16 of the flexible web and a second inspection system 240 focused on the second side 20 of the web. To measure the surface contaminant particles high intensity light can be amplified to a level that is reflected by small particles or surface discontinuities. The reflected light can then be measured by sensitive elements located in the reflected light path. In this manner, individual dirt particles can be isolated and counted electronically as they pass through the inspection point.
[0042] After the first inspection station 220 , the first side 16 of the flexible web 12 is cleaned with the web cleaning apparatus 150 of FIG. 3 . The second side 20 of the flexible web is then cleaned with another web cleaning apparatus 150 . A second inspection station 250 having a first inspection system 230 focused on the first side 16 and a second inspection system 240 focused on the second side 20 is located after the second web cleaning apparatus. The flexible web then passes to a winder 260 for winding into a roll.
[0043] Additional web processing equipment can be located either before or after each of the web cleaning apparatus. For example, a slitting section 270 could be located before the web cleaning apparatus and the equipment then used to remove small particles created by the slitting. Alternatively, a coating section 280 could be located after the web cleaning apparatus. In general, where contaminant free, flexible web surfaces are needed, the web cleaning apparatus can be employed to clean one or both sides of the flexible web.
[0044] The web cleaning line also includes tension sensing rollers, pull rolls, and idler rollers as known to those of skill in the art to transport the flexible web through the line while maintaining control of the web. Additionally, depending on the web material being cleaned, static control equipment such as active or passive static elimination bars and grounding conductors can be deployed at various points throughout the web cleaning line to neutralize any static build up by the flexible web.
[0045] After being subjected to the cleaning operation of FIG. 1 , 2 , or 3 , the first surface and/or the second surface of the web is substantially free of extremely small dirt and debris. In particular, more than about 90%, or more than about 95%, or more than about 97% of small dirt and debris particles having a particle size of 3 microns or greater can be removed from the surface of the web being cleaned.
[0046] The effectiveness of this wet web cleaning apparatus has been compared to dry web cleaning systems and found far superior. For example, nipped contact cleaning roll (CCR) systems and high velocity air knives with vacuum bar particle removal nozzles have been shown using highly sophisticated automated and microscope inspection techniques to redeposit particles on the first surface and do not effectively remove extremely small dust and debris.
Example 1
[0047] An experimental set up was constructed generally as depicted in FIG. 2 . A backup roll 14 constructed from 10 inch (25.4 centimeters) outer diameter aluminum metal cylinder was provided. A web of 0.002 inch (0.00508 centimeter) thick and 9 inches (22.86 centimeters) wide of optical grade polyester film, commercially available from 3M, St. Paul, Minn. was wrapped around the backup roll approximately 90 degrees as it was conveyed through the apparatus. The approximate length of the web was 200 ft.
[0048] While the web was conveyed around the backup roll at a line speed of 15 feet/minute (4.572 meters/minute), two CD spray manifolds 42 , each having a single row of four spray nozzles 42 , created a first and a second high pressure spray zone ( 50 , 52 ). Each spray nozzle (Spraying Systems Company model number TPU150017) had a single orifice of 0.010 inch equivalent diameter and was provided with de-ionized water filtered to 0.2 micron absolute and pure to a resistive level of 18 MOhm while supplied at a pressure of 1500 psi. The flexible web was dried by the exit gas curtain 26 using an Exair model #2012SS air bar oriented at a 13 degree angle to direct and focus the main flow of compressed air in a line across the flexible web so as to remove substantially all water from the web. The first and second inspection systems ( 54 , 56 ) inspected the first surface to measure dirt particles before and after web cleaning.
Comparative Example 2
[0049] For Comparative Example 2, a tacky roll cleaning system, 6RNWC-IIA, manufactured by Polymag Tek Inc., Rochester, N.Y. was used. The 6 roll narrow web cleaner system is designed to remove loose particulate contamination from a moving substrate. The POLYMAG® blue contact cleaning rolls contact both sides of the web as it transports through the web cleaner. Surface contamination is transferred from the web to the contact cleaning rolls. The 1.25″ O.D. contact cleaning rolls are then continuously cleaned with two adhesive tape rolls. The top contact cleaning rolls and adhesive tape roll assemblies create a nip between the web and the lower fixed contact cleaning rolls. The web drives the four contact cleaning rolls and the two tape rollers. The contamination from the web is collected on the surface of the adhesive tape rolls. When the adhesive tape rolls become saturated, a layer of tape can be removed. Each adhesive tape roll contains approximately 66 feet of adhesive tape. Approximately one foot of tape is used per tape change.
[0050] A web of 0.002 inch (0.00508 centimeter) thick and 9 inches (22.86 centimeters) wide of optical grade polyester film, commercially available from 3M, St. Paul, Minn. was conveyed through the tacky roll cleaning system at a line speed of 15 fpm with the nip pressure set at 60 psi. The approximate length of the web was 200 ft. The first and second inspection web systems inspected the first surface to measure dirt particles before and after the tacky roll cleaning system.
Comparative Example 3
[0051] For Comparative Example 3, a dual ultrasonic web cleaner manufactured by Web Systems, Inc., Broomfield, Colo. was used. The web cleaner has two ultrasonic nozzles located on opposite sides of a cross-direction vacuum tube that is curved for close placement to an idler roller. The web to be cleaned is conveyed around the idler roller underneath the ultrasonic web cleaner.
[0052] A web of 0.002 inch (0.00508 centimeter) thick and 9 inches (22.86 centimeters) wide of optical grade polyester film, commercially available from 3M, St. Paul, Minn. was conveyed through the ultrasonic web cleaning system at a line speed of 15 fpm. The approximate length of the web was 200 ft. The first and second inspection systems inspected the first surface to measure dirt particles before and after the ultrasonic web cleaning system.
[0000]
TABLE 1
Web Cleaning Results
Counts Before
Counts After
% of
Cleaning
Cleaning
Particles
(counts/m{circumflex over ( )}2)
(counts/m{circumflex over ( )}2)
Removed
Example 1
455
4
99
Comparative
282
162
42
Example 1
Comparative
385
318
17
Example 2
[0053] Table 1 presents the results of the three experiments. As seen, the web cleaning method of the present invention removes significantly more dirt and debris having a size of 3 microns or greater from the surface of the web than the prior existing methods.
[0054] Other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. It is understood that aspects of the various embodiments may be interchanged in whole or part or combined with other aspects of the various embodiments. All cited references, patents, or patent applications in the above application for letters patent are herein incorporated by reference in a consistent manner. In the event of inconsistencies or contradictions between the incorporated references and this application, the information in the preceding description shall control. The preceding description in order to enable one of ordinary skill in the art to practice the claimed invention is not to be construed as limiting the scope of the invention, which is defined by the claims and all equivalents thereto.
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A method of web cleaning, particularly relatively soft polymeric webs, without using dipping baths or ultrasonic energy. The method includes conveying the web against a backup roller and spraying the web with a high pressure liquid while the web is supported by the backup roller. Thereafter, residual fluid from the high pressure stream is stripped from the web by a gas curtain while the web is supported by the backup roller. In many convenient embodiments, the web is contacted with a cleaning roller while the web is in contact with the backup roller.
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This application is a continuation-in-part of U.S. patent application Ser. No. 09/304,616, filed May 3, 1999, now U.S. Pat. No. 6,350,083.
FIELD OF THE INVENTION
The present invention pertains to the field of powered roller screeds used to screed cementitious material.
BACKGROUND OF THE RELATED ART
Concrete structures are formed by pouring a cementitious material, such as cement and aggregate (comprising concrete slurry) into a form, or other container, and permitting the material to cure under proper conditions. In the case of a. concrete pad, such as a floor, foundation, or roadway, concrete is poured onto a ground, or support, surface and contained by forms connected to, and rising above, the ground surface. The forms are longitudinal members arranged along a border of a desired location for the concrete pad to contain the viscous concrete and provide a guide for the concrete's thickness and to level the top surface of the concrete.
After concrete is poured between forms, it is spread evenly between the forms. A screed is then used to remove excess concrete and level the top surface of the concrete so it is even with the forms. Often, several passes of a screed over the concrete is necessary to achieve the desired surface. Precision is required to conform to building codes and to perform quality work.
A very primitive screed, which is still useful on small jobs, is a simple straight edge such as a straight board. The board, chosen long enough to span the forms, is laid on top of each form and thereafter worked side-to-side and pulled down the length of the forms by workers at each end of the board. This process pushes forward excess concrete: excess concrete is concrete that is higher than the top surface of the forms. While quite suitable for small jobs, such a screed is impractical on large jobs because of the work required to move the excess concrete.
A more practical screed for larger jobs is disclosed in Mitchell, U.S. Pat. No. 4,142,816. Mitchell discloses a powered screed having a hydraulic motor to spin a tubular member while the screed is pulled along the forms by two workers, one each located on either side of the forms. As with most rotary screeds, the tubular member spins in a direction opposite a direction of travel of the screed. By spinning the tube, this screed provides a good surface to the concrete. However, substantial work is required to pull the screed along the forms. The hydraulic motor, spinning the tube, does not assist to propel the screed forward and the heavy concrete that builds up in front of the screed requires a large amount of force to move. In addition, workers located at each end of the Mitchell screed must keep the screed tube substantially perpendicular to the forms—frequently this is a difficult task because of uneven amounts of concrete from side-to-side and unequal strengths of the workers.
Larger, powered screeds are suitable for large, high-volume jobs. U.S. Pat. No. 5,456,549 discloses a powered rotary screed having a modular frame that spans across concrete-retaining forms to support a strike tube and drive tubes. The frame provides rigidity and support so that the screed can span large distances between forms. The strike tube rotates opposite the direction of screed travel to screed the concrete and the drive tubes provide motive force to propel the screed.. While very useful for large jobs, and jobs that are not constrained by space limitations, these larger screeds are difficult to use in close quarters and are more difficult to transport.
Accordingly, there is a need in the industry to provide a powered screed that can be easily controlled during use, and conveniently transported and set up for use.
SUMMARY OF THE INVENTION
The present invention provides a frameless roller screed having two tubes: a strike tube and a drive tube. The strike tube is located at a leading edge of the screed and is made to rotate so as to oppose the direction of motion of the screed. The strike tube contacts rough laid concrete to level the concrete to the height of the forms and finish the surface of the concrete. The rotational motion of the. screed tube provides a better quality finish to the concrete surface than can be achieved with a non-rotating strike tube or a strike tube that rotates in the direction of travel.
In preferred embodiments, the drive tube of the present invention is a split drive tube having independently controlled portions that provide superior control of the screed during operation. The drive tube is split into first and second drive tube portions that are separately controlled by the operator so that left and right ends of the screed may be independently driven to adjust for misalignment that may occur as the screed moves along the forms. Oftentimes, uneven concrete will present uneven resistance to the screed and impede the forward progress of the screed on one side, thereby misaligning the screed on the forms. The split drive tube of the present invention permits the operator to adjust the motive power at one end of the screed relative to the other end so as to compensate for such misalignment.
In preferred embodiments, the first and second drive tube portions are cylindrical and the two portions are axially aligned and coupled. The drive tube portions are coupled so as rotate independently of each other and each portion is separately driven to permit separate control of the respective portions.
Preferably, hydraulic motors drive the strike tube and the drive tube. The strike tube is powered by a single motor for control of the rotational speed and direction of rotation of the strike tube.
The drive tube is powered by two motors. One motor controls each one of the respective two drive portions, thus allowing separate control of the first and second drive portions as to rotational speed and direction of rotation.
In addition, the screed includes handles located on opposite ends of the screed that are arranged as levers to assist with control of the screed. The handles are coupled to the screed such that an operator can push a distal end of the handle downward, or raise the distal end upward, to lever the drive tube about the strike tube. Pushing down on the handle tends to lift the drive tube off of the forms so that forward motion of the screed may be easily, and quickly, halted. Alternatively, lifting the handles places more of the screed's weight on the drive tube and increases the drive tube's pressure on the forms so that the drive tube can provide more motive force without slipping.
Using the handles as the primary means to control the screed during operation requires trained operators at each end of the screed. However, by providing the drive tube as a split drive tube, as disclosed in the present invention, allows one person control and operation of the screed.
The roller tubes of the present invention are coupled together by plates located on distal ends of the screed. The screed has no frame that extends substantially over the concrete, or spans the forms.
Accordingly, the present invention provides a frameless, powered rotary screed having a split drive tube with separately controllable ends that permit the screed operator to control the screed's motive force at, each end separately to adjust for uneven concrete and prevent skewing of the screed on the forms.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of a power driven roller screed of the present invention including an environment of screed forms supporting the roller screed and cementitious material located between the forms. The screed tubes are shown in broken view to represent indefinite lengths.
FIG. 2 is a top plan view of a preferred embodiment of a drive end of the roller screed showing the motors and their respective connections to the strike and drive tubes.
FIG. 3 is an end-view elevation of the roller screed drive end of FIG. 2 .
FIG. 4 is a cross-section, side-view elevation of the roller screed drive end of FIG. 2 .
FIG. 5 is a schematic diagram of a preferred embodiment of a hydraulic system for the split drive tube screed of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As stated, a conventional method of making a concrete pad, or floor, is to pour concrete onto a surface between concrete forms. With respect to FIG. 1, viscous concrete 10 is poured onto a floor, or ground surface, between two spaced-apart, longitudinal forms 12 a and 12 b (collectively, forms 12 ). The concrete is spread so that it covers the floor surface and contacts the forms 12 . It is then necessary to screed a top surface of the concrete as an initial finishing step.
A preferred embodiment of a screed 14 of the present embodiment is shown located atop the forms 12 and includes a strike tube 16 and split drive tube 18 . The strike tube 16 and drive tube 18 are coupled by end plates: a drive element plate 20 and idler element plate 22 . Attached to the drive element plate 20 is a control handle 24 having a control mechanism 26 mounted thereon. Attached to the idler element plate 22 is a second handle 28 .
Hydraulic hoses, shown collectively at 30 , provide hydraulic pressure from a hydraulic source (not shown) to rotate the strike tube 16 and drive tube 18 . The strike tube 16 is the leading-edge of the screed at the point of contact with the concrete as the screed proceeds along the forms 12 . The drive tube 18 frictionally engages the forms and is hydraulically powered to move the screed along the forms and is the trailing edge of the screed. In the arrangement of FIG. 1, the screed will travel in the direction indicated by arrow 32 .
In general, the control mechanism 26 is operated to control hydraulic power to the strike tube 16 and drive tube 18 . Preferably, the rotation speed of the strike tube 16 will be fast relative to the rotation speed of the drive tube 18 . In addition, the drive tube and strike tube will rotate in different directions. Thus, the strike tube will be driven to rotate such that a top of the strike tube is moving opposite the direction of travel and a top of the drive tube 16 is moving in the direction of travel 32 . Further, in preferred embodiments, the strike tube has a smooth surface and the drive tube has a non-slip surface where the drive tube. rests atop the forms 12 . Accordingly, the strike tube 16 slips on the forms 12 and the drive tube frictional engages the forms 12 to drive the screed along the forms.
The relatively high rotational speed of the strike tube, and its reverse rotation direction, provides a finish surface to the concrete 10 . Additional finishing of the surface may also be necessary.
Preferably, the control handle 24 is pivotally mounted to the screed 14 . In the preferred embodiment, the control handle 24 includes a bushing 34 that is rotatably coupled to a pin 36 that is fixedly attached to the drive element plate 20 . The control handle may be rotated outboard of the screed in order to make the screed more maneuverable in tight situations. For example, by rotating the control handle outboard 90 degrees from the orientation shown in FIG. 1 so that the longitudinal handle extension 38 is substantially aligned with the longitudinal direction of the strike tube 16 , the strike tube can be driven very close to a vertical wall.
Similarly, the second handle 28 includes a bushing 34 that is rotatably mounted on a pin 36 that is fixedly attached to the idler element plate 22 so that the second handle 28 may be rotated relative to the idler element plate so as to maneuver the screed.
In operation, an operator will grab the control handle 24 and operate the controls on the control mechanism 26 . A second worker will grab the second handle 28 . Subsequently an operator will use the control mechanism 26 to provide hydraulic power to hydraulic motors 62 , 78 , and 88 , which in turn will rotate the drive tube 18 and the strike tube 16 .
Controls are provided to control the direction of rotation, and the speed of rotation, of each tube individually. As stated, preferably, the strike tube 16 is controlled so as to spin at relatively high rotational speed and opposed to the direction of travel. In contrast, the drive tube 18 is operated to propel, or drive, the screed 14 in the direction of travel 32 at a rate of speed approximately equal to a walking pace. Thus, an operator is located at each handle and the controls are operated to spin the strike tube and rotate the drive tube to move the screed so that freshly poured concrete in front of the screed 14 is screeded level with the forms 12 . It may be desirable to make additional passes over the concrete to achieve the desired finish.
The screed may be controlled during operation by raising and lowering the handles. When the operators raise the distal end of the handles, the screed pivots about the strike tube and more weight is placed on the drive tube thereby allowing the drive tube to obtain a better grip on the forms and provide more motive force to the screed. Alternatively, pushing down on the distal end of the handles pivots the screed about the strike tube and raises the drive tube off the forms thereby reducing the pressure of the drive tube on the form and the ability of the drive tube to push the screed forward. The operators can fine tune control of the screed by varying degrees of raising and lowering the distal ends of the handles.
The split drive tube 18 of the present invention further assists in controlling the screed during operation and enables operation of the screed by a single operator. Rotatably-coupled, axially-aligned drive tube portions can be independently controlled to control the speed and power applied to each respective drive tube portion. Thus, a drive tube end that encounters more resistance to forward motion can be driven with greater power to overcome a tendency of the screed to become skewed. If the screed becomes skewed, the drive tube portion at the end that is lagging behind can be made to rotate more quickly so as to cause the lagging end to catch up to the advanced end. Conversely, the advanced end may be slowed, or temporarily stopped, to allow the lagging end to catch up.
The Tubes
Preferably, the strike tube 16 and drive tube 18 are similar in dimensional characteristics. Each tube is approximately six inches in diameter and fabricated of a structural metal such as steel or aluminum. Oftentimes it is desirable to have heavy tubes, making steel, or iron, a preferred material. The ends of each tube, and tube portions, are sealed so as to close off an interior of the tubes.
Preferably, the tubes are connected to the plates 20 , 22 by thrust bearings 40 that are bolted to the plates 20 , 22 . Where the tubes connect to a hydraulic motor,, a shaft having a splined portion and a threaded portion (not shown) is provided wherein the splined portion passes through the bearing and plate and connects to a coupler 42 , which in turn connects to the hydraulic motor. This method of connection is know in the art and taught in U.S. Pat. No. 5,456,549.
As shown, hydraulic motors 62 , 78 , and 88 are mounted on a motor plate 44 that is space-apart from the drive element plate 22 . This arrangement permits space to make connections between drive and strike tube axles 80 , 90 , splined shafts, couplers 42 , and the motors 78 , 88 .
In order to prevent misalignment of the tubes relative to the plates 20 , 22 , and relative to each other, at least one plate, and preferably both plates, are provided as an anti-skew box 46 . With reference to the box member 46 of the drive element plate 20 , a preferred embodiment of the box member 46 includes plates 48 and flanges 50 arranged as a box-like parallelogram. The box member 46 further includes a bottom plate 52 to provide additional rigidity to the box member 46 . Additionally, further plates or cross-members may be provided as desired for additional rigidity.
The anti-skew boxes 46 provide connection of the strike and drive tubes to the plates 48 at two spaced-apart locations that are rigidly connected. Accordingly, the relationship of the plates to the tubes' axles is substantially more rigid than would be a single point connection between the plates and the tubes' axles. Accordingly, the anti-skew box maintains the drive plate 20 at an orientation substantially orthogonal to the strike and drive tubes 16 , 18 and assists in maintaining a parallel orientation of the drive tube and strike tube.
The drive tube is split into a first portion 58 and a second portion 60 . The portions are cylindrical, axially aligned, and arranged so that each portion is at opposite ends of the screed 14 . Thus, each drive tube portion 58 , 60 setsatop the opposite sides of the forms 12 b and 12 a, respectively as shown in FIG. 1 .
The second portion 60 includes first and second cylinders 60 a and 60 b that are fixedly coupled together. The cylinder 60 a is a drive cylinder and preferably includes a non-slip outer surface to assist in gripping the forms 12 to propel the screed. The drive cylinder 60 a is rotatably coupled to the idler plate 22 . Bolted to the drive cylinder 60 a is the cylinder 60 b that serves as a spacer cylinder. The spacer cylinder 60 b has a length that is selected to adjust the overall length of the screed to the form width and so that the combined length of the first and second cylinders 60 a and 60 b and the first drive tube portion 58 is substantially equal to a length of the strike tube 16 .
The first drive tube portion 58 is also a drive cylinder, similar to the first cylinder 60 a. In particular, the first drive tube portion includes a non-slip outer surface to grip the forms 12 to assist with propelling the screed.
The first drive tube portion 58 is belt driven by a hydraulic motor 62 that is mounted directly on the drive element plate 20 . The first portion motor 62 drives a first belt gear 64 that is coupled to a second belt gear 68 by a belt 66 . The second belt gear 68 is fixedly coupled a block 70 that is rotatably mounted to the drive element plate 20 by a ball bearing assembly 72 that is coupled to a circular flange 74 that is welded to the plate 20 . The block 70 is fixedly coupled to the first drive tube portion 58 at an end thereof. The first drive tube portion 58 is further supported by a bushing 76 located within the tube.
Accordingly, when hydraulic power is supplied to the motor 62 , the motor turns the belt 66 which turns the block 70 and thus turns the first drive tube portion 58 . The hydraulic motor 62 may be controlled to drive the first drive tube portion in either a first direction of rotation or a second, opposite, direction of rotation. The hydraulic motor 62 is provided with an adjustment in the form of a arcuate slot 77 cut in the drive element plate 20 to permit the motor to be rotated about mounting bolt 80 to tighten the belt.
The second drive tube portion 60 is driven by a hydraulic motor 78 that is coupled to the motor plate 44 . Coupler 42 couples the motor 78 to a shaft 80 that passes through a thrust bearing 40 . The shaft continues through, but not contacting, the second belt gear 68 and connects to an inner tube 82 , that is located within the first drive tube portion 58 , by a block coupler 84 . The inner tube 82 proceeds within the first drive tube portion 58 to a stepped block 86 that bolts to spacer cylinder 60 b of the second drive tube portion 60 . The combination of the stepped block 86 , inner tube 82 , and block coupler 84 rotate freely within the first drive tube portion 58 and ride within bushing 76 .
Thus, motor 62 may be operated to rotate the first drive tube portion 58 and the motor 78 may be operated to rotate the second drive tube portion 60 . The motors may be arranged so as to operate independently or cooperatively. In independent operation the motors each have separate controls and are independently controlled as desired. In cooperative arrangement, the motors share hydraulic (or electric) power and a single control determines relative power as between the motors to change the relative speed of rotation of the two drive tube portions 58 , 60 . Other arrangements are within the scope of the invention. A preferred arrangement for operation of the motors is disclosed below.
The strike tube 16 is driven by a hydraulic motor 88 attached to the motor plate 44 . A coupler 42 couples the motor 88 to an axle 90 of the strike tube 16 . The axle 90 passes through a thrust bearing 40 , the drive element plate 20 , and couples to the strike tube 16 . Preferably, the strike tube 16 is independently operated. In general,the strike tube will run at a constant rate of rotation and is controlled only to stop the strike tube, or reverse direction of rotation.
Drive Mechanism and Power Supply
With reference to the schematic diagram of FIG. 5, a preferred embodiment of a hydraulic system for control of the three motors 62 , 78 , and 88 , and hence the tubes 16 , 18 , is described. A hydraulic oil reservoir 100 provides hydraulic fluid to a pump 102 via hydraulic line 104 . From the pump, hydraulic fluid is directed to a selector valve 106 that controls the hydraulic flow to the screed via a disconnect 108 . A relief valve 110 is located between the pump 102 and the selector valve 106 to shunt overpressure fluid from the high pressure side of the pump.
At the screed, the hydraulic fluid flow is split at a flow divider 112 into two paths; one to a hydraulic motor 114 that drives the strike tube 16 and one path that flows to hydraulic motors 116 and 118 that drive the split drive tube 18 . In preferred embodiments, the divider is set to create a theoretical flow of approximately 7.78 gallons per minute to the strike tube motor 114 and 2.50 gallons per minute to the drive tube motors 116 and 118 . These flows are sufficient to rotate the strike tube at a rate up to 400 revolutions per minute and the drive tube at a rate up to 40 revolutions per minute.
The actual flow to the strike tube motor 114 is controlled by a directional control valve 120 that includes a flow control valve, represented at 122 . The control valve 120 has three positions for forward rotation, no rotation, and backward rotation. The flow control 122 is internal to the directional control valve 120 and is controlled by the same lever 124 as the directional control valve 120 .
The hydraulic flow to the drive tube motors 116 and 118 proceeds from the flow divider 112 to a flow control valve 126 and then to a first directional control valve 128 . From the first control valve 128 , the hydraulic fluid flows to the first drive tube motor 116 , then to a second directional control valve 130 , and then to the second drive tube motor 118 . The first and second control valves 128 , 130 each have three positions for driving a respective motor forward or backward, and a neutral position that does not drive the motor. The valves 128 , 130 are shown set at the neutral position in FIG. 5 . The flow control valve 126 controls the speed of the motors, and hence the rate of rotation of the drive tube portions 58 , 60 . Because the motors 116 , 118 are connected in series, both motors are driven at the same rotational speed. However, each motor may be individually controlled as to its direction of rotation, or placed in neutral.
The flow valves 122 , 126 are pressure compensated valves. The hydraulic fluid leaves the screed via disconnect 132 , through a filter 134 , and to the reservoir 100 .
Additional Alternative Embodiments
In the embodiment of FIGS. 1-5, the drive tube 18 includes the first drive tube portion 58 and the second drive tube portion 60 that has the first cylinder 60 a and the spacer cylinder 60 b. Alternatively, the second drive tube portion may be a unitary cylinder that extends from the first drive tube portion to the idler plate 22 .
In the configurations shown and described above, separate motors 62 , 78 control the first and second drive tube portions, respectively. In alternative embodiments, the first and second drive tube portions 58 , 60 may be driven by a single motor, and a clutch, or other variable drive mechanism or power transfer device, may be used to permit separate control of power to the respective portions 58 , 60 .
In the embodiments of FIGS. 1-4, the hydraulic motors 78 and 88 are mounted outboard of the drive element plate 20 . Alternatively, the hydraulic motors 62 , 78 and 88 may be mounted above ends of the tubes 16 , 18 and provide motive power to the tubes by gear, belt, or chain connection to sprockets mounted on the tube axles 80 , 90 .
In FIG. 1 the control mechanism 26 is generically represented as including four control levers. Alternatively, the control mechanism 26 may take many different forms, such as including dead man switches, or knobs, or other control means.
The hydraulic flow schematic of FIG. 5 provides a preferred embodiment. However, alternative embodiments of routing the hydraulic power to the motors is also within the scope of the invention. The drive tube motors 116 , 118 may be arranged in parallel and provided with separate flow control valves so that each drive tube motor may be separately controlled as to rotational speed. Alternatively, one drive tube motor may be used to drive both drive tube portions 58 , 60 , wherein a clutch, or other variable power transfer device, is used to control the power provided to the respective drive tube portions so as to permit individual control of the drive tube portions.
Summary
This patent specification sets forth a detailed description of a preferred embodiment of the invention as known to the inventor at the time the underlying patent application was filed. Also disclosed are such alternative embodiments, known at the time of filing, that readily occur to the inventors. No attempt is made to describe all possible embodiments, modes of operation, designs, steps or means for making and using the invention.
Where necessary, the specification describes the invention and states certain arrangements of parts, materials, shapes, steps, and means for making and using the invention. However, the invention may be made and used with alternative arrangements, materials, and sizes. Thus, it is intended that the scope of the invention shall only be limited by the language of the claims and the law of the land as pertains to valid patents.
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A powered rotary screed provides a powered strike tube that rotates to provide a finish to wet concrete during screeding and a drive tube that provides motive power to the screed to assist with the difficult task of removing excess concrete from a poured pad, or other horizontal concrete surface. The drive tube is split to provide two separate portions that can be independently controlled for easy control of the screed as the screed works concrete. The drive tube portions are elongate cylinders that are axially aligned and rotatable relative to one another. Separate motors drive respective drive tube portions and can be individually controlled to prevent skewing of the screed.
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FIELD OF INVENTION
The present invention relates to the field of processing scene graphs used in the display of computer-generated images. More specifically, the present invention relates to a method and apparatus for quickly and accurately creating well-behaved affine transformations of bounding spheres.
BACKGROUND OF THE INVENTION
Computer graphics is used in a wide variety of applications, such as in business, science, animation, simulation, computer-aided design, process control, electronic publication, gaming, medical diagnosis, etc. In an effort to portray a more realistic real-world representation, three-dimensional objects are transformed into models having the illusion of depth and displayed onto a two dimensional computer screen. Conventionally, polygons are used to construct these three-dimensional objects. Next, a scan conversion process is used to determine which pixels of a computer display fall within each of the specified polygons. Thereupon, texture is selectively applied to those pixels residing within specified polygons. In addition, hidden or obscured surfaces are eliminated from view. Finally, lighting shading, shadowing, translucency, and blending effects are applied.
For a high-resolution display, having over a million pixels, displaying a three-dimensional scene on a computer system is mathematically intensive and requires tremendous processor power. Furthermore, the computer system must be extremely fast to handle dynamic computer graphics, for example, displaying a three-dimensional object in motion. Even more processor power is required for interactive computer graphics, whereby three-dimensional images change in response to user input. Still more processor power is required to achieve a scene with more intricate details.
Given the tremendous demands that rendering scene graphs places on the processor. the number of complex mathematical computations performed should be kept to a minimum. One conventional alternative to performing complex mathematical operations is using mathematical shortcuts to estimate parameters. However, these shortcuts often fail to yield accurate results.
An example of this problem is calculating which portion of the object or scene graph needs to be displayed on the computer monitor. Conventionally, a bounding volume, which is stored in the scene graph, is compared with a viewer frustum or viewpoint. If they intersect. the computer displays the portion of the scene graph which corresponds to the bounding volume. If they do not intersect, there is no need to process the details of the un-displayed portion of the scene graph. During conventional image processing, the size and shape of the bounding volume is altered by a transform matrix. This matrix rotates, translates, squashes, or scales the object, as well as the bounding volume. It is computationally very difficult to arrive at the size and shape of the altered bounding volume. Conventionally, the exact size of a bounding sphere around the altered bounding volume may be calculated. However, this can require complex mathematical operations, such as solving a cubic polynomial. Another conventional method is to estimate the size of the bounding sphere. However, estimation is sometimes mathematically intensive, and mathematical shortcuts are often inaccurate. For example, some conventional methods produce accurate results for only a limited class of transform matrices.
Therefore, a need exists for a method and apparatus for obtaining a bounding sphere for the ellipsoid that results when an affine transformation matrix operates on a bounding volume. The method and apparatus needs to be computationally fast, as well as accurate for any type of affine transform matrix.
SUMMARY OF THE INVENTION
The present invention relates to a method and apparatus for obtaining a bounding sphere for the ellipsoid that results when an affine transformation matrix transforms a bounding volume. The present invention accomplishes this by using Gershgorin intervals to obtain a new radius for the bounding volume. The invention operates on a scene graph, which is comprised of a number of nodes arranged in a hierarchical organization. At least one of these nodes is an affine transformation matrix, which is used for operations such as rotations, scaling, and translations. Associated with the transformation matrix is a bounding sphere. The present invention calculates the radius of a new bounding sphere that encircles the ellipsoid formed when the affine matrix transforms the old bounding volume. The use of Gershgorin intervals is fast and yields accurate results. Thus, the present invention provides for a method and apparatus that is computationally fast and produces a well-behaved affine transformation of bounding spheres.
In another embodiment, the present invention compares the transformed bounding sphere with a viewer frustum to decide whether to display the corresponding portion of the scene graph and whether to continue traversing down the scene graph. Thus, the present invention provides a method and apparatus for fast and accurate rendering of scene graphs.
These and other objects and advantages of the present invention will no doubt become obvious to those of ordinary skill in the art after having read the following detailed description of the preferred embodiments, which are illustrated in the various drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
The operation of this invention can best be visualized by reference to the drawings.
FIG. 1 shows a computer system upon which the present invention may be practiced.
FIG. 2 shows an exemplary scene graph.
FIG. 3 shows a viewer frustum for determining which portion of a scene graph should be displayed.
FIG. 4 shows a viewer frustum and bounding volumes for determining which portion of a scene graph should be displayed.
FIG. 5 shows a scene graph with an affine transformation matrix node and bounding sphere nodes.
FIG. 6 shows a bounding sphere and the ellipsoid that is formed when the sphere is transformed by an affine matrix.
FIG. 7 is a flowchart describing the steps in calculating the new radius for the bounding sphere.
FIG. 8 provides details for calculating the Gershgorin intervals.
DETAILED DESCRIPTION
A method and apparatus for a computationally fast and well-behaved affine transformation of bounding spheres is described. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be obvious, however, to those skilled in the art that the present invention may be practiced without these specific details, in other instances, well-known structures and devices are shown in block diagram form in order to avoid obscuring the present invention.
FIG. 1 shows a computer system upon which the present invention may be practiced. Initially, an original three-dimensional scene is created and described in file format (e.g., VRML) by a programmer. The programmer describes both components of the scene (e.g., geometry, materials, lights, images, movies, and sounds) as well as the relationships among those components. These relationships may be static (e.g., a transformation hierarchy) or dynamic (e.g., the values of transformations in the hierarchy). Changes in one element of the scene graph may be made to effect changes in others. For instance, a change in position of a light-bulb shaped geometry can be made to cause a change in position of light source. In addition, information about the locations and characteristics of viewpoints may be included in the scene. Once created, the files are stored in the storage device 104 (e.g., a hard disk drive) of the computer system 110 .
In practice, applications running on a processor 101 will be used to build a scene graph in order to have a graphics subsystem 108 draw it onto a display device 105 . Optionally, the user may choose to edit the three-dimensional scene by inputting specific commands via the input device 115 (e.g., a keyboard, mouse, joystick, lightpen, etc.). The user may also interact with the three-dimensional scene (e.g., flight simulation, game playing, etc.) through user input device 115 .
FIG. 2 shows a pictorial representation of a scene graph. The graph is comprised of nodes, which are abstract representations of objects. In FIG. 2, the overall person is represented by node 201 . The person node 201 is comprised of an upper body node 203 and a lower body node 205 . Each of these nodes has its own set of nodes as well (i.e., child nodes). For example, the upper body is comprised of a left arm node 207 and a right arm node 209 . Likewise, the lower body is comprised of a left leg node 211 and a right leg node 213 . In turn, the right leg node 213 is comprised of a right thigh node 221 , a right calf node 223 , and a right foot node 225 . The scene in FIG. 2 contains little detail because only a few nodes are shown. However, almost limitless detail can be achieved by adding more levels of nodes.
Rendering a hierarchical scene graph for display requires traversing it to decide which portions should be displayed. FIG. 3 shows a view frustum 300 from point of view 301 for determining what should be displayed on computer screen 305 . Anything falling within the view frustum 300 should be displayed. In this example, since left arm 307 falls within the view frustum 300 , it should be displayed. However, the right arm 309 falls outside the view frustum 300 and should not be displayed.
To assist in the rendering process, the preferred embodiment of the present invention stores bounding volumes at each node of the scene graph. FIG. 4 shows bounding volumes for the whole person 402 , lower body 406 , right leg 414 , right thigh 422 , right calf 424 , and right foot 426 . In one embodiment, when rendering a scene with respect to a certain viewpoint 401 , a bounding volume is compared with the frustum 400 . If they do not intersect, there is no need to traverse further down the scene graph. For example, because the lower body bounding sphere 406 does not intersect with the view frustum 400 , not only is the lower body not displayed, but also there is no need to traverse further down the scene graph. In other words, it is not necessary to compare the bounding volumes of the lower body's children nodes (i.e., the leg nodes) with the view frustum. This is because the bounding volume of the lower body node 406 contains the union of the bounding volumes of all of the nodes in its subgraph (i.e., its children nodes, grandchildren nodes, and so on down the hierarchy).
The preferred embodiment also stores affine transform matrix nodes in the scene graph. FIG. 5 shows such a matrix node 508 . These affine matrices transform a portion of the scene graph in some manner, such as scaling rotating, translating, or squashing. FIG. 5 also shows bounding volumes for the right leg 514 , right thigh 522 , right calf 524 , and right foot 526 . Each node is the scene graph has such a volume, although for simplicity others are not shown. As an example, the affine matrix 508 might perform right hip rotation, although it will be understood by those in the art that many other operations are possible. Furthermore, the matrix transforms all the nodes below it. For example, the affine matrix transforms nodes 513 , 514 , and nodes 521 - 526 . Thus it transforms not just the object nodes (e.g., legs) but also transforms the bounding spheres.
FIG. 6 shows how the affine transform matrix will generally transform the original bounding sphere 601 , having a first radius 611 , into an ellipsoid 602 . The preferred embodiment of the present invention teaches a way to calculate a radius 612 for a bounding sphere 603 , such that the bounding sphere 603 completely surrounds the ellipsoid 602 . Sphere 605 is of the ideal size, as it completely encloses the ellipsoid 602 and has the smallest possible radius 607 . According to the present invention, the second sphere 603 will always be large enough to fully contain the ellipsoid 602 , although it could be somewhat larger than absolutely necessary. It can be shown that the new radius 612 can never be more than the sqrt(3) times as large as the ideal size radius 607 , given that a 3×3 affine transform matrix is used. Thus, the present invention provides a method and apparatus for an accurate calculation of the radius 612 of transformed bounding spheres.
More specifically, the present invention calculates how much the radius 611 for the sphere 601 should be expanded or contracted to form a new sphere 603 , as described. The most accurate answer could be found by multiplying radius 611 by the singular value of the affine transform matrix. (Which, in this case, is equal to the square root of the largest eigenvalue of the matrix times its transform.) Unfortunately, this is a complex calculation. However, the eigenvalues of any real valued 3×3 symmetric matrix always lie within the respective Gershgorin intervals. The present invention calculates the upper bounds of the three Gershgorin intervals for the affine matrix times its transpose. Thus, an upper bound on the singular value is found. Finally, the old sphere radius 611 is multiplied by the upper bound on the singular value. This method is much simpler mathematically than conventional methods. Thus, the present invention provides for a method and apparatus for fast calculation of the radius of transformed bounding spheres.
FIG. 7 shows a flowchart for calculating the new radius of the transformed sphere, according to the present invention. In step 701 , the six unique entries of the affine matrix times its transpose are calculated. (Because there will always be only six and not nine unique entries for the 3×3 matrix, the present invention saves even more processing time.) In step 703 , the upper bounds of the three Gershgorin intervals are found. In step 705 , the largest of the upper bounds is selected. In step 707 , the square root is taken. Finally, in step 709 , the radius of the old bounding sphere is multiplied by the square root just calculated. This provides a radius for the transformed bounding sphere that is at least as large as necessary, but may never be more than sqrt(3) times as large as necessary, given that a 3×3 affine matrix is used.
FIG. 8 shows more details for the calculation of the upper bounds of the Gershgorin intervals. In FIG. 8, a 3×3 matrix 801 and its transpose 803 are shown. Matrix 805 is the symmetric matrix that results from multiplying the matrix by its transform. The three Gershgorin intervals 807 are shown as well.
The following is a mathematical proof that the Gershgorin upper bound on the maximum singular value of a 3×3 matrix M is at most sqrt(3) times the actual singular value of M. (And thus the radius calculation can never be more than sqrt(3) times as large as necessary.)
Let M′ denote transpose (M).
We know that (the maximum singular value of M)>=(maximum column length in M), since M scales the length of the corresponding unit basis vector by that amount.
Squaring both sides, we get: (maximum eigenvalue of M′M)>=(maximum diagonal entry of M′M).
But note that (maximum diagonal entry of M′M) is actually the maximum of the absolute values of all the entries of M′M (since the entries of M′M are the pairwise dot products of the columns of M, and the maximum such dot product is achieved as the dot product of the longest column vector with itself).
So (maximum eigenvalue of M′M)>=the absolute value of each entry of M′M.
So the Gershgorin upper bound on the maximum eigenvalue of M′M, which is of the form: |a|+|b|+|c| for some entries a,b,c of M′M,<=3*(maximum eigenvalue of M′M).
Taking the square roots of both sides, this says that the Gershgorin upper bound on the maximum singular value of M is<=sqrt(3) times the actual maximum singular value of M.
Another embodiment of the present invention multiples the transpose of the affine matrix times the affine matrix instead of the reverse. As the actual eigenvalues are the same regardless of the order of multiplication, the result is acceptable. However, reversing the multiplication may result in a faster calculation. This is because in certain cases the matrix columns are more likely to be pairwise orthogonal than the rows. Thus, this embodiment of the present invention provides for a method and apparatus that is computationally fast, as well as accurate.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents.
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The present invention relates to a method and apparatus for obtaining a bounding sphere for the ellipsoid that results when an affine transformation matrix transforms a bounding volume. The present invention accomplishes this by using Gershgorin intervals to obtain a new radius for the bounding volume. The invention operates on a scene graph, which is comprised of a number of nodes arranged in a hierarchical organization. At least one of these nodes is an affine transformation matrix, which is used for operations such as rotations, scaling, and translations. Associated with the transformation matrix is a bounding sphere. The present invention calculates the radius of a new bounding sphere that encircles the ellipsoid formed when the affine matrix transforms the old bounding volume. The use of Gershgorin intervals is fast and yields accurate results. Thus, the present invention provides for a method and apparatus that is computationally fast and produces a well-behaved affine transformation of bounding spheres.
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This is a continuation, of application Ser. No. 821,409, filed Aug. 3, 1977, abandoned.
BACKGROUND TO THE INVENTION
The invention relates to a method for the production of workpieces turned on the peripheral surface on multi-station machine tools, wherein:
rod stock is introduced into a clamping device of the machine tool,
is clamped fast there,
a rod section is cut off at a distance from the clamping device,
the free end protruding from the clamping device is turned.
The invention further relates to a multi-station capstan machine for carrying out the method.
Such a method is carried out with the ordinary multi-station automatic capstan machines which are ordinarily provided with:
a turret or turntable which is stepwise indexable,
a plurality of clamping devices, mounted at circumferential intervals on the turntable, for clamping rod stock from which the turned workpieces are to be produced,
a charging or loading station and a plurality of working stations distributed in the peripheral direction, to which the rod stock clamped fast in the clamping devices can be fed in working sequence by the movement of the turret,
and a cutter device associated with the loading station for the rod stock.
On such automatic machines a rod section is cut off and clamped fast in the clamping device, the length of which section corresponds to the length of the desired workpiece. The clamping devices as a rule are firmly connected with the turret so that as a rule work is carried out on automatic machines with the workpiece stationary and turning tools in rotation. Ordinarily the turret is arranged horizontally and the clamping devices are directed radially so that there is sufficient space for the arrangement of the machining units around the turret. However machines are also known (Ger.Pub.Spl No. 21 02 150) where the turret can move about a horizontal axis of rotation and the clamping devices are oriented axially in relation to this axis of rotation.
One essential advantage of the method for the production of turned parts on turret machines consists in that according to choice it is possible to work rod stock or so-called ring stock (rolled-up rod or wire material) as starting material.
It is disadvantageous that on the known machines turning work on workpieces is possible only on the parts which protrude from the clamping device. At the clamped portion no turning work can be executed. Thus the production of workpieces on such machines is limited as a rule to those parts where the whole peripheral surface does not have to be worked, that is to those parts where there is still a sufficiently large zone left free for clamping. In order to overcome this disadvantage, machines have been constructed in small numbers where the workpiece is firstly turned from one side, then taken out of the clamping device and clamped afresh in a new clamp adapted to the turned diameter, and turned further. This method has the disadvantage that considerable extra expense is necessary for the clamping devices and the workpiece reversing device. Moreover a station is occupied for reversing which otherwise could be used for machining. Furthermore it is disadvantageous that the central axis of the first clamp is practically always offset in relation to the central axis of the second clamp. Moreover with this method the workpieces must often be clamped by such small surfaces that there is danger of the material being distorted by compression at the clamped surface, especially if heavy material-removal takes place in the second clamped position. This leads to corresponding waste.
Workpieces which are to be turned over the whole circumference in one clamped position can hitherto be produced only on single-spindle and multi-spindle automatic rod machines. As known, these work with rotating workpiece. The rod stock is loaded into the spindle drum and advanced by sections through the clamping device in each case, especially a pair of clamping jaws, of the spindle drum so far that it protrudes with its free end by at least one feed length, corresponding to the workpiece length plus the width of a severing tool, from the clamping device. At this free end the clamped-fast rod stock is machined to the desired workpiece shape. The feed of the rod stock is carried out in various ways. In some cases the material rod is grasped on the peripheral surface at the rear end by a retaining gripper and pushed by sections through the clamping jaws, the ejection of the remainder piece taking place to the rear through the retaining gripper. Otherwise a feed gripper is arranged before the clamping gripper of the spindle drum. The material rod is pushed with a push rod through this feed gripper and the clamping gripper, and the feed gripper takes over the further feed movement of the rod by sections. The rod remainder is expelled forward, namely by the next succeeding new material rod. In the case of both types of construction the finished workpiece is cut from the material rod by means of a cutting tool. In the case of the single spindle automatic machine only one workpiece is produced during each machine cycle, the tools come into action in succession. In automatic multi-spindle machines several tools on several spindles are in action at the same time, which is economical in the case of high production figures.
However the single and multi-spindle automatic machines have the following disadvantages in comparison with the automatic turret machines:
expensive spindle halting if operations other than turning are to be executed, for example milling, transverse drilling, transverse thread cutting, riveting, crimping, fitting. These operations can be carried out only with the spindle stationary;
expensive equipment, if work has to be carried out on the workpiece in several longitudinal axes, that is eccentrically of the axis of rotation;
noise nuisance resulting from rotation especially of long material rods of large diameter in their guides;
In the case of automatic multi-spindle machines, very expensive rod-loading devices, if these work fully automatically;
In the case of automatic multi-spindle machines with spindles aligned axially of the axis of rotation of the spindle drum, only a narrow tool space is available, so that tool changing and adjustment are correspondingly difficult.
The invention is based upon the problem of providing a method and an apparatus of the initially mentioned kind so that rod pieces turned on their entire peripheral surface can be produced on multi-station turret machines in one single clamping action. Thus the essential advantage of the automatic multi-spindle machines as regards turning possible over the whole length of the workpiece is to be achieved, but while retaining the essential advantages of the turret machines, namely the possibilities:
of carrying out the whole machining with the workpiece stationary, so that all the connected advantages such as simple execution of eccentric turning work, lower noise nuisance, simpler rod loading devices, are obtained,
in the case of clamping devices aligned radially of the axis of rotation of the turret, of being able to arrange the machining stations more favourably in the radial direction,
of being able to machine material rolled into rings.
SUMMARY OF THE INVENTION
In solution of this problem the initially stated method is characterised in accordance with the invention in that:
of the rod stock a section is introduced into the clamping device, clamped fast there and cut off from the remainder of the stock, which section has a length equal to a multiple of the machining length and additionally a clamping section sufficient for the clamping of a single machining length section,
in that this multiple section is moved by sections out of the clamping device according to the machining length in each case and clamped fast during the turning by means of a following machining length section in each case, the final machining length section being clamped fast by means of the additional clamping section provided,
and in that the machined workpiece is cut--preferably sawn--from the clamped-fast remainder of the multiple section in each case.
By "machining length" there is here understood the length of a workpiece produced in one clamping action plus the width of the severing tool. If in accordance with a known method several workpieces are produced in one clamp firstly in the form of one cohering piece which is finally cut up into individual pieces, within the meaning of the invention there is understood by "machining length" the length of these workpieces produced in one clamping action plus their cutting tool widths. By "rod stock" there is also understood so-called ring stock, which consists of rod or wire material rolled into ring form and ordinarily is formed into straight rod stock before introduction into the clamping device of the turret.
With the method in accordance with the invention all the advantages of the multi-spindle machine and the advantages of the turret machine are obtained, while the above-described disadvantages in each case are avoided. All turned parts which hitherto could be manufactured only on automatic multi-spindle machines can be produced on turret machines likewise by the method according to the invention. Furthermore by the use of this method further advantages are achieved which make the production of turned parts on turret machines still more attractive. These advantages are for example the possibility to provide a greater number of machining stations, without detriment to the accessibility of the tool space, that is to say the division of the operations can be made still more effective than in the case of the multi-spindle machine.
The possibility of using up material rods is here surprisingly great. While in the ordinary automatic single and multi-spindle machines the remainder piece must be at least of the length of the clamping zones of the clamping gripper and the retaining gripper of the rod loader or of the clamping gripper and feed gripper or the length of all three grippers, the remainder pieces according to the method in accordance with the invention are as a whole surprisingly small, since the remainder pieces of each multiple section needs to be only so long that it suffices for the clamping of one individual machining length section (the last). It is essential here that on automatic turret machines the severing of the stationary workpiece can take place with a saw blade which can be substantially thinner than the width of the cutting tool in the ordinary cutting of the rotating tool on automatic multi-spindle machines, for the cutting tool for reasons of strength cannot be made as narrow as a saw blade. According to the method in accordance with the invention a material rod having a total length for example of 3-4 m. is cut (according to the size and nature of the turret machine) for example into 5-20 pieces of approximately 200-800 mm. Firstly it is to be assumed that in the case of 5-20 pieces, of which one remainder piece is left over in each case, being necessary for the clamping of the last worked piece, as a whole a higher proportion of remainder pieces occurs than in the case of the single or multi-spindle automatic machine. That however is not so, for in the manner as explained for cutting away with a cutting tool more material is cut than in the case of cutting with a saw blade. As a rule the saw blade can be made about half as wide as the cutting tool. In the case of the tool width of 2 mm accordingly the saw blade can be 1 mm in width, that is if 15 workpieces are manufactured from a multiple rod section, then for the clamping of the last machine length 14 mm. are available as clamping length, without less parts being produced from this rod piece than in the case of manufacture of the same part on an automatic multi-spindle machine with cutting off by a cutting tool. It is here advantageous that according to the method in accordance with the invention the short remainder pieces are integral pieces, so that for example in the case of expensive non-ferrous metal a higher material re-sale price can be obtained than in the case of metal cut to shavings.
It is possible to introduce the rod stock--as in the multi-spindle machine--into the clamping device from the side opposite to the working side. In further development of the invention however the rod stock is pushed into the clamping device of the turret from the working side--radially inward in the case of clamping devices directed radially of the axis of the turret--and the cut-off multiple section is moved out of the clamping device by sections according to the respective machining length in the opposite direction--that is radially outward in the case of clamping devices directed radially of the axis of rotation of the turret.
A multi-station machine having the features as stated initially is characterised in accordance with the invention in that:
To each clamping device there is allocated on the side remote from the working side a guide for a rod stock section which comprises a multiple of the machining length and a clamping section sufficient for the clamping of one individual machining length section, in that preferably at the charging station a conveyor device is arranged by which this rod multiple section can be moved out of the clamping device by sections corresponding to the machining length in each case, and in that at the last machining station there is arranged a severing device--preferably a saw--by which the machined workpiece can be severed from the remainder of the rod multiple section clamped fast in the respective clamping device.
As conveyor device for the severed rod multiple section in each case there is expediently arranged a drive device which charges the end of the rod multiple section remote from the machining side. However as conveyor device for the severed rod multiple section in each case there can also advantageously be arranged a gripper device which grasps the rod multiple section at the end facing the working side. A feed gripper and/or a retaining gripper grasping the peripheral surface at the rear end of the rod are not necessary. In principle suitable drive devices or gripper devices, the use of which is proposed according to the invention, are known in other machines.
Further details and advantages of the invention appear from the following description of examples of embodiment as represented diagrammatically in the drawing, and from the Claims.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows a plan view of an automatic turret machine according to the invention,
FIG. 2 shows a partial elevation in the direction of the arrow II in FIG. 1,
FIG. 3 shows a lateral elevation, partially in section along the line III--III in FIG. 1,
FIG. 4 shows a vertical partial section along the line IV--IV in FIG. 1,
FIG. 5 shows a vertical partial section along the line V--V in FIG. 1,
FIGS. 5a-f show in diagrammatic representation the working operations at the various stations, namely in lateral elevation in the direction of the arrows Va-f in FIG. 5,
FIG. 6 shows a modified clamping device in vertical section analogous to the sectional plane according to FIG. 3,
FIG. 7 shows a modified conveyor device for the rod multiple section, and
FIG. 8 shows the head of this conveyor device in enlarged representation, partially in section, together with adjoining parts of the machine.
DESCRIPTION OF PREFERRED EMBODIMENTS
The automatic machine as illustrated has a turret 1 stepwise indexable about a vertical rotation axis 1a, around which there are arranged uniformly spaced from each other in the circumferential direction a charging station St1 and a plurality of machining stations St2-St6 each with machining or working unit 2-6 such as for instance disclosed in the U.S. Pat. Nos. 3,895,424 and 3,596,545 for machining workpieces as shown in FIGS. 5A-5F. According to the number of the stations the turret 1 has six clamping devices 7-12 distributed uniformly in the circumferential direction for rod stock from which the workpieces are to be produced. The rod stock clamped fast in the respective clamping device 7-12 is fed in sequence to the individual stations St1-St6 by the turret movement.
At the charging station St1 a rod loader 13 is arranged which conveys the rod stock W into the respective clamping devices 7-12 of the turret 1. This loader has a drive device 14 with plunger 15 which presses upon the rear end of the respective rod W. Through a lug 16 the plunger 15 is connected with a drive chain 17 the drive 18 of which is merely diagrammatically indicated. The rod loader has guides 19 for the rod stock W.
With each clamping device 7-12 on the side remote from the machining units 2-6 there is associated a radially extending guide 20 in the form of a semi circular channel of such length that it is suitable as guide for a rod material section 21-26 comprising a multiple of the machining length and a clamping section sufficing for the clamping of an individual machining length section. The guides 20 extend radially of the rotation axis 1a and end close to this axis. On this rotation axis there is arranged a replaceable stop piece 27 common to all the guides. Beneath the turret 1 at the charging station St1 there is an apparatus 28 for actuating the respective clamping device 7-12 in known manner. The apparatus 28 may, for instance, include a fluid operated cylinder unit having a vertically displaceable piston rod, the upper end of which engages a vertically movable shank, corresponding to shank 37 in FIG. 3 of U.S. Pat. No. 3,596,545. Such a shank is provided at each of the clamping devices 7-12 and respectively vertically aligned with the apparatus 28 after each indexing of the turret 1. The clamping devices are self-locking and open only if actuated by the apparatus 28. On the other hand, the apparatus 28 may include a cam and lever arrangement as disclosed by elements 39, 40 and 41 in U.S. Pat. No. 3,596,545.
Moreover at the charging station St1 there is a vertically raisable stop 29 which is actuated by a piston drive (schematically indicated at FIG. 1) and cooperates through a lug 30 projecting laterally from the stop 29 with a feeler 31. The feeler, as well as the other feelers mentioned, may be an electric eye or a limit switch, to create when the lug 30 is aligned with the feeler an electric impulse.
At the charging station St1 there is further arranged a conveyor device 32 by which the rod section 21-26 can be moved by sections corresponding to the machining length in each case out of the respective clamping device 7-12. This conveyor device 32 is a drive device having a cylinder 33, a piston 34 axially movable therein with piston rod 35 on the outer end of which there is a drive lug 36 which acts upon the rod multiple section 21-26 at the end face remote from the machining side, that is radially from the interior outwards. On the lug 36 there is seated a feeler 37 which together with two further feelers 38, 39 controls the movements of the conveyor device 32 in the manner described below. For this purpose the feelers 37, 38, 39 which are preferably in the form of elastic eyes or photo-electric cells of well known construction are connected by electrical conductors a control device 40 which, on the one hand, is in control connection 41 with a compressed air source 42 connected through conduits 43 and 44 with the cylinder 33 of the conveyor device 32, and, on the other hand, is in control connection 45 with a control device 46, which, on the one hand, is connected through a lead 47 with a feeler 48 preferably also in form of an elastic eye cooperating with the lug 16 of the drive device 14 of the rod loader 13 and, on the other hand controls the drive 18 of the rod loader 13 through a lead 49.
Furthermore at the charging station St1 there is arranged a saw 50 with saw blade 51. This saw 50 is movable transversely of the rod stock W in the direction of the arrow 52a (FIG. 4) by a cylinder/piston drive system 52.
At the last machining station St6 a second severing device 53 with a saw blade 54 is arranged by which the machined workpiece can be severed from the remainder of the rod multiple section 21-26 in each case clamped fast in the respective clamping device.
The clamping devices 7-12 clamp the respective rod sections 21-26 by means of two jaws 55, 56 (FIG. 5) which work centrally against one another in the direction of the arrow 57. The material W' protruding forwards out of the clamping device 7-12 corresponds to the workpiece length except for the width of the subsequent severing cut and a small safety length, and can be machined freely in stages at the stations St2-St6.
In departure from the known method on such machines, where at the station St1 the rod stock W is advanced by one workpiece length, clamped and severed, the method according to the invention works in a manner in which a longer part section 21 of the rod stock W is advanced at the charging station St1 almost to the center of the turntable, to the stop piece 27, and then clamped by the clamping device 7. From this rod stock piece 21, that is the piece cut off by the saw blade 51 from the rod stock W, as many workpieces can be produced as there are workpiece lengths plus severing tool width in the entire rod length of the piece 21--plus a remainder clamping piece. This remainder clamping piece is so long that it suffices for the clamping of the final machining length section.
The stop piece 27 is exchangeable and dimensioned so that the remainder clamping piece becomes smaller than one machining length section, so that after the finishing of the last complete workpiece on renewed advance by the lug 36 it can drop down between the stop 27 and the clamping device 7. The stop piece 27 is changed according to the workpiece length.
To explain the operations it is assumed that the clamping devices 7, 8, 9, 10, 11 and 12 are empty. It is further assumed that the clamping devices 7-12 initially are located between two stations, that is to say the clamping device 8 for example between stations St2 and St3. The supply conduit 44 to the cylinder 33 of the conveyor device 32 is charged with pressure. The engaging lug 36 thus stands in the maximum extended position, close to the rotation axis 1a of the turret 1. On the starting of the machine the turret 1 completes the commenced partial rotation and is locked in the usual way. Such turntables which can be automatically indexed and be locked in any position are for instance produced in series by Kingsbury Machine Tool Corporation in Keene, N.H. Directly after the locking the stop 29 is driven upwards in the direction of the arrow 29a either by operation of valves by the operator or by an automatic sequence control. In the upper position of the stop 29, in which its upper surface is just below the pad 15, the feeler 31 cooperating with the lug 30 gives as electrical control pulse to operate solenoid controlled valves for the opening of the clamping device 7, and pressure charging of the supply conduit 43 of the cylinder 33 from the source of compressed air 42. The lug 36 which is firmly connected with the piston rod 35 moves in the direction of the arrow 35a towards its retracted position 36' shown in dot-and-dash lines in FIG. 3. If the lug 36 can arrive at all in this position, this signifies that the clamping device 7 is empty, for the short remainder piece remaining in the clamp drops down between the clamping device 7 and the stop 29 on advance of the lug 36. Then a feed movement is initiated in the rod loader 13 through the feeler 39. The rod stock W is pushed through the guides 19 until it strikes upon the central stop piece 27. The lug 36 is in this case pushed again into its extended radially inner position by the rod stock at which the feeler 38 will issue an electric signal to the control switch 40 so that the conduits 43, 44 are rendered pressureless simultaneously with the loading operation of the rod loader 13, so that the piston 34 is not loaded at either side and the lug 36 can be entrained without resistance. After the lug 36 has reached the feeler, the latter gives an additional control pulse for a feed control, for example to the cylinder/piston drive system 52 of the saw 50, also to the stop 29 and further to the clamping device 7 which is just situated at the station St1. By this control impulse the clamping device 7 is closed and the stop 29 is driven back into the lower position represented in FIG. 3, so that the saw blade 51 can sever the rod stock W. After the severing operation and the return of the saw 50, the latter initiates a control pulse by engaging a limit switch not shown in the drawing for the further indexing of the turret 1 in the direction of the arrow 1b, so that the next clamping device can be loaded with rod stock W, so that all six clamping devices are loaded in sequence.
After the loading of the first part rod 21, sawing off and further indexing of the turntable 1, the first machining can be commenced at the station St2 with the unit 2. If one of the machinings on station St2-St6 lasts longer than the loading and sawing off, then further indexing is effected by an interlocking circuit of known construction only when the unit last having completed its machining likewise liberates the further indexing with a corresponding pulse. Thus both pulses must be present before a turntable step can take place. In order to avoid impacts, the piston 34 of the conveyor device 32 is provided with known damping means in its forward and rear positions.
The procedure was described above for absence of rod part pieces 21-26. If however a part piece is present, the lug 36 on its way from the radially inner position to the radially outer position 36' strikes the end of the rod part piece at some point and pushes the latter, with clamping device at station St1 opened, against the stop 29 situated in the upper position, so that at the following stations the rod zone W' advanced afresh can be machined. So that the lug 36 does not strike at full speed upon the rod part piece, the position of the latter is explored with the leading feeler 37 fastened to the lug 36 and connected in circuit with the control device 40. The control device 40 then reduces over a corresponding valve, not shown in the drawing, the return speed of the piston 34 so that the rod section W' is pressed lightly upon the stop 29 and can be clamped in the clamping device 7-12 by means of the clamping apparatus 28. During all these operations the guide channel 20 supports the respective rod part piece 21-26.
The feed control of the machining units 2, 3, 4, 5 and 6 is actuated in known manner after each indexing step, irrespective of whether a loading operation takes place simultaneously with the individual working operations or not. In order to prevent the feeler 38 from giving the pulse for clamping and sawing to the station St1 on every advance of the lug 36, the pulse is processed further only if a pulse from the feeler 39 has preceded.
The two cycles, in the one case machining with charging operation and in the other machining alone--can proceed at two completely different times. As a rule the charging operation and the sawing off of the material rod pieces will last longer than the machining, so that according to how many workpieces can be produced from a rod part piece, a larger number of short cycles can be followed by six longer cycles.
Since it is not guaranteed that the material rods fed by the rod loader are of equal length, it must be expected that on the one or the other occasion a shorter rod part piece will remain over. This would then in fact strike upon the central stop piece 27, but would no longer be grasped by the clamping device at station St1. In order to avoid this, in the position of the plunger 15 with lug 16 as illustrated in FIG. 3 a pulse is instigated by the feeler 48 which instantaneously stops the feed drive of the plunger 15 by means of the drive chain 17. The stop position of the plunger 15 is selected so that this residual rod stock W remains stationary about 3 mm. before the saw blade 51, so that only these 3 mm are severed.
In FIGS. 5a-f the production steps at the individual stations of the turntable are shown:
Station St1: Open clamping device 7, advance material W' in direction of arrow to stop 29;
Station St2: Machining of outer peripheral surface;
Station St3: Knurling;
Station St4: Drilling;
Station St5: Internal machining;
Station St6: Sawing off by means of the saw blade 54 of the severing device 53.
In the case of workpiece requiring a smaller number of machining operations, during indexing of the turntable through 360° two workpieces or even two or three different workpieces, if the material diameter is the same, can be produced at the same time. Only a second or third conveyor device 32, but without rod loader 13, is necessary, for example at the position 32a in FIG. 1. In the case of a 10-station machine for example three different workpieces can be produced as follows:
______________________________________Station 1: LoadStation 2: Shape first workpieceStation 3: Drill, saw offStation 4: Re-clamp materialStation 5: ShapeStation 6: Cut thread second workpieceStation 7: Drill, saw offStation 8: Re-clamp materialStation 9: Shape third workpieceStation 10: Saw off______________________________________
In the modified embodiment according to FIG. 6 the respective clamping device 7-12 for the respective rod part piece 21-26 is formed as gripper clamping device 7a. Such a clamping device in each case has a gripper 59 which is clamped by means of a piston 60 and a thrust piece 61. In the case of this gripper clamping the material cannot be advanced from the rear with the lug 36 in the manner as shown in FIGS. 1-3, but must be drawn from the front out of the gripper 59 with the apparatus 62 as illustrated in FIGS. 7 and 8. The extraction takes place at the charging station St1. The finished workpiece is cut off by means of the saw blade 54 one station ahead of station St1. The gripping apparatus 62 makes an advancing movement towards the gripper at every cycle. The gripper fingers 63, 64 are closed over the piston 65 so that the rod residue protruding from the gripper 59 is grasped. By the rearward movement of the gripper 62 by one workpiece length plus severing tool width the material is entrained with the gripper opened. After clamping of the gripper and opening of the gripper fingers 63, 64 the turntable 1 can be further indexed. When the rod part piece is completely consumed and the remainder clamping piece has dropped away downwards, the gripper fingers 63, 64 at the next sequence can carry out a greater travel, so that a lug 66 connected with the piston will pass a feeler 67 whereby a control pulse is given to the rod loader 13 for the loading of a new rod part piece. For this purpose the feeler 67 is in control connection through a lead 68 with the drive 18 of the rod loader 13 (analogous with the control connection 48 in FIG. 3). In the embodiment according to FIGS. 6-8 a tube 20a instead of a semi circular channel can be used as guide 20 for the respective rod multiple section 21-26, as shown in dot-and-dash lines in FIG. 6.
At the charging station then the charging operation takes place analogously as described with reference to FIGS. 1-3: The rod stock W is pushed through the apparatus 62 forward into the gripper 59 until it strikes upon the central stop piece 27 of the turntable. Then the saw 50 is actuated by a control pulse, so that the material can be severed with the saw blade 51.
The surprisingly low loss of material in the carrying out of the method according to the invention appears from a comparison of the following examples, starting in each case from material rods having a total length of 4 m.:
(a) Material waste in the case of automatic single and multi-spindle machines, caused by loss in cutting and by the residual piece which can no longer be machined:
EXAMPLE 1
______________________________________Material diameter: 14 mmWorkpiece length: 20 mmCutting tool width: 2 mmRemainder piece using aloading magazine: app. 80 mm (85 mm)Number of workpieces = (4000-85):(20 + 2) = 178 pieces______________________________________
EXAMPLE 2
______________________________________Material diameter: 22 mmWorkpiece length: 48 mmCutting tool width: 3 mmRemainder piece: app. 80 mm (124)Number of workpieces = (4000-124):(48 + 3) = 76 pieces______________________________________
(b) Material waste in the method according to the invention, caused by loss in the sawing of a rod into part pieces and the subsequent sawing of workpieces from these part pieces:
EXAMPLE 1
______________________________________Number of rod part piecesPossibility A: 16 part pieces @ 250 mmPossibility B: 16 part pieces @ 242 mm 1 remainder part piece 104 mm if 24 mm are deducted for 15 × 1.6 mm saw widthNumber of workpiecesWorkpiece length: 20 mmSaw width: 1 mm In the case of A: 250:21 = 11 pieces Remainder 18.9 mm In the case of B: 242:21 = 11 pieces Remainder 11 mm______________________________________
This remainder is sufficient for the clamping of the last part.
From the remainder part piece there can still be produced
______________________________________104:21 = 4 pieces Remainder 20 mm for clamping the last part.______________________________________
Thus in all 16×11+4=180 workpieces can be produced. Thus despite division into rod part pieces, two workpieces more than in the case of the single or multi-spindle automatic machine.
With a workpiece length of about 10 mm, with the method according to the invention approximately 20 workpieces more can be produced from a rod 4 m in length than in the case of the known automatic lathes.
EXAMPLE 2
Number of rod part pieces with 265 mm length
4000:265=15 rod parts pieces
with a saw width of 1.6 mm.
Number of workpieces
265:(48+1.5)=5 rod part pieces
Remainder for clamping the last workpiece=17.5 mm.
Total producible workpieces
15×5=75 workpieces
That is in all 1 part less than the known method.
As regards the waste, it is possible to work according to the invention the more advantageously, the shorter are the workpieces to be.
Within the scope of the invention modifications are still possible by the application of technically equivalent means. It would be a more expensive and to that extent less favourable but nonetheless possible modification, to cut rod part pieces to length from workpiece rod stock completely separately from the capstan machine and only then to introduce them into the clamping devices of the capstan and clamp them fast. Moreover machines are possible in which the clamping device are not exactly radially directed, but directed for example secantially or even axially. Then the charging station and the individual machine stations are correspondingly differently arranged. In the case of thin rod stock, intersecting arrangements of guides 20 lying one above the other are possible, so that then the rod multiple sections 21-26 can be as long as corresponds to the diameter of the capstan and an additional machining length.
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The method and apparatus relates to the production of turned workpieces on multi-station machine tools. In such machines rod stock is introduced into a clamping device (collet chuck) of the machine and is clamped thereby. A rod section is severed at a distance from the clamping device and the free end protruding from the clamping device is turned. In such a process a section from the rod stock is introduced into the clamping device, clamped fast there and severed, which section comprises a multiple of the machining length and in addition a clamping section sufficing for the clamping of one single machining length section. This multiple section is moved by sections corresponding in each case to the machining length section out of the clamping device. The rod stock is clamped fast during turning over a following machining length section in each case, the last machining length section being clamped fast by means of the provided additional clamping section. The machined workpiece is sawn from the clamped-fast residue of the multiple section in each case.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from Chinese Patent Application Serial No, 200710121397.X filed Sep. 5, 2007, the disclosure of which, including the specification, drawings and claims, is incorporated herein by reference in its entirety.
TECHNICAL FIELD
This disclosure relates to structured-light vision measurement technology, and more particularly, to a calibration method for structure parameters of structured-light vision sensor.
BACKGROUND
Structured-light vision measurement is a measurement method based in taking images of measurement points or light stripes, which is formed by the intersection of a structured-light projected by a laser and the surface of an object being measured, by a camera, and then acquiring 3D information regarding the object surface using a laser triangular principle. According to a mode of laser projection, structured-light vision measurement may be divided into point structured-light, single line structured-light, multiple lines structured-light and circle structured-light, etc. Structured-light vision measurement has the advantage of a large scale of measurement, noncontact, high speed, good system flexibility and moderate precision, which is widely used in the areas of reverse engineering and products online testing, etc.
The key to successful application of structured-light vision measurement is the calibration of structured-light vision sensor, which comprises calibration of the camera's intrinsic parameters and structure parameters, wherein the calibration method of the camera's intrinsic parameters is not introduced here because it is relatively mature. So far, as to the calibration for the structure parameters of the structured-light vision sensor, many scholars have researched the subject and presented some new methods such as a fiber drawing method, sawtooth target method and a cross ratio invariability method based on the 3D target, etc.
To be more specific, the so called “fiber drawing method” lets the structured-light project on some spatial distributed fibers which are non-coplanar. Because of the dispersion of the fibers, bright points are formed on the fibers and imaged on the image plane. The spatial coordinates of the bright points may be measured by electronic theodolite, thereby permitting solving of the position parameters between the structured-light and the camera by the bright points' coordinates in the image plane and spatial. This calibration method needs two electronic theodolites to measure the spatial coordinates of the bright points. If more calibration points are acquired, multiple times of manual aim are needed, of which the operations are complicated.
When it comes to the sawtooth target method, an article entitled “A New Structure Parameters Calibration Method of Structured-light Vision Sensor” and published in the Chinese Journal of Scientific Instrument, 2000, 21(1):108-110 by Fajie Duan et al. presents a structure parameters calibration method of a structured-light vision sensor according to the features of structured-light vision sensor, in which a simple calibration target and a 1D bench are used to realize the highly precise calibration of a line structured-light sensor. In this method, no other auxiliary apparatus is needed to measure the coordinates of the points on the light plane. However, the operations of the method are complicated because the attitude of the 1D bench or the structured-light sensor should be adjusted in order to make the light plane perpendicular to the edge line. Moreover, the cost of processing a sawtooth target is high, while the sawtooth edge line is limited and the calibration points that can be acquired are less.
Concerning the cross ratio invariability method based on a planar target, it is a calibration method for the structure parameters of a structured-light vision sensor. The cross ratio invariablilty method is described in an article entitled “Complete Calibration of a Structured-light Stripe Vision Sensor Through Planar Target of Unknown Orientations[J], Image and Vision Computing, Volume 23, Issue 1, January 2005, Pages 59-67)” by Fuqiang Zhou. This method uses the cross ratio invariability principle to acquire a calibration point, the lines of which on the target are few, usually 3 to 10 lines. Only one calibration point can be found in a line of feature points (at least three). Therefore, using this method, 3 to 10 calibration points from the target at one position may be obtained. This method requires no auxiliary apparatus, and there is no occlusion problem and the operations are simple. That is why the method is only suitable for line structured-light calibration, and there will be a large fitting error when the method is used to calibrate non-line structured-light.
As to the rapid calibration method of the line structured-light sensor based on a coplane reference, this calibration method is for the structure parameters of a structured-light vision sensor, as described in a Chinese patent by Jigui Zhu, entitled, “Rapid Calibration Method of Line Structured-light Sensor Based on Coplane Reference”, the patent number of which is 200510013231.7. The method calibrates a line structured-light based on an intersection line of the coplane reference and the plane determined by the optical center of the camera and the images of the line light stripes. This method requires no auxiliary apparatus, and there is no occlusion problem and the operations are simple, whereas, it can only be used in the calibration of a line structured-light or a multiple lines structured-light.
According to the analysis above, the fiber drawing method requires electronic theodolites as an auxiliary apparatus and multiple times of manual aim which is complicated to operate. A few calibration points may be acquired in the sawtooth target method because the sawtooth edges are limited, but the cost of processing the sawtooth target is high. The scope of the calibration method of cross ratio invariability based on planar target and rapid calibration method based on coplane reference for line structured-light sensor is small. The two methods are only suitable for calibration of line structured-light or multiple lines structured-light.
SUMMARY
Accordingly, one focus of this disclosure is to present a calibration method for the structure parameters of a structured-light vision sensor, which can provide high efficiency of structured-light calibration simple operation without requiring an auxiliary apparatus, and extent the application scope of the calibration of structured-light.
The technical scheme of an embodiment of the disclosure is described as follows.
A calibration method for the structure parameters of a structured-light vision sensor comprises the following steps:
A. setting up coordinate frames of a camera and an image plane;
B. setting up a target coordinate frame, acquiring images of a planar target which is used to calibrate structure parameters of the sensor, and finding coordinates in the camera coordinate frame of stripes projected by structured-light on the planar target; and
C. acquiring the coordinates in the camera coordinate frame of the stripes projected by the structured-light on the target plane multiple times and fitting a structured-light equation according to all the coordinates of light stripes acquired.
In the schemes above, the structured-light in step C may be a structured-light of any pattern.
In step C above, in one embodiment, acquiring the coordinates of the light stripes projected on the target plane multiple times includes moving the planar target arbitrarily multiple times, and repeating step B each time the planar target is moved.
In another embodiment, before step B above, the planar target is placed with feature points arbitrarily in the measurement area of the structured-light vision sensor, and bright light stripes are formed on the planar target by the projection of the structured-light.
In step B above, acquiring the images of the planar target used to calibrate the sensor's structure parameters may further comprise: taking images of the planar target with the camera and correcting distortion on the images of the planar target, wherein the images of planar target includes light strips and at least four non-collinear feature points.
In step B above, acquiring the coordinates in the camera coordinate frame of the stripes projected by the structured-light on the planar target comprises:
b1. extracting the coordinates of feature points on the images of the planar target used to calibrate the structure parameters of the sensor;
b2. solving a homographic matrix between the image plane and the target plane, and a rotation matrix and translation vector from the target coordinate frame to the camera coordinate frame according to the feature points extracted;
b3. extracting the coordinates of the light stripes on the images of the planar target used to calibrate the structure parameters of the sensor, solving the coordinates in the target coordinate frame of the light stripes on the target according to a transformation between the image plane and the target plane, and converting the coordinates into the camera coordinate frame according to the transformation from the target coordinate frame to the camera coordinate frame.
The calibration method for the structure parameters of a structured-light vision sensor presented in the disclosure, in which the position of the planar target is moved arbitrarily multiple times and the coordinates of the light stripes are calibrated only by four or more non-collinear feature points on the target images, can provide high efficiency of a structured-light calibration, simple operation without requiring an auxiliary apparatus to acquire coordinates of calibration points. The structured-light projected from the laser projector can be any pattern of structured-light, so that the implementation is more flexible and diverse, and the application scope of the calibration of structured-light can be extended.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of specification, illustrate an exemplary embodiment of the present disclosure and, together with the general description given above and the detailed description of the preferred embodiment given below, serve to explain the principles of the present disclosure.
FIG. 1 illustrates the flow diagram of an exemplary calibration method for structure parameters of a structured-light vision sensor;
FIG. 2 illustrates a schematic representation of the calibration method;
FIG. 3 is a plan view of a planar target;
FIG. 4 is a schematic illustration of a structured-light sensor for measuring a 3D shape of an inner surface of a through hole in a microminiature component;
FIGS. 5 , 6 , and 7 illustrates various views of images of a planar target when placed at three different positions to calibrate a structured-light vision sensor.
DETAILED DESCRIPTION
While the claims are not limited to the illustrated embodiments, an appreciation of various aspects of the present disclosure is best gained through a discussion of various examples thereof. Referring now to the drawings, illustrative embodiments will be described in detail. Although the drawings represent the embodiments, the drawings are not necessarily to scale and certain features may be exaggerated to better illustrate and explain an innovative aspect of an embodiment. Further, the embodiments described herein are not intended to be exhaustive or otherwise limiting or restricting to the precise form and configuration shown in the drawings and disclosed in the following detailed description.
FIG. 1 illustrates a flow diagram of a calibration method for structure parameters of a structured-light vision sensor according to an embodiment of this disclosure. As shown in FIG. 1 , the calibration method disclosed herein comprises the following steps.
1) First, coordinate frames of an image plane and camera are set up, respectively. As shown in FIG. 2 , O c -x c y c z c and O-UV are the coordinate frames of the camera and the image plane respectively, which are set up according to the position of the camera.
2) Next, the target coordinate frame is set up, taking the images of the planar target using the camera and correcting any distortion of the above images. The planar target with feature points is placed arbitrarily in the measuring range of the structured-light sensor. When the laser projector operates, it projects a pattern of light stripes on the planar target. Here, the planar target is set in advance. As shown in FIG. 3 , the set target is a 2D plane with square markers thereon. The corners of the squares are used as feature points. The numbers of the feature points could range from about 4 to 200. In one embodiment, the length of the squares sides are from about 3 mm to 50 mm, and the tolerance of the lengths of each side are from about 0.001 mm to 0.011 mm.
As shown in FIG. 2 , the target coordinate frame is set up according to the position of the planar target, which is defined as O t -x t y t z t .
The image of the planar target should include the light stripes generated by the projector and at least four non-collinear feature points. The distortion correction mentioned above utilizes the intrinsic parameters of the camera to correct the distorted image of the planar target. The distortion correction method has been studied in depth by prior researches, and will not be discussed here.
3) Next, the coordinates of at least four non-collinear feature points on the planar target image is extracted after the distortion correction is conducted in step 2.
In the present embodiment, the pixel-precision coordinates of the corner points are determined using a shape operator based on the Hessian matrix, then the gray level distribution of the neighborhood of the feature points is described by the second order Taylor expansion, and finally the sub-pixel coordinates of the feature point is solved by calculating a saddle point of the curved surface.
Detailed implementation of the sub-pixel detector is explained in Dazhi Chen's article, entitled, “A New Sub-Pixel Detector for X-Corners in Camera Calibration Targets[C], WSCG'2005 Short Papers Proceedings, 13 th International Conference in Central Europe on Computer Graphics, Visualization and Computer Vision, 2005, Plzen, Czech Republic,” the disclosure of which is incorporated herein by reference.
4) Next, the transformation between the image plane and the target plane is solved, and transformation from the target coordinate frame to the camera coordinate frame using the coordinates of the feature points extracted in step 3.
The transformation between the image plane and target plane, as mentioned above, refers to the homographic matrix between the two planes, denoted by a 3×3 matrix H, and the transformation from the target coordinate frame to the camera coordinate frame refers to the coordinate transformation denoted by a 3×3 rotation matrix R and a three-dimensional translation vector T.
Typically a linear solution of 3×3 homographic matrix H between the two planes is solved utilizing the least square method, which requires the image coordinates and the corresponding coordinates in O t -x t y t z t of at least four non-collinear feature points. Then, the optimal homographic matrix H is acquired by using the Levenberg-Marquardt nonlinear optimization. Finally, the rotation matrix R and the translation vector T from O t -x t y t z t to O c -x c y c z c are computed by decomposing H.
Details of algorithms for computing the homographic matrix H, rotation matrix R and the translation vector T have been discussed in Z. Y. Zhang's article entitled “A Flexible New Technique for Camera Calibration[R] (Microsoft Corporation, NSR-TR-98-71, 1998), the contents of which are incorporated herein by reference.
5) The coordinates of the light stripes on the planar target image after the said distortion correction in step 2, is extracted. And the coordinates in the target coordinate frame of the light stripes using the homographic matrix H is solved, finally transforming them into the camera coordinate frame.
In step 5), the normal directions of the light stripes, as well as the second derivative along the direction, are acquired by calculating the image point's Hessian matrix and the vector corresponding to the eigenvalue which is the max absolute value in the Hessian matrix, and the center position of the sub-pixel level light stripes is determined. Details of extracting the light stripes center is discussed in greater detail in Carsten Steger's article, “Unbiased Extraction of Curvilinear Structure from 2D and 3D Images [D](Germany, Technology University Munich, 1998),” the contents of which are incorporated herein by reference. The coordinates of the light stripes in the target coordinate frame are acquired by matrix H, and then they are transformed to the camera coordinate frame O c -x c y c z c by the rotation matrix R and translation vector T gotten in step 4).
6) Next, the planar target is moved arbitrarily multiple times, and steps 2 to 5 are repeated after each movement to acquire the coordinates of the light stripes in the camera coordinate frame O c -x c y c z c . Here, the number of times the planar target is moved is not restricted, and the number of movements can be set in advance.
7) Next, the equation of the structured-light in O c -x c y c z c is fitted using the coordinates of the light stripes in O c -x c y c z c , which are acquired in steps 5) and 6). Then, the equation is stored for the measuring application.
An application of structured-light sensor is described to explain the calibration method for structure parameters of the present embodiment.
FIG. 4 illustrates a structured-light sensor for measuring a 3D shape of an inner surface of a through hole in a microminiature component. When the sensor works, the conical light beam emitted by the laser 41 is projected to the conical mirror 42 . After reflection, it forms a conical structured-light which is projected to the inner surface 43 of the measured object and forms circular light stripes on the surface. The light of the stripes penetrates the glass tube 44 and goes through the endoscope 45 . Then the light stripes are imaged by the CCD camera 46 . Before using the system, the equation of the conical structured-light should be calibrated.
According to the procedure shown in FIG. 1 , the equation of the conical structured-light is calibrated using the planar target with a pattern shown in FIG. 2 . The target is moved three times arbitrarily, and three images of the target are acquired for calibration, as shown in FIG. 5 , FIG. 6 , and FIG. 7 .
The coordinates of the feature points 51 , 52 , 53 and 54 in FIG. 5 are extracted, which are (119.1, 114.5), (386.3, 115.2), (385.2, 383.4), (119.7, 382.6) respectively, and the corresponding coordinates in the target coordinate frame are (−15, 15), (20, 15), (20, −20), (−15, −20) respectively.
The homographic matrix H 1 is computed according to step 4), the rotation matrix R 1 and translation vector T 1 from the target coordinate frame O t -x t y t z t to the camera coordinate frame O c -x c y c z c are:
H
1
=
[
7.6104
-
0.0389
233.5335
0.0187
-
7.7101
230.1376
0
-
0.0002
1
]
R
1
=
[
0.994262
0.038286
0.099884
0.045158
-
0.996699
-
0.067475
0.096971
0.071598
-
0.992709
]
T
1
=
[
4.233
-
4.245
86.446
]
The coordinates of the feature points 61 , 62 , 63 and 64 in FIG. 6 are extracted, which are (140.7, 103.4) (364.3, 105.6), (363.2, 374.9), (141.0, 372.8) respectively, and the corresponding coordinates in the target coordinate frame are (−10, 15), (15, 15), (15, −15), (−10, −15) respectively.
The homographic matrix H 2 is computed according to step 4), the rotation matrix R 2 and translation vector T 2 from the target coordinate frame O t -x t y t z t to the camera coordinate frame O c -x c y c z c are:
H
2
=
[
8.9194
-
0.0395
230.0268
0.0891
-
9.0287
239.3832
0
-
0.0002
1
]
R
2
=
[
0.968369
-
0.003242
0.249500
0.009868
-
0.998636
-
0.051277
0.249326
0.052118
-
0.967016
]
T
2
=
[
3.526
-
3.458
71.957
]
The coordinates of the feature points 71 , 72 , 73 and 74 in FIG. 7 are extracted, which are (127.5, 136.3) (377.4, 138.9), (375.4, 388.1), (127.1, 387.7) respectively, and the corresponding coordinates in the target coordinate frame are (−10, 10), (15, 10), (15, −15) (−10, −15) respectively.
The homographic matrix H 3 is computed according to step 4), the rotation matrix R and translation vector T from the target coordinate frame O t -x t y t z t to the camera coordinate frame O c -x c y c z c are:
H
3
=
[
10.0674
-
0.0170
227.5667
0.1521
-
10.0951
237.9409
0.0004
-
0.0003
1
]
R
3
=
[
0.999364
0.022667
0.027530
0.024393
-
0.997649
-
0.064043
0.026014
0.064674
-
0.997567
]
T
3
=
[
2.558
-
3.609
55.349
]
Finally, the equation of the structured-light fit by the coordinates of the three light stripes in the camera coordinate frame is:
x 2 +1331 y 2 +3 z 2 +80 xy+ 119 yz+ 4 zx− 218 x− 7305 y− 324 z+ 10000=0
The equation of the structured-light will be employed by the structured-light vision sensor in the measuring process.
The foregoing description of various embodiments of the disclosure has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise embodiments disclosed. Numerous modifications or variations are possible in light of the above teachings. The embodiments discussed were chosen and described to provide the best illustration of the principles of the disclosure and its practical application to thereby enable one of ordinary skill in the art to utilize the disclosure in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.
|
This disclosure provides a calibration method for structure parameters of a structured-light vision sensor, which includes setting up the coordinate frames of a camera, image plane and target for calibration. The calculation of coordinates in the camera coordinate frame of stripes, projected by structured-light, on the planar target and a structured-light equation fitting according to the coordinates in the camera coordinate frame of the stripes on the planar target, by moving the planar target arbitrarily multiple times. The calibration method of the structured-light vision sensor provided by the disclosure is easy to operate and no auxiliary apparatus is needed, which can not only promote the efficiency of the calibration of structured-light, but also extend the application scope of calibration of structured-light.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is directed toward an apparatus for managing cables, wires, cords, and the like, and more particularly, to a cable clip for organizing and routing cables and wires in various directions.
[0003] 2. Description of Related Art
[0004] The tangling and disarray of cords and wires associated with computers, appliances, and other machines is all too common. Anyone who has tried to set up a computer and all accessories knows that separating the wires is a burdensome task. Once they are detangled, maintaining order is also challenging. Similarly, the wires attached to other devices, such as cellular phones, rechargers, PDA's, etc. are also difficult to manage. Inherent in the organization and management of wires, is the need to route them in a desired direction or path.
[0005] There are many products available that assist in organizing, managing and routing wires. These products vary in form and composition. The simplest cord organizer is the widely used nylon wire tie, having a head and a pawl that loops around the wires. A general-purpose nylon wire tie can group wires together and when used in conjunction with an adhesive backed mounting base, it can be used to anchor wires to a flat surface. However, a typical general-purpose nylon wire tie cannot be reused, because the head is self-locking and once the pawl is inserted into the head it is locked in and is cut off in order to remove the wire tie. A releasable cable tie has interlocking teeth along its pawl and is adjusted by depressing a tab connected to the head. The releasable cable tie can be reused, however, it is generally not compatible with an adhesive backed mounting base and thus cannot anchor wires to a flat surface.
[0006] Cord clips are another commercially available product used for organizing cables. Generally, cord clips have an adhesive backed base and a retaining arm designed to hold cords. The use of a cord clip is advantageous over a releasable cable tie, in that the cord clip can attach cords to a flat surface in addition to organizing them. Additionally, cord clips that have thicker retaining arms are advantageous over general-purpose ties, as they partially cover the cords, thus allowing for slightly more stable positioning. However, cord clips are often very small and flimsy, and cannot hold large cords or cables. Also, cord clips are difficult to handle, in that the rounded retaining arm of the clip is made of rigid plastic and a has a small range of motion. This rigid structure can only be raised a rather limited amount and the cables inserted in the clip invariably are smaller in diameter than that of the clip. A cable that is slightly larger than the cord clip would have to be forced in to the clip, likely resulting in damage to the cable or breaking of the cord clip.
[0007] Known cord organizers have mountable bases with hooks or channels that allow for turning and looping cords. For example, one known organizer has multiple swivel hooks aligned along the top and bottom of the base that allow for the cords to be wrapped around them, but has at least two drawbacks. Firstly, each hook extends straight up or down. Because they do not curve around the cord, they fail to encase the cord. If a long cord is not wrapped around the hooks tightly or if it is tugged at and the tension is released, the cord will easily unwind and will tangle. Secondly, these swivel hooks can become loosened over time and break off, once again, causing the cord to unwind. The organizer is generally very bulky and is intended to be used in clinical settings for medical machine cords. It is not intended to route wires.
[0008] Another known cord organizer has a base with channels and posts designed to receive cables and loop them along the base. This product makes it possible to run wires in parallel channels along the base plate. However, the channels and posts are rigid in their design and are thus too limiting in terms of the cables they can hold. Moreover, this product does not route cables. Instead, the channels that extend from the base are designed to have the cables pass through them and loop around the posts in order to organize the cables.
[0009] Thus, the various cord organizers described above fail to route cables, wires, and cords at a desired angle. Further, because these cord organizers are designed merely to bunch wires together, they fail in directing a wire in a particular path. Although multiple products can potentially be used in conjunction with each other to direct a wire or cord at a particular angle, this is far too cumbersome and aesthetically unpleasant.
[0010] For each of the foregoing reasons, a need exists for a product that provides for convenient organization and management of cables, wires, and cords and is designed to manage cables of varying sizes securely, allowing for stable grounded routing in a desired angle, without damaging them.
SUMMARY OF THE INVENTION
[0011] The present invention provides a cable clip for organizing, managing and routing wires that overcomes the aforementioned drawbacks of the prior art. The cable clip includes a head for routing one or more cables in three or more directions and has a rigid base. In one embodiment, the head comprises a flexible dome-shaped head and the base is circular in shape. The dome-shaped head includes a first slot that extends radially across the dome-shaped head and is perpendicular to a second slot that extends radially across the dome-shaped head, each slot having arcuate openings of a circular shape on opposing ends. Each arcuate opening provides an entry or exit point for a cable or wire and each slot is a transit path for the same. The first slot with arcuate openings has larger arcuate openings then the second slot with arcuate openings. The two slots and four arcuate openings result in four retaining arms having a rounded contour that encase and maintain wires in the dome-shaped head. Because the dome-shaped head is made of a flexible material, the retaining arms allow for convenient entry and exit for cables of varying sizes, as well as removal and reinsertion of the cables without destruction of the invention. It should be appreciated that a different number of slots and arcuate openings as well as different sized slots and different shaped arcuate openings could also be advantageously utilized in order to vary the number, size and directions of cables that could be routed using a single cable clip.
[0012] The cable clip can be mounted to a flat surface from its circular base. In a first embodiment of the invention, the cable clip can be affixed to a flat surface using an adhesive layer covering the circular base. In another embodiment of the invention, a screw can be inserted through the central aperture of the circular base in order to attach the cable clip to a wall or desk using a drill or similar device. In yet another embodiment of the invention, a friction fit pin can be inserted into the central aperture of the circular base in order to affix the cable clip into a hole, such as in a wall or desk. Finally, all three embodiments can be incorporated into one cable clip, in which the adhesive layer is covered by a protective film. This allows the user to have the option of peeling off the protective film to use the adhesive layer, or keeping the protective film intact in order to use either a screw or friction fit pin to attach the cable clip to a flat surface.
[0013] A more complete understanding of the cable clip will be afforded to those skilled in the art, as well as a realization of additional advantages and objects thereof, by a consideration of the following detailed description of at least three embodiments. Reference will be made to the appended sheets of drawings that will first be described briefly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is an perspective view of an exemplary cable clip having a circular base covered with an adhesive layer and a peel-off protective film.
[0015] FIG. 2 is a cross-sectional view of the exemplary cable clip of FIG. 1 and illustrates the circular base affixed to a dome-shaped head.
[0016] FIG. 3 is a top view of the cable clip and illustrates two possible transit paths for a single cable through the dome-shaped head of the cable clip.
[0017] FIG. 4 is a side view of the cable clip and illustrates two transit paths for multiple cables through the dome-shaped head of the cable clip.
[0018] FIG. 5 illustrates a screw coupled to the cable clip that is used to screw the cable clip to a flat surface.
[0019] FIG. 6 illustrates a friction fit pin coupled to the cable clip that is used to affix the cable clip to a flat surface.
[0020] FIG. 7 illustrates an exemplary use of the cable clip for routing cables and wires along a straight path on a wall and a second exemplary use of the cable clip for routing cables and wires in a ninety-degree direction, around a corner, on a ceiling.
[0021] FIG. 8 further illustrates an exemplary use of the cable clip for directing a cable or wire in an approximate ninety-degree direction.
[0022] FIG. 9 another exemplary use of a cable clip as a cable plug end, for holding the ends of loose cables.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] The present invention provides a cable clip for organizing and routing cables, wires and the like. More particularly, the present invention satisfies the need for a product that provides for convenient organization of wires and that is also designed to route wires of varying sizes securely, allowing for stable grounded routing at a desired angle, with no damage to the wires. In the detailed description that follows, like element numerals are used to describe like elements shown in one or more of the figures.
[0024] FIG. 1 provides an perspective view of a cable clip 1 . The cable clip 1 includes a generally circular base 2 made from a rigid material and in one embodiment, a dome-shaped head 3 made from a flexible material. The circular base 2 has a generally flat back surface 4 with a central aperture 5 . In one embodiment, the underside of the back surface 4 may include an adhesive layer 6 for permanent or releasable attachment of the cable clip 1 to a corresponding flat surface such as a wall or desk. The adhesive layer 6 is covered by a protective film 7 that can be peeled off when ready for use. FIG. 2 is a cross-sectional view of the cable clip 1 . The rigid circular base 2 is permanently affixed to the bottom 8 of the flexible dome-shaped head 3 during the manufacturing process by either injection molding, creating one unitary structure, or by permanent adhesive. As illustrated in FIGS. 1 and 2 , the flexible dome-shaped head 3 extends downward from the top portion and at the bottom portion, encircles the outer perimeter 9 of the circular base 2 , thereby enclosing the circular base 2 . One skilled in the art will appreciate that the head of the cable clip is not limited to being dome-shaped. Instead, in other embodiments the cable clip includes a head for routing one or more cables in three or more directions.
[0025] FIG. 3 illustrates a top view of the exemplary cable clip 1 . The flexible dome-shaped head 3 has a first slot 10 that extends radially along the dome-shaped head 3 and a second slot 11 that extends radially along the dome-shaped head 3 , although offset circumferentially from the first slot 10 by roughly 90° forming an opening 12 at the top of the dome-shaped head 3 (see FIG. 2 ). Furthermore, the first and second slots 10 , 11 form arcuate openings 13 , 14 on opposite sides of the dome-shaped head 3 and provide first and second transit paths 15 , 16 . Arcuate opening 13 , 14 are circular in shape, with the diameter of arcuate opening 13 being approximately twice that of acruate opening 13 . This allows once cable clip to be utilized with varying sizes of cables or wires. The resulting dome-shaped head 3 has four retaining arms 17 a - 17 d , that extend up from the circular base 2 towards the center of the dome-shaped head 3 and correspond with the opening 12 at the top of the dome-shaped head 3 . It should be appreciated that a different number of slots and arcuate openings as well as different sized slots and different shaped arcuate openings could also be advantageously utilized in order to vary the number, size and directions of cables that could be routed with the cable clip.
[0026] Referring now to FIG. 4 , the cable clip 1 is intended to engage a cable, wire or the like. A cable 18 can enter the cable clip 1 from any of the arcuate openings 13 , 14 , travel across the transit paths 15 , 16 and exit from the opposite arcuate openings 13 , 14 , with arcuate opening 14 accommodating larger diameter cables than arcuate opening 13 . Additionally, a cable 18 can be inserted into the cable clip 1 from the opening 12 at the top of the dome-shaped head 3 , as the flexible retaining arms 17 a - 17 d allow for the opening 12 to expand to receive a cable 18 by flexing outward. Furthermore, the retaining arms 17 a - 17 d are intended to maintain the cable 18 in the dome-shaped head 3 by flexing back to their original position, thus providing for easy ingress and egress for the cable 18 . The retaining arms 17 a - 17 d also provide enclosure for the cable 18 .
[0027] In one embodiment of the present invention, the cable clip 1 can be attached to a flat surface by peeling off the protective film 7 (see FIG. 1 ) and attaching the cable clip 1 to the flat surface (e.g., wall, desk, table, etc.) with the adhesive layer. In another embodiment of the present invention, a screw 19 can be inserted through the central aperture 5 of the circular base 2 of the cable clip 1 , as illustrated in FIG. 5 . Thus, the cable clip 1 can be securely attached to an object that is made of wood (e.g., wall, desk, table or other furniture item) by using a screw 19 . This provides for a stable clip that will securely hold a cable 18 . In yet another embodiment of the present invention, the cable clip 1 can be affixed to a surface (e.g., wall, table, desk, etc.) using a friction fit pin 20 . Referring now to FIG. 6 , a friction fit pin 20 is attached to the cable clip 1 by being inserted through the central aperture 5 of the circular base 2 . The friction fit pin 20 has a head portion 21 that is bigger than the central aperture 5 of the circular base 2 and allows for the friction fit pin 20 to attach to the circular base 2 . The friction fit pin 20 has a tail end portion 22 with multiple tabs 23 . The tail end 22 of the friction fit pin 20 can be inserted into a hole in a surface (e.g., wall, table, desk, etc.), wherein the cable clip 1 will be securely held in place by the multiple tabs 23 in conjunction with the friction fit pin 20 . It should be appreciated that other sizes and shapes of screw 19 and friction fit pin 20 could be routed using the cable clip 1 for a particular application.
[0028] The above-described three embodiments can be incorporated into one cable clip 1 , in which the protective film 7 covers the adhesive layer 6 . This allows the user to have the option of peeling off the protective film 7 to use the adhesive layer 6 , or keeping the protective film 7 intact in order to use either a screw 19 or a friction fit pin 20 to attach the cable clip to a flat surface.
[0029] The present invention can be used for multiple purposes. In addition to organizing cables and wires, the cable clip 1 can also route and manage wires. FIG. 7 illustrates the use of the cable clip 1 as a way to route wires along a wall and ceiling in a desired direction or path. As shown in FIG. 7 , multiple cable clips 1 can be used to route wires in either a straight path or at an angle in a corner. Thus, the present invention allows for easy routing of a cable 18 at approximately 90 degrees. This is further illustrated in FIG. 8 . A cable 18 can enter the first slot 10 through one arcuate opening 13 along the first transit path 15 , be directed into the second slot 11 by being turned roughly 90 degrees, and can then exit the cable clip 1 out of the adjacent arcuate opening 14 , having passed through the second transit path 16 . In this instance, the retaining arm 17 b between the adjacent arcuate openings 13 and 14 will securely hold the cable 18 in place. It should be appreciated that other angles between the transit paths could be used as desired for a particular application.
[0030] Cable clip 1 can also be used to take-up excess slack in a cable or cord by looping the cable several times back and forth between arcuate openings 13 and 14 (not shown) or looping a cable or cord back upon itself and inserting the looped cable or cord into slot 10 or slot 11 (not shown).
[0031] Yet another use of the cable clip 1 is illustrated in FIG. 9 . Here, the cable clip 1 can be attached to a flat surface by any of the attachment methods described above and a cord or cable 18 , for example one that is attached to a cellular phone charger, can be managed by the cable clip 1 . The cable clip 1 is thus used as a cable plug end, allowing for the cable to sit on top of the desk when the cellular phone is not attached to its charging cable. This eliminates the nuisance of the charging cable falling to the floor and allows for convenient and easy accessibility to the charging cable 18 . Here the cable clip 1 is primarily used to hold a cord or cable in place and is advantageous over the prior art described above, because it eliminates the need to wind the cable around a spool.
[0032] It is readily apparent that the present invention solves the problems posed by the prior art and overcomes their disadvantages. The flexible dome-shaped head 3 of the cable clip 1 has multiple advantages, in that it is intended to receive larger cables and wires, encloses them thereby protecting the wires and also allows for convenient ingress and egress. Unlike nylon wire ties, cables and wires can be inserted and removed from the present invention multiple times without having to destroy the invention. It solves the problems of exposed wires that are simply bunched together with ties and allows for easy entry and encasement of wires, unlike the adhesive back cord clips. It holds the wires safely and securely and eliminates the risk of unwinding and tangling. Unlike the rigid channels and posts of prior art cable organizers, the arcuate openings 13 , 14 of the present invention outlined by the flexible retaining arms 17 a - 17 d are intended to receive larger and/or multiple cables of varying sizes and the flexible material of the retaining arms 17 a - 17 d do not damage the cables. Moreover, the rigid circular base 2 allows for better anchoring to flat surfaces as compared to the prior art, that utilize thin plastic bases that are generally attached to a flat surface with adhesive pads.
[0033] Having thus described several embodiments of a cable clip and system used to organize, manage and routes cables and wires, it should be apparent to those skilled in the art that certain advantages of the within cable clip and system have been achieved. It should also be appreciated that various modifications, adaptations, and alternative embodiments thereof may be made within the scope and spirit of the present invention. It should be apparent that many of the inventive steps described above would be equally applicable to other cable clips with various numbers and sizes of arcuate openings on the cable clip head, as well as heads with other than a dome-shape.
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A system and apparatus are provided for managing cables, wires, and cords, and more particularly, to organize and route cables and wires in various directions. For example, there is provided an apparatus comprising: a cable clip with a rigid circular base and a flexible dome-shaped head, wherein the base includes a central aperture and an adhesive layer covered by a protective film on one side and is integrated with the dome-shaped head on the other side. The dome-shaped head has a plurality of slots that extend radially across the head and intersect with one another, forming an opening. In one embodiment, each slot has circular shaped arcuate openings on opposites sides creating first and second transit paths for a cable or wire. The resulting dome-shaped head has a plurality of retaining arms that receive cables, retains them, and can be attached to a surface by a variety of methods.
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This application claims priority under 35 USC § 119 (e) (1) of provisional application number 60/011,204, filed Feb. 6, 1996.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to infrared (IR) scanners and, more specifically, to oscillating type IR scanners.
2. Brief Description of the Prior Art
The purpose of a scanner of the type discussed hereinbelow is to sweep in azimuth a two-dimensional infrared scene across a one-dimensional array of detectors, thus creating a two-dimensional image of the scanned scene with the infrared scanning system. This is accomplished by precisely controlling the position of a mirror which scans the scene in synchronization with the sampling of the detector. Conversely, this process may be viewed as sweeping the column of detectors across the field of view. Some scanners can also hold a static position (i.e., not scanning). An interlacer can be provided which moves in elevation in the cross-scan axis up and down one half of a detector pixel distance to scan between the prior positions of adjacent detector elements and increase the vertical resolution of the system.
The main performance attributes of an IR scanner are linearity, repeatability and efficiency. Historically, polygon scanners have had a greater advantage over the oscillating scanners in terms of linearity and repeatability performance. However, the low scan efficiency plus added power, weight and size of a polygon scanner renders it unsuitable for deployment in some systems.
Prior art galvanometer based scanners have been incapable of providing the linearity and repeatability required for focal plane array (FPA) base imaging systems.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided an IR scanner of the oscillating type that provides high quality IR images for target acquisition, display and tracking purposes in a FPA based IR imaging system. The system in accordance with the present invention has the advantage over the polygon and the galvanometer based scanners of reduced size, weight and power requirements and improved performance.
A DC motor is used to drive the mirror of the scanner in the scanning direction with retrace at the end of the scan. The feedback from the DC motor is a resolver (sensor) which is used in a new way from that of prior art scanners. A major difference as compared with prior art scanners is that the position that is entered into the resolver is the position to which the mirror is to scan at each of plural points along the scanning path with an error signal being provided by the resolver as opposed to entry of the present position of the mirror from the resolver with operation thereon as provided in the prior art. In the prior art, the resolver provides the sine and cosine data of the present angle of the mirror whereas, in accordance with the present invention, the sine and cosine data of the desired angle for each of the plural points along the scan path of the mirror is entered into or provided to the resolver with the resolver then providing an error signal indicative of the difference between the desired angle of the mirror and the present angle of the mirror. Accordingly, the output of the resolver is an error signal which is indicative of the difference between the present position of the mirror and the desired position of the mirror at that point in time. The control loop then controls the mirror and drives this error to zero via the DC motor. This difference provides several advantages for the accuracy of the scanner in terms of temperature and component tolerances. Measurement of the error as opposed to the actual angle of the mirror improves the resolution of the system significantly because the angles being measured are large compared to the error signal which is generally small, thereby decreasing the required measured dynamic range.
Another novel feature is the adaptive control of the system in addition to and in conjunction with the closed loop control which gradually drives the system error toward zero.
Briefly, the motor controlling the scanning mirror is initially driven by a current driver which is controlled by a combination! signal which is the sum of! a preprogrammed acceleration profile, this signal being a predicted, fixed and stored profile designed to move the mirror exactly in synchronism with the array of detectors. A resolver receives signals (e.g. sine and cosine signals) indicative of the desired position of the mirror and motor at plural points in time during a scan, compares these signals with the actual position of the motor and mirror and provides an error signal. This error signal is operated upon in a closed loop system by a series of filters. These filters are standard digital filters and provide sufficient bandwidth to control the position error without overshooting and effecting marginal stability conditions. The output of the filters is an error signal which is summed with the preprogrammed acceleration profile signal. The output of the filters is also operated upon by an adaptive process which is designed to compensate for fixed or slowly changing anomalies in the known parameters of the loop. The kinds of parameter errors that the adaptive process corrects are such things as errors in the acceleration feed-forward gain, friction effects, temperature effects on the analog components, etc. The function of the adaptive process is then to build and store additive values of current command in a table, the entries corresponding to each bin of the scan command profile. These values are added to those generated by the compensation output from the filters and the acceleration feed-forward functions to finally control the motor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the basic elements of a scanning system and the scene being scanned;
FIG. 2 is a block diagram of a scanner system in accordance with the present invention;
FIG. 3 is a more detailed block diagram of the architecture of a scanner in accordance with the present invention; and
FIG. 4 is a schematic description of the operations provided in the microprocessor 51 wherein the input is from the ADC 49 and the output is to the DAC 53 as described with reference to FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The purpose of the scanner is to scan a two-dimensional infrared scene. With reference to FIG. 1, the scanner includes a detector array 1, which is generally a one-dimensional array of IR detector elements, generally about 480 such elements. The scene 5 is detected by the detector elements of the detector array 1 via a scanning mirror 3 which traverses the scene of interest and reflects the received infrared radiations indicative of the observed scene onto the detector array. The mirror 3 then returns to its original start position and commences a new scan and retrace operation. The number of scans is generally at a rate of about 60 Hz, though this number is arbitrary and is often other than 60 Hz. The scene detected by the detector array is then reconstructed in standard manner, such as, for example, a visual display, via video processing 7. It is imperative that the scanning mirror 3 travel at a velocity corresponding to the sampling rate of the detector array 1, any deviation from that velocity being a performance loss.
Referring now to FIG. 2, there is shown a block diagram of a scanner system in accordance with the present invention which includes a scanner assembly 10 composed of a scan mirror 17, a DC motor 15 and a resolver control transformer 19 and control circuitry therefor. The scanner system includes a microcontroller 11 which controls a current driver 13 which provides drive current to a DC motor 15. The motor 15 controls the scanning of a scanning mirror 17 as well as a resolver control transformer 19 which senses the present position of the motor 15 and the mirror 17. The microcontroller 11 also provides a position command signal indicative of the desired (or required) position of the mirror 17 into a position command generator 21. The position command generator 21 provides this position by providing appropriate sine and cosine signals to the resolver 19, the latter providing an error signal to a position error processing circuit 23 indicative of the difference between the position command signal and the present position as determined by the resolver. This error signal is sent back to the microcontroller 11 which, through its software and adaptive algorithms, adjusts the current driver 13.
The resolver 19, which is a position sensor, takes input signals representing the sine and cosine of the desired angle and outputs a signal representing the error from that position. The electromechanical equations describing the operation of the resolver, which, in the preferred embodiment is a 1-speed resolver, are: ##EQU1## where: V A =magnitude of the carrier ω=frequency of the carrier (20 kHz * 2 * π)
Tr=transformation ratio of the resolver (gain)
φ=desired angle for which the resolver error voltage is zero
Θ=actual rotor angle with respect to stator.
While the above equations, per se, are well known, it should be noted that they are applied in a manner which is backward from that generally used.
Referring now to FIG. 3, which is a more detailed block diagram of the architecture of a scanner in accordance with the present invention, there is shown a resolver 31 which is a transformer having coils 33, 35 and 37 of which coil 37 is movable. As coil 37 moves, an error signal is provided in that coil. At all times, a microprocessor (shown as the line enclosing 39, 41 and 51) provides sine 39 and cosine 41 signals indicative of the desired position of the scanner and sends these signals to a 16 bit multiplying DAC (MDAC) 43. The MDAC multiplies each of the sine and cosine signals 39 and 41 by a reference sine wave received via low pass filter 45, which acts as a carrier to be modulated (such as, for example, A sin (20 kHz) and provides a modulated carrier sine wave and cosine wave as a result of the multiplication, the modulated sine wave exciting the coil 33 and the modulated cosine wave exciting the coil 35. The resolver 31 is wound so that coil 37, which is a secondary for the other coils 33 and 35 will produce the angular position error when excited by coils 33 and 35 as described. Normally, a single sine reference excites coil 37, the output being an angular position indicated by the sine and cosine of the angle on coils 33 and 35. Therefore the resolver is used backwards. The error signal which appears at coil 37 and is filtered in a bandpass filter 45 to improve the signal to noise ratio. The error signal is then demodulated in demodulator 47 to remove the carrier (e.g. 20 kHz) and provide a DC signal. The DC signal is converted to a digital signal in a 16 bit ADC 49, the digital signal being brought into a microprocessor 51 where it is worked on by the algorithms therein. The purpose of the algorithms is to determine from the error signal the amount of motor drive required to force the error to zero. A signal indicative of the amount of motor drive required is provided to a DAC 53 by the microprocessor 51 which then drives a current driver 55 which then drives the motor 57. The motor 57 then drives the load 59, which is the equivalent of the mirror and resolver, to a new position. As an alternative or in addition, an optical position sensor 61 for determining the position of the motor can be used to further stabilize the system performance over temperature in terms of angle drift or offset, this being fed back to the microprocessor to provide additional fine tuning.
Referring now to FIG. 4, there is shown a schematic description of the operations provided in the microprocessor 51 for a specific example which is provided by way of example and not by way of limitation wherein the input is from the ADC 49 and the output is to the DAC 53 as described with reference to FIG. 3. The output of the ADC 49, which is the loop position error, is filtered in a G4 filter 63 which is a first order lead-lag whose lead corner frequency is at 21 Hz and whose lag corner frequency could be, for example, at 2606.69 Hz. The s-domain structure of this filter is, for the specific example, which is provided by way of example and not of limitation:
G4(s)=329.78(s+132.113)/(s+1.637×10.sup.4).
The z-domain equivalent of the filter of this example is achieved by applying the bilinear transform in which the Laplace operator, s, is replaced by:
s=(2/τ)(1-z.sup.- /1+z.sup.-1)
where τ is the scan loop sample period, 1.9960=100.4 μsec. This substitution results in the following z-domain transfer function:
G4(z)=(4096(1458-144-z.sup..sup.-1))/32787-3207z.sup.-1.
The output of filter 63 is scaled by a scaler 65 and the output thereof is then filtered by a G4A filter 67 and then by a G8 filter 69.
The G4A filter 67 is a first order lead-lag whose lead corner frequency is 364.4 Hz and whose lag corner frequency is, for example, at 927.58 Hz. The s-domain structure of this filter is:
G4A(s)=2.027(s+2288.56)/(s+5825.18).
The z-domain equivalent of this filter is achieved by applying the bilinear transform as above, resulting in the following z-domain transfer function:
G4A(z)=(512(112-89z.sup.-1))/32787+17996z.sup.-1.
The G8 filter is a double "integral plus proportional" filter whose lead corners are, for example, 101.86 Hz. The s-domain structure of this filter is:
G8(s)= 6352.5(s.sup.2 +1.243g×10.sup.3 +4.092×10.sup.5)!/s.sup.2.
The z-domain equivalent of this filter is achieved by applying the bilinear transform as before, resulting in the following z-domain transfer function:
G8(z)= (12718-24620z.sup.-1)+11928z.sup.-2 !/(1-2z.sup.-1 +z.sup.-2).
The G4, G4A and G8 filters are standard digital filters and provide sufficient bandwidth to control the position error without overshooting and effecting marginal stability conditions.
The output of the filter 69 is sent to adaptive B filter 71 followed by adaptive bin memory 75 and adaptive A filter 79 with scalers 73, 77 and 81 between each of the adaptive algorithm blocks. The adaptive filters are the learning portion of the algorithm. They are the part of the algorithm that provides <one percent performance because the learning compensates for errors which would otherwise prevent the performance from reaching the <1 percent point. Accordingly, the G-filters drive the error toward zero.
The adaptive portion of the algorithm is designed to compensate for fixed or slowly changing anomalies in the known parameters of the loop. The kinds of parameter errors that the adaptive process corrects are such things as errors in the acceleration feed-forward gain, friction effects, temperature effects on the analog components, etc. The function of the adaptive process is then to build and store additive values of current command in a table, the entries corresponding to each bin of the scan command profile. These values are added to those generated by the compensation output from G8 filter 69 and the acceleration feed-forward functions. There is a table which depends upon the specific implementation or rate. For example, there can be one table for 60 Hz operation and another for 30 Hz operation, etc. Experience has shown that if the gain of the adaptive process is too high, instabilities can develop in the loop dynamics. In order to avoid this potential difficulty, the gain on the output of adaptive B filter 71 is adjusted as a function of run time after any state change of the scanner.
The adaptive process has three sections, these being a low pass filter to reduce the noise input to the process which is adaptive B filter 71, and adaptive bin memory 75 which is a table of registers containing values for each type of operation, there being 166 values for 60 Hz and 332 values for 30 Hz operation in the preferred embodiment, and an adaptive A filter 79 which forms a linear combination of three values found in three consecutive bins of the adaptive bin register.
The structure of the adaptive B filter 71 in the s-domain is:
ADAPT B(s)=1.63×10.sup.8 /(s.sup.2 +39117s+3.78×10.sup.8)
and in the z-domain is:
ADAPT B(z)=(3405.4+6810.8z.sup.-1 +3405.4z.sup.-2)/(32787-543.2z.sup.-1 +97.36z.sup.-2.
The values stored in the adaptive bin register 75 are the integrated values of the output of filter 71 for each of the loop update time intervals corresponding to the commanded scan profile. Each previous value for a given interval is updated by adding the new output of filter 71 for that interval on each successive scan. As the scans continue, these values converge to a constant or nearly constant value. The function of the adaptive process is to drive the output of the G8 filter 69 to zero, thus implying zero loop error.
With reference to adaptive A filter 79, experience has shown that the group of bins from which the output is formed must be advanced with respect to the actual bin number associated with the scan command profile in order to achieve acceptable performance. This advance imposes lead on the output which has been found to be necessary to achieving the desired performance. The system will commence operation with some predetermined advance and adjust the advance thereafter on the basis of test results. The structure of the adaptive A filter 79 in the s-domain is:
ADAPT A(s)=1.25×10.sup.7 /(s.sup.2 +20955s+2.16×10.sup.8)
and in the z-domain is:
ADAPT A(z)=(395.7+791.42z.sup.-1 +395.7z.sup.-2)/(32768-11649z.sup.-1 +6233z.sup.-2.
The output of the G8 filter 69 is also applied to a summing circuit 85 via a scaler 83, this output being the torque command required to correct the loop position error in the system. Also summed in the summer 85 only during the retrace portion of the scanning operation is an acceleration feed-forward signal provided by an acceleration feed-forward profile 87 which is scaled by scaler 89. The correction provided by summer 85 is summed in the summer 91 with the adaptive correction provided by the adaptive circuitry to provide the output signal to the DAC 53 for controlling the motor 15. It can be seen that the standard closed loop control is provided to summer 85 and, in addition, a learning signal is provided in summer 91. Also, there is the acceleration command from processes 87, 89, which is an open loop input and assists the loop in meeting the retrace acceleration requirements. The implementation of this function is actually accomplished by precomputing a table of equivalent current command values. This is the current command required to obtain the acceleration required to perfectly execute the retrace scan profile. This computation is based on an a priori knowledge of the DAC gain, the current driver gain, the motor torque constant and the load inertia.
It can be seen that the acceleration command is calculated in advance and loaded as a pre-existing table of values. It is defined by an equation which is specific to the project using the scanner and, based upon the actual position of the scanner. A correction factor is provided for that error which goes to summer 85. Accordingly, the output of summer 85 is the predicted current plus a correction factor. The correction factor is further processed by the adaptive process to further correct the error signal, this further corrected error signal being summed in summer 91 with the output of summer 85. A correction is being made at every measured point in each scan in accordance with the present invention, this involving many tens and possibly hundreds of points during each scan as opposed to a single correction or just a few overall corrections as provided by the prior art. The result is a much greater degree of linearity, repeatability and efficiency as compared with prior art scanners.
Though the invention has been described with reference to a specific preferred embodiment thereof, many variations and modifications will immediately become apparent to those skilled in the art. It is therefore the intention that the appended claims be interpreted as broadly as possible in view of the prior art to include all such variations and modification.
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A scanner which includes a motor for driving a load and circuitry for providing a position error signal responsive to the difference between a predicted position of the load and the actual position of the load, preferably a mirror scanning a scene. The motor is driven in response to the position error signal. The position error signal is provided plural times during a single scanning of the scene. The circuitry for providing a position error signal includes a closed loop filter system for filtering the error signal to provide a filtered error signal, an adaptive filter system for operating on the filtered error signal to provide an adaptively filtered error signal and summing circuitry for summing signals indicative of the predicted position, the filtered error signal and the adaptively filtered error signal. The closed loop filter system includes, in series, at least one first order lead lag filter and a double integral plus proportional filter. The adaptive filter system includes, in series, a low pass filter, a register and an integrator.
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BACKGROUND OF THE INVENTION
The present invention relates to surface cleaning apparatus and in particular to such apparatus that uses a liquid to clean carpet, upholstery and the like. Further, the present invention relates to devices such as cleaning solution buckets and latching devices, useful in such equipment. Such extractors are typically used with a cleaning solution which is dispensed to a carpet either from a tank in a floor unit of the extractor or from a hose connected to a faucet, having a siphoning device to siphon concentrated cleaner, typically from a bottle, into a stream of water at a predetermined ratio. After dispensing solution to the carpet, the solution and dirt from the carpet are vacuumed up with a floor tool, sucked through a vacuum hose to a floor unit and deposited in a recovery tank. After a period of use, the recovery tank has filled or overfilled and must be emptied. Typically, this is a cumbersome, awkward and messy task, often resulting in some spillage of dirty water.
The patent issued to Cyphert (U.S. Pat. No. 4,216,563) discloses a floor unit having a castered base housing a vacuum motor, a removable cleaning solution dispensing tank and a removable dirty water recovery tank. A power cord and a vacuum hose connect to the base unit. Each tank is a specially-molded, elongated container with one small access opening on its top, near one end. The cleaning solution tank contains a pump for dispensing cleaning solution. A hose, connected to the pump, extends from the tank to a floor tool used to dispense cleaning solution. A power cord also extends from the tank and plugs into a receptacle in the base unit to provide power for the pump. The pump adds to the weight of the tank and the dispensing hose and power cord can get in the way when the tank is removed from the base unit for filling or to discard excess solution. If the solution tank is not removed for filling, a bucket or hose would be used. Either way, spillage can occur on the plug connection for the pump, resulting in a short circuit or shock. The access opening in the recovery tank is relatively small and adjacent intake and exhaust plenums built into the end of the tank. Dirty water is likely to spill into one of the plenums when the tank is tipped to be emptied, causing a mess.
The patent to Wimsatt et al. (U.S. Pat. No. 4,314,385) discloses an extractor having a floor-supported housing on casters. The housing contains a vacuum motor and a cleaning solution pump. In operation, a recovery tank is assembled on top of the base unit and a cleaning solution bag is carried inside the housing. A solution pickup hose is connected to the pump and penetrates the wall of the solution bag. Solution from the bag is pumped through a dispensing hose, to a dispenser tool and onto the carpet. Using a bag for the cleaning solution has an inherent propensity for spillage and problems. The recovery tank is essentially a deep pot with a coaxial suction conduit piercing the bottom of the pot. A vacuum hose is connected on the side of the pot. Liquid can be drawn into the pot and flow into the suction conduit, flooding the vacuum blower and floor unit housing, giving rise to significant electrical shortage and shock hazard. The pot does not have a handle, making carrying and emptying difficult. Further, dirty water can spill through the vacuum hose connector when the pot is emptied, creating a mess.
The patent to Burgoon et al. (U.S. Pat. No. 4,200,951) discloses an extractor wherein the recovery tank sits within the cleaning solution tank. If the cleaning solution tank is filled without the recovery tank in place, the solution will overflow when the recovery tank is inserted. Further, when the recovery tank is removed, solution will drip from the exterior of the recovery tank. The recovery tank has no handle, making removal, carrying and emptying difficult.
The patent to Blase et al. (U.S. Pat. No. 4,864,680) discloses compact carpet extractor. This extractor has a lower, wheeled tank body and an upper housing, latched together with over center latches. This extractor uses the faucet connection method for dispensing cleaning solution. The lower tank portion is floor-supported and fitted with casters. The upper housing contains a vacuum motor and provides for power and vacuum hose connection. Incoming water and air enter an air and water separator chamber which opens into the lower tank. The suction means also opens directly into the lower tank.
Latching devices, such as an over center latch, often find use in such extractors as well as other items where one member is to be latched to another. A typical over center latch comprises four main parts: a base part, fastened to the first of two pieces to be latched together; a lever part, pivotally connected to the base; a clasping part, pivotally connected to the lever; and a hook provision on the second of the two items to be latched together. In operation, the clasping part engages the hook and the lever is manipulated to draw the hook and base together. Typically, the clasping part is riveted to the lever and the lever part is either riveted to the base or force-fit over projecting pins on the base, engaging apertures on the lever. Such latches are disclosed by the patents to Cheney (U.S. Pat. No. 3,008,745) and Stollman (U.S. Pat. No. 3,321,230). Riveting the parts together is time-consuming and results in a connection which is loose or does not pivot freely. Force-fitting the lever causes deformation and breakage.
SUMMARY OF THE INVENTION
The above shortcomings are resolved by the extractor of the present invention in which two open top buckets are removably held in a floor-supported carriage. A . vacuum motor, and preferably a solution pump, is mounted in a housing, removably seated over the buckets. The vacuum motor and a suction chamber are arranged in the housing such that dirt and liquid, vacuumed from a carpet, are deposited into one bucket. The pump is arranged such that cleaning solution is pumped out of the other bucket and dispensed t the carpet.
This arrangement allows the mechanical and electrical components of the extractor to be separated from the buckets. Each bucket is easily removable from the carriage, unencumbered by hoses, cords, added weight and other interference. Electrical shock hazard is eliminated, in part because liquid cannot fall up into the housing. Further, the housing can be removed and the buckets transported in the carriage for the convenience of the operator.
In another aspect of the invention, the cleaning solution bucket handle has an integral chemical tray which opens upwardly when the handle is laid flat and opens downwardly when the handle is pivoted upward. Thus, a chemical can be measured into the chemical tray when the handle is laid flat and dispensed into the solution bucket by lifting the handle upward.
In another aspect of the invention, the housing and carriage are latched together, capturing the buckets, by a unique over center latch. The latch comprises a hook on the housing, a base portion, snapped into the carriage, a lever portion, hingedly pinned together with the base, and a top clasping portion. The clasping portion has two legs which pivotally engage the lever portion and overlap the ends of the pivot pin, capturing the pin.
These and other advantages and features of the invention will become apparent upon review of the following specification in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the extractor with a hose and a floor tool attached;
FIG. 2 is a perspective view of the extractor with the housing lifted above the buckets and carriage, showing the tops of the buckets;
FIG. 3 is a perspective view of the buckets lifted above the carriage;
FIG. 4 is a longitudinal section view of the extractor of FIG. 1;
FIG. 5 is an exploded view of the carriage, the buckets and one latch of the extractor of FIG. 1;
FIG. 6 is a perspective view of the hinge pin being inserted to assemble the base and lever parts of the latch used o the extractor of FIG. 1; and
FIG. 7 is a perspective view of the latch used in the extractor of FIG. 1 in the open position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the preferred embodiment, extractor 10 comprises a carriage 50 which removably carries a bucket 82 for cleaning solution and a bucket 72 for recovering dirty solution. An extractor vacuum motor 34, a fluid pump 38, a vacuum inlet 22 and a vacuum plenum 30 are located in a housing 20 which removably seats on top of buckets 72 and 82. Housing 20 is latched in place atop buckets 72 and 82 by latches 90 mounted on a carriage 50. Buckets 72 and 82 are thus sandwiched between housing 20 and carriage 50.
Plastic housing 20 has generally parallel, vertical sidewalls 21, joined by vertical end walls 23 and 25 which are semicircular in horizontal cross section. Sidewalls 21 and end walls 23 and 25 descend from a slightly domed top 29 with a recess 27 for a folding handle 26. As seen in FIG. 4, an end portion of housing 20 defines an open bottom vacuum plenum 30 circumscribed by housing end wall 23 and an interior vertical wall 23a. Plenum 30 seats over recovery bucket 72. Vacuum plenum 30 provides a chamber in which the energy of incoming air and water can be dissipated. Thus as with any plenum, plenum 30 has a cross section, lateral to the direction of suction flow, which is enlarged, relative to the lateral cross section of vacuum inlet 22. A vacuum hose connects to plenum 30 and bucket 72 via a vacuum hose connector 22. Plenum 30 also has a water and air separator baffle 32. Separator baffle 32 is a vertical plate descending from the top of housing 30 and extending in front of the opening from hose connector 22. Baffle 32 is curved about a vertical axis so a to be generally parallel to the curved end wall 23 of housing 20. The curvature of baffle 32 helps dissipate the energy of incoming foamed recovery water and separate air from water. An end wall 35 extends from each end of baffle 32 to end wall 23 of housing 20, forming separator chamber 33.
A vacuum motor 34 in fluid communication with plenum 30 is mounted generally in the center of housing 20. A vacuum passage 35 extends from the inlet of vacuum motor 34 to an opening into vacuum plenum 30 through interior wall 23a.
A cleaning solution pick-up 36 is connected with a cleaning solution pump 38, mounted in an enclosed chamber 39 in the end of housing 20, adjacent end wall 25, opposite vacuum plenum 30. A hose 40 connects pump 38 with a cleaning solution hose connector 24, mounted on housing 20, near connector 22. A power cord 42 is connected to housing 20 and supplies power to pump 38 and motor 34 via control switches 28, shown in FIG. 1. Cord 42 is stored in a cord storage chamber 43, near pump 38. Housing 20 also features a latch hook 44 on each sidewall 21 near the middle thereof, FIG. 2.
Housing walls 21, 23 and 25 terminate in a bottom lip 20a which seats over the top edges of buckets 72 and 82. A central inverted sealing channel extends between sidewalls 21 near the center thereof and seats over the top edges of the facing flat vertical walls 75 of buckets 72 and 82.
Carriage 50 has an upper portion 52 and a lower portion 54, FIGS. 4 and 5, each of molded plastic. The upper and lower portions, 52 and 54, snap together to capture a rub strip 56 that circumscribes the perimeter of carriage 50. Upper portion 52 of carriage 50 has an elongated toroidal shape with a downwardly projecting inner wall 58. Lower portion 54 is of mating configuration and includes an inwardly projecting bottom rim 60 and a crosspiece 62 extending across the middle of lower portion 54 to define a partial floor for supporting buckets 72 and 82. Rim 60 projects inwardly beyond wall 58 such that wall 58, rim 60 and crosspiece 62 define an elongated, oval-shaped bucket receiving well 68, FIG. 3. Crosspiece 62 has a stiffening contour 64 in the preferred embodiment. Carriage 50 also features casters 66, mounted in the bottom of lower portion 54.
Buckets 72 and 82 are removably held in receiving well 68 of carriage 50. In the preferred embodiment, buckets 72 and 82 each have vertical sidewalls 71, flat bottom 73, a flat wall side 75, a hand grip 78 and handle rests 80, FIGS. 4 and 5. Buckets 72 and 82 are generally "D"-shaped in horizontal cross section such that the flat sidewalls 75 can be positioned closely adjacent one another in back-to-back relationship. Buckets 72 and 82 thus utilize their space in carriage 50 more efficiently.
Recovery bucket 72 has a hoop-style handle 74, fastened inside bucket 72 with plastic snap-in rivets 76. Handle 84 is likewise of the hoop style and includes integral chemical tray 86. Handle 84 is likewise fastened inside bucket 82 with rivets 76. Each handle folds flat inside each bucket, resting on rests 80 (FIGS. 4 and 5). Each hand grip 78 is a generally rectangular protrusion into bottom 73 and flat wall side 75 of the bucket. When a bucket is placed in carriage 50, contour 64 engages grip 78 and the bucket is properly positioned in the carriage, FIG. 4. Handle rests 80 are also a generally rectangular protrusion, protruding into the bucket near each end of flat wall side 75. Chemical tray 86 is a shallow tray extending between the opposite side legs of handle 84 so that the tray is generally contained within the plane of the handle. Tray 86 opens upwardly when handle 84 is in a horizontal position. When handle 84 is rotated upwardly, any chemicals in tray 84 empty out of it into bucket 82.
Buckets 72 and 82 are removably held in well 68 of carriage 50, FIG. 3. Housing 20 is seated upon sidewalls 71 of buckets 72 and 82 and is latched to carriage 50, capturing the buckets by two latches 90, FIG. 1. Each latch 90 has a base 96 with a flange 99, FIG. 5, circumscribing one end of base 96. Base 96 is connected to carriage 50 by inserting base 96 through mounting apertures 51 and 53 in carriage 50. Flange 99 acts as a stop when base 96 is inserted into carriage 50 and keeps base 96 from pulling through mounting apertures 51 and 53 in carriage 50 when latch 90 is closed. A recess 110 on the side of base 96 aligns with locking tab 55 in aperture 53 to lock base 96 into carriage 50. A sleeve 101 is provided at the other end of base 96 to receive a hinge pin 98.
A lever 94 is hingedly connected to base 96. Lever 94 is generally U-shaped with side flanges 95 and a connecting web 97. A hinge pin hole 105 is provided near the end of each flange 95. An aperture 104 is also provided in each flange 95, near hinge pin hole 105 and away from the end of the flange. Lever 94 is assembled to base 96 by aligning hinge pin holes 105 with sleeve 101 and inserting hinge pin 98 therethrouqh. Hinge pin 98 is slip-fit into hinge pin holes 105 and sleeve 101.
A clasp 92 is pivotally connected to lever 94. Clasp 92 is generally U-shaped with side legs 100 and a top web 108 closing the top end of U-shaped clasp 92. A sidewall 108a extends between legs 100 and descends from top web 108. Each leg 100 has a widened portion 106 near its lower end and a peg 102 protruding toward the opposing leg, near its lower end. Each peg 102 engages a corresponding aperture 104 on lever 94 and clasp 92 is pivotally connected to lever 94. Widened portion 106 of clasp 92 overlaps the ends of hinge pin 98 and captures the pin in place. Thus, base 96 is snapped into carriage 50, lever 94 is hingedly connected to base 96 and clasp 92 is pivotally connected to lever 94.
In use, a cleaning chemical concentrate is portioned into tray 86 in the horizontal position and dispensed into bucket 82 by pivoting handle 84 to the vertical position, FIG. 3. With its open top, solution bucket 82 is conveniently filled with water, typically by filling from a faucet, to mix a cleaning solution. Buckets 72 and 82 are positioned in receiving well 68 of carriage 50 with flat wall side 75 of one bucket adjacent to the flat wall side of the other bucket in back-to-back relationship. Each of the buckets 72 and 82 are positioned in are 68 of carriage 50. Housing 20 is positioned on top of buckets 72 and 82 such that pick-up 36 is inserted ,into bucket 82 and plenum 30 is positioned over bucket 72, FIG. 2. The clasping portion 92 of each latch 90 is manipulated upward to engage each latch hook 44 on the side of housing 20 and each lever 94 is manipulated downward to the closed position, latching housing 20 to carriage 50 and capturing buckets 72 and 82 therebetween. Vacuum hose 14 and solution supply hose 16, each connected at one end with a floor tool 12, are connected with connection 22 and connection 24, respectively, FIG. 1. Power cord 42 is plugged into a convenient power supply and control switches 28 are manipulated to turn on solution pump 38 and vacuum motor 34, FIG. 4.
The operator uses floor tool 12, FIG. 1, to dispense solution to a carpet and to vacuum solution and dirt from the carpet. Solution, dirt and air are sucked through vacuum hose 14, vacuum hose connector 22 and into separator chamber 32, FIG. 4. Dirt and water hit convex plate 33 and fall into recovery bucket 72. Air is sucked through separator chamber 32, into plenum 30 and exhausted by vacuum motor 34. As the cleaning operation continues, solution bucket 82 empties and recovery bucket 72 fills. The amount of dirty water received by recovery bucket 72 is limited by the amount of solution contained in solution bucket 82. Buckets 72 and 82 are the same size in the preferred embodiment, thus recovery bucket 72 will not overfill.
When recovery bucket 72 has filled, control switches 28, FIG. 1, are manipulated to turn off pump 38 and motor 34, FIG. 4. Lever 94 of each latch 90 is manipulated upward to open the latches, FIG. 2. Each clasp 92 is removed from each latch hook 44. Housing 20 is removed and set aside, exposing buckets 72 and 82. Recovery bucket 72 is easily removed and carried away via handle 74 for disposal of its contents, FIG. 3. By holding handle 74 with one hand and lifting at bucket grip 78 with the other hand, bucket 72 is easily emptied. Likewise, bucket 82 can be emptied of extra cleaning solution.
The above-described embodiment is merely a preferred embodiment of the invention. Changes and modifications in the specifically-described embodiment can be carried out without departing from the scope of the invention, which is intended to be limited only by the scope of the appended claims and all equivalents to which we are entitled as a matter of law.
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A liquid extraction surface cleaning apparatus having a cleaning solution tank and a recovery tank held in a floor-supported carriage with the tanks having sidewalls extending above the carriage. A housing which contains a suction fan, a suction chamber, a suction inlet connecting with the chamber and a water and air separator sits on top of the tanks with the suction chamber over the recovery tank. The housing is latched to the carriage capturing the tanks. A cleaning solution dispensing means extracts cleaning solution from the solution tank. Each tank has a pivotally connected handle and the cleaning solution tank has a chemical dispensing tray integral to its handle.
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This application claims priority from provisional patent application Ser. No. 60/218,396, filed Jul. 14, 2000, entitled Modular System and Fixture for Positioning and Clamping a Workpiece.
FIELD OF THE INVENTION
The present invention generally relates to workpiece positioning and fixating systems, and more particularly to a modular apparatus and system for positioning and clamping a workpiece.
BACKGROUND OF THE INVENTION
Workpiece positioning and clamping systems are well known in the art. For example, U.S. Pat. No. 4,655,445, issued to Morse discloses an apparatus for selectively positioning a workpiece adjacent to a guide on a substantially planar work surface of a power tool assembly. The positioning apparatus is adapted to selectively position the workpiece at selected ones of a plurality of predetermined lateral offsets with respect to a cutter. The positioning apparatus includes an indexing member having a plurality of index holes and an elongated index pin element. The indexing member is affixed to either the workpiece or the guide, and the pin element is affixed to the other of the workpiece or the guide, so that the workpiece may be positioned adjacent to the indexing member and the guide, with the pin element extending through and interferingly engaging one of the index holes. This apparently permits the generation of a succession of cuts in a workpiece which are substantially uniformly spaced along a reference axis.
U.S. Pat. Nos. 4,500,079 and 4,801,225, issued to Morghen disclose a removable and replaceable locating pin adapted to locate a workpiece on a tooling fixture for machining. The locating pin is adapted to cooperate with a workpiece for positioning the workpiece in various directions of restraint. The locating pin is provided with manually actuatable locking means that permit easy adjustment or removal of the specific locator pin as a particular machining operation may require.
U.S. Pat. No. 4,896,086, issued to Miyahara, et al., discloses a method and apparatus for positioning a workpiece to a pallet on a working line. The line transports plural kinds of workpieces. Plural positioning pins are provided at various locations on each pallet to enable all the workpieces to be carried by the pallets. Each positioning pin has a set position and a reset position. All positioning pins are first reset to the reset position, thereafter, a selected positioning pin is set to the set position to accommodate a particular kind of workpiece. The positioning of the workpiece is accomplished by fitting a positioning hole defined by the selected workpiece onto the selected positioning pin.
U.S. Pat. No. 4,968,012, issued to Haddad, et al., discloses a modular workpiece holding apparatus for locating and holding a workpiece in a predetermined position. The apparatus includes a base having a plurality of external faces, each with a plurality of bores arranged in an X-Y grid pattern of parallel rows. The bores alternate vertically and horizontally between first and second different diameter bores. A riser is mounted at a predetermined position on the base by bushings and fasteners extending between the riser and the bores in the base. The bushings in each riser are arranged in diagonally opposed pairs such that one pair of bushings engages the first diameter bores in the base, while the second opposed pair of bushings engages the second enlarged diameter bores in the base. A workpiece attachment member is mounted on the mounting head end of each riser to locate and hold a workpiece. The mounting head of each riser is axially in line with the riser mounting base or offset from the riser mounting base. Each bushing includes an internal bore having a threaded end portion and an enlarged, coaxial, smooth portion. Each fastener includes a plurality of threads adjacent one end and an unthreaded portion extending from the threaded end so as to be movably retainable within a bushing in the riser mounting base after the threaded end portion of the fastener is threaded through the threaded end of the bore in the riser mounting base.
U.S. Pat. No. 5,026,033, issued to Roxy, discloses a universal system for support and positioning a workpiece for use with a device such as an inspection system. A plurality of individual alignment devices are inserted into predetermined holes of a platform having a matrix of holes. Individual alignment devices support, clamp, datum point position, and provide reference points. Each alignment device includes stanchions of varying length. These stanchions appear to be capable of being connected to each other. Once an alignment device is positioned in a hole, it can be fine tuned in all directions to get an exact location, so that workpieces of widely varying types, shapes and sizes can be positioned using the same set of alignment devices.
U.S. Pat. No. 5,044,616, issued to Jakob discloses a locating device for positioning a workpiece on a processing apparatus. A first embodiment includes a base and a fixture plate with positioning means between the base and the fixture plate. An abutment defines a fixed reference point for locking the fixture plate on the base through a clamping mechanism. The clamping mechanism also includes release cylinders so that the fixture plate can be quickly interchanged for introducing a new workpiece. A second embodiment includes a base structure that comprises a first clamping unit and a second clamping unit that support a fixture plate. First positioning means secured to each clamping unit cooperate with second positioning means secured to the fixture plate. Clamping means engage and lock the fixture plate in position. The clamping means include locking members that are slidably disposed in channels in the blocks.
U.S. Pat. No. 5,226,638, issued to Ausillio discloses a clamp having slip plane positioning capability that enables a clamp nose and an attached pressure foot, which are initially non-permanently attached to a clamp arm, to be brought into a final predetermined coordinate position before the clamp nose is fixedly attached to the clamp arm. The clamp nose has a pressure foot mounted at one end. An open-ended slot is formed at the other end of the clamp nose and slidingly engages opposed side walls of one end of the clamp arm. A fastener threadingly extends through a portion of the clamp nose binding the slot into engagement with the clamp arm to non-permanently attach the clamp nose to the clamp arm. The clamp nose and the pressure foot are positionally adjusted with respect to the clamp arm, at final assembly, to bring the pressure foot into a predetermined coordinate position before the clamp nose is fixedly secured to the clamp arm.
U.S. Pat. No. 5,362,036, issued to Whiteman discloses a modular welding fixture for positioning a workpiece. The fixture includes a base table having an array of openings through the surface and an array of locator mounting holes colocated in spaced relationship, with respect to the openings, to accommodate at least one vertical end locator having a base plate that is removably mountable to the base table at preselected positions. The locator has means for locating and holding at least a portion of a workpiece. The fixture further includes at least one horizontal locator having a base plate that is removably mountable to the base table at preselected positions, and the base plate includes means for locating and holding at least a portion of a workpiece.
U.S. Pat. No. 5,415,383, issued to Ausillio discloses a clamp having slip plane positioning capability that enables a clamp nose and an attached pressure foot, which are initially non-permanently attached to the clamp arm, to be brought into a final predetermined coordinate position before the clamp nose is fixedly attached to the clamp arm. The clamp nose has a pressure foot mounted at one end. An open-ended slot is formed at the other end of the clamp nose and slidingly engages opposed side walls of one end of the clamp arm. In one embodiment, a fastener threadingly extends through a portion of the clamp nose surrounding the slot, and into engagement with the clamp arm to non-permanently attach the clamp nose to the clamp arm. In another embodiment, aligned bores and slots are formed in adjoining surfaces of the clamp nose and the clamp arm so as to receive fasteners therethrough to non-permanently mount the clamp nose on the clamp arm. The clamp nose and the pressure foot attached thereto are positionally adjusted with respect to the clamp arm at final assembly to bring the pressure foot into a predetermined coordinate position before the clamp nose is fixedly secured to the clamp arm.
U.S. Pat. No. 5,481,811, issued to Smith discloses a modular system for the support and positioning of a workpiece for use with an inspection system. The modular system includes a base having a plurality of exterior faces, at least some of which have an array of equally spaced holes forming a grid pattern. At least one riser is attached to the base cube by a fastener, which can be inserted into the riser by defeating an outwardly biased locking member at the inner end of the fastener, extending through the riser and into the holes of the base cube. The fastener is used to provide positive location and fastening of the risers to the base cube. Functions of individual risers include support, clamping, datum point positioning and providing reference points.
U.S. Pat. No. 5.516.089, issued to Seniff et al., discloses a workpiece locating unit that is receivable in a T-slot formed in a workpiece supporting table member. It provides a pin or other locating device cooperable with a locating feature on a workpiece to aid in accurately positioning the workpiece on the work supporting surface of the table member. The unit has four corners each providing an abutment surface for engagement with one or the other of two vertical slot surfaces. Two diagonally opposite ones of the abutment surfaces are rigid and the other two diagonally opposite ones of the abutment surfaces are resilient. The resilient abutment surfaces resiliently engage the two vertical surfaces of the slot and urge the unit about a vertical axis to hold the rigid abutment surfaces engaged with the vertical slot surfaces eliminating lateral looseness between the unit and the table member and providing accurate positioning of the locating device of the unit as the unit is moved from one position to another along the length of the slot.
These and other prior art positioning and clamping systems often require multiple fixtures and component parts to be on hand in order to accommodate multiple parts that are to be positioned in any given manufacturing shift. This requires extensive inventories of clamps and associated fixtures, as well as, well trained and technically sophisticated personnel to properly select and operate them. This adds to the cost and complexity of such systems. Also such prior art positioning and clamping systems do not lend themselves to a modular design, that is in conformance with NAAM standards, and that allows for fine adjustments of position of a clamped workpiece through the selection of easily identifiable and assembled modular parts. As a consequence, there has been a long felt need for a workpiece positioning and clamping system that avoids the foregoing problems in the prior art.
SUMMARY OF THE INVENTION
The present invention provides a modular system for locating and clamping a workpiece in space. One aspect of the present invention provides a positioning blade comprising a riser mount having a bottom edge surface, a first side edge surface, a second side edge surface, a top edge surface, and including a plurality of first mounting-bores and a plurality of first positioning-bores defined through the riser mount between the edge surfaces. A clamp mount is provided on the blade that projects outwardly from the first side edge surface, and includes a plurality of second mounting-bores and a plurality of second positioning-bores. The first positioning-bores comprise a predetermined positional relationship to the second positioning-bores. A locator arm is also provided on the blade and projects outwardly from the second side edge surface. The locator arm has a plurality of third positioning-bores where the third positioning-bores comprise a predetermined position relative to the first positioning-bores and the second positioning-bores.
A system for positioning and clamping a workpiece is also provided that includes in combination the foregoing positioning blade mounted on means for elevating the workpiece, e.g., a riser, and means for clamping the workpiece.
A kit for forming a variety of fixtures for positioning and clamping a workpiece is also provided that includes a plurality of position determining modules wherein each module comprises a positioning blade having a different set of positional locations for its positioning-bores.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will be more fully disclosed in, or rendered obvious by, the following detailed description of the preferred embodiment of the invention, which is to be considered together with the accompanying drawings wherein like numbers refer to like parts and further wherein:
FIG. 1 is a perspective view of a plurality of modular systems and fixtures for positioning and clamping a workpiece formed in accordance with the present invention, positioned upon a platform shown in phantom and holding a partially broken-away workpiece;
FIG. 2 is a perspective view of a modular system and fixture for positioning and clamping a workpiece formed in accordance with one embodiment of the present invention;
FIG. 3 is a side elevational view of the modular system and fixture for positioning and clamping a workpiece shown in FIG. 2;
FIG. 4 is a perspective view of a modular positioning blade formed in accordance with the present invention;
FIG. 5 is a perspective view of an alternative embodiment of modular positioning blade;
FIG. 6 is a perspective view of another alternative embodiment of modular positioning blade including a transition portion;
FIG. 7 is a perspective view of yet another alternative embodiment of modular positioning blade with transition portion;
FIG. 8 is a further embodiment of a modular positioning blade with an alternative transition portion;
FIG. 9 is a perspective view of another modular positioning blade;
FIG. 10 is a perspective view, partially in phantom, of a modular system and fixture for positioning and clamping a workpiece having a modular positioning blade mounted on a riser with a clamping assembly assembled to a portion of the modular positioning blade;
FIG. 11 is a perspective view, partially in phantom, of an alternative embodiment of the modular system and fixture for positioning and clamping a workpiece shown in FIG. 10;
FIG. 12 is a perspective view, partially in phantom, of a further alternative embodiment of the modular system and fixture for positioning and clamping a workpiece of the present invention;
FIG. 13 is a perspective view, partially in phantom, of yet another alternative embodiment of the modular system and fixture for positioning and clamping a workpiece of the present invention;
FIG. 14 is a perspective view, partially in phantom, of another alternative embodiment of the modular system and fixture for positioning and clamping a workpiece of the present invention;
FIG. 15 is a perspective view, partially in phantom, of another alternative embodiment the modular system and fixture for positioning and clamping a workpiece of the present invention;
FIG. 16 is a perspective view, from a rear side, of a fully assembled modular system and fixture for positioning and clamping a workpiece in accordance with the present invention;
FIG. 17 is a broken-away view of a portion of a clamp assembly used in connection with the present invention;
FIG. 18 is a partially broken-away, perspective view of a portion of a modular positioning blade and clamp assembly; and
FIG. 19 is a partially, broken-away, perspective view of a portion of a clamp assembly showing an alternative positioning of pressure feet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
This description of preferred embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description of this invention. In the description, relative terms such as “horizontal,” “vertical,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing figure under discussion. These relative terms are for convenience of description and normally are not intended to require a particular orientation. Terms including “inwardly” versus “outwardly,” “longitudinal” versus “lateral” and the like are to be interpreted relative to one another or relative to an axis of elongation, or an axis or center of rotation, as appropriate. Terms concerning attachments, couplings and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. The term “operatively connected” is such an attachment, coupling or connection that allows the pertinent structures to operate as intended by virtue of that relationship. In the claims, means-plus-function clauses are intended to cover the structures described, suggested, or rendered obvious by the written description or drawings for performing the recited function, including not only structural equivalents but also equivalent structures.
Referring to FIGS. 1-4, a modular system and fixture for positioning and clamping a workpiece 5 comprises a riser 7 , a modular positioning blade 9 , and a clamp assembly 11 . More particularly, riser 7 includes a mounting plate 18 and a seat plate 21 , with a stiffening support 23 fastened between them to add to the rigidity and ability of riser 7 to support significant loads. Modular positioning blade 9 is mounted to a top portion 24 of each riser 7 . A plurality of positioning-bores 25 and mounting-bores 26 are defined in top portion 24 of each riser 7 (FIG. 16 ). Positioning-bores 25 are accurately sized and shaped, and selectively and precisely located in top portion 24 for operatively locating modular positioning blade 9 on riser 7 , via dowel pins 27 . Conventional fasteners, e.g., bolts 28 or the like, are positioned through mounting-bores 26 so as to fasten modular positioning blade 9 to top portion 24 of riser 7 .
A plurality of risers 7 are often mounted on a platform 12 in a predetermined matrix of holes having an adequate distance from each other such that risers 7 can be positioned to clamp virtually any size or shape workpiece. For example, a typical workpiece clamped with the present invention may be an automobile roof, hood, trunk lid, or side panel (shown generally in FIG. 1, and identified by reference numeral 30 ). Of course, other non-automotive parts may also be clamped with the present invention. The dimensions and general shape of risers 7 are subject to industry agreed upon standards, with specific tolerance allowances, which would be known to those skilled in the art.
Referring to FIGS. 2-15, modular positioning blade 9 preferably comprises a planar metal or polymer plate, and includes a riser mount 32 , a clamp mount 34 , and a locator arm 36 . Referring to FIGS. 4-9, riser mount 32 is often generally rectilinearly shaped, and includes a bottom edge surface 40 , side edge surfaces 42 , 43 , a top edge surface 45 , multiple mounting-bores 48 , and multiple positioning-bores 50 . Riser mount 32 is typically arranged to be below clamp mount 34 and locator arm 36 , with top edge surface 45 arranged on an incline so as to provide a transition between clamp mount 34 , locator arm 36 , and riser mount 32 . Thus, when mounted to riser 7 , modular positioning blade 9 is oriented such that riser mount 32 is arranged below locator arm 36 and clamp mount 34 .
In some embodiments, a transition portion 38 interconnects riser mount 32 with clamp mount 34 and locator arm 36 . Mounting-bores 48 are sized and shaped to receive fasteners, such as bolts 28 or the like. Mounting-bores 48 are often arranged in parallel rows extending along riser mount 32 . In some embodiments, additional mounting bores 48 and positioning-bores 50 are located trough transition portion 38 of modular positioning blade 9 to secure and position additional fixtures, tools and/ or locators (FIGS. 6, 7 , 12 and 13 ).
Positioning-bores 50 are accurately sized and shaped, and selectively and precisely located on riser mount 32 so as to operatively receive dowel pins 27 , and thereby to selectively and precisely position modular positioning blade 9 and clamp arm assembly 11 on riser 7 . Positioning-bores 50 are often arranged within the parallel rows of mounting-bores 48 , and may be defined through riser mount 32 alone, or through riser mount 32 and transition portion 38 . Advantageously, positioning-bores 50 may be located at varying, predetermined fixed distances from bottom edge surface 40 . Also, a variety of modular positioning blades 9 may be provided, each having positioning-bores 50 located at different predetermined positions along the length of riser mount 32 or transition portion 38 , e.g., in ten, fifteen or twenty millimeter increments as measured from bottom edge surface 40 . This feature allows for a family or kit to be provided comprising a plurality of individual modular positioning blades 9 , each having a differently positioned set of positioning-bores 50 .
Clamp mount 34 projects outwardly from a top portion of side edge surface 42 , and includes mounting-bores 58 and positioning-bores 60 . Mounting-bores 58 are sized and shaped to receive fasteners, such as bolts 28 or the like, and are often arranged in parallel rows along clamp mount 34 . Positioning-bores 60 are accurately sized and shaped, and selectively and precisely located on clamp mount 34 so as to operatively receive dowel pins 27 , and thereby to selectively and precisely position clamp arm assembly 11 relative to riser 7 . Positioning-bores 60 are often arranged within the parallel rows of mounting-bores 58 .
Advantageously, positioning-bores 60 may be located at varying, predetermined fixed distances from positioning-bores 50 , so as to establish their true position relative to riser 7 . Also, positioning-bores 50 and positioning-bores 60 are preferably arranged in mutually parallel relation to one another. A variety of modular positioning blades 9 may be provided, each having positioning-bores 60 at different predetermined positions along the length of clamp mount 34 , e.g., in ten, fifteen, and twenty millimeter increments.
Locator arm 36 projects outwardly relative to a top portion of side edge surface 43 , and includes a top surface 65 , a bottom surface 66 , and a front face 67 . A plurality of longitudinally extending through-bores 68 are defined between top surface 65 and bottom surface 66 , and are sized and shaped to receive a releasable fastener, such as a bolt 70 or the like. Through-bores 68 are sized, shaped, and selectively located on top surface 65 of locator arm 36 so as to operatively position a portion of clamp assembly 11 , as will hereinafter be disclosed in further detail. Advantageously, through-bores 68 may be located at varying, predetermined fixed distances from positioning-bores 60 . Positioning-bores 50 and positioning-bores 60 are preferably arranged in substantially perpendicular relation to through-bores 68 .
Referring to FIG. 1-3 and 10 - 19 , clamp assembly 11 includes a lower pressure foot 75 , an upper pressure foot 80 , a fluid operated cylinder 85 , and a pivotal clamp arm 90 . More particularly, lower pressure foot 75 is mounted to top surface 65 of locator arm 36 , and includes a leg 77 and an anvil 81 that are joined together so as to form an “L”-shaped support. Anvil 81 includes a rearwardly radiused end surface 84 , and joins leg 77 at a right angle at the other end. Leg 77 includes at least one trough-bore 89 that is sized and shaped to receive releasable fastener 70 to thereby releasably fasten lower pressure foot 75 to locator arm 36 . Radiused end surface 84 of anvil 81 comprises a curvature that corresponds to, and is complementary with, the curvature present in workpiece 30 . Upper pressure foot 80 is releasably mounted to the under side of pivotal clamp arm 90 , and includes a leg 87 and an anvil 91 that are joined together so as to form an “L”-shaped support. Anvil 91 may include a rearwardly radiused end surface, or may have another surface profile as needed for a particular task. Leg 87 joins anvil 91 at a right angle, and includes at least one through-bore that is sized and shaped to receive releasable fastener 70 to thereby releasably fasten upper pressure foot 80 to pivotal clamp arm 90 . It will be understood that pressure feet 75 , 80 may have various other shapes and configurations, as required for a particular workpiece, without departing from the scope of the present inventions
Referring to FIGS. 16 and 17, fluid operated cylinder 85 includes a closed chamber formed within a cylindrical body 108 . End caps 112 and 114 are mounted on opposite ends of cylindrical body 108 and are interconnected by connecting rods 116 . A piston (not shown) is mounted in cylindrical body 108 of fluid operated cylinder 85 . The piston is moved by the bidirectional application of pressurized fluid to opposite sides of it. The pressurized fluid causes a piston rod 120 that is connected to one end of the piston, and extending outwardly from one end of cylinder 108 through end cap 119 , to reciprocate in extendible and retractable linear directions with respect to fluid operated cylinder 85 .
A mounting plate 122 is fixedly connected to end cap 119 , and has a central aperture through which piston rod 120 slidably extends. Mounting plate 122 supports a pair of spaced, plate-like support members 125 and 128 . Each of support members 125 and 128 includes a number of spaced mounting-bores 130 which are used to receive fasteners 28 for fixedly mounting support members 125 and 128 to clamp mount 34 . Bores 130 are arranged to correspond in position with mounting-bores 58 of clamp mount 34 , and are sized and shaped to receive fasteners 28 . At least a pair of positioning-bores 131 extend through support members 125 and 128 , and are arranged to correspond in position to positioning-bores 60 on clamp mount 34 . A pair of spaced, strip-like covers 136 and 138 are disposed between support members 125 and 128 and are welded to support plate 125 on opposite sides of piston rod 120 . An additional cover member 140 is disposed in an overlapping end arrangement with cover member 138 .
The linear reciprocal, bidirectional movement of piston rod 120 is converted to pivotal movement of clamp arm 90 by an assembly including a tubular sleeve 142 having an internally threaded bore at one end that threadingly engages a threaded adapter 144 mounted on the exterior end of piston rod 120 . An opposed end portion 146 of tubular sleeve 142 has a flattened shape with a central bore extending therethrough which receives a pivot pin 148 . Cover member 140 is fixedly attached to the flattened portion of sleeve 142 and is movable. Also mounted to pivot pin 148 is a first end of a link 150 . A second end of link 150 is fixed to a pivot pin 152 extending between the support plates 125 and 128 .
Pivotal clamp arm 90 comprises a first end 154 and a spaced-away second end 156 . First end 154 has a recessed portion which has a central bore that is fixedly mountable about pivot pin 152 . Linear extension and retraction of piston rod 120 due to activation of fluid operated cylinder 85 results in pivotal movement of first end 154 . This causes pivotal movement of pivot pin 152 and the recessed portion of clamp arm 90 . In turn, first end 154 of the clamp arm 90 pivots in one direction and second end 156 pivots in an opposite direction. This arrangement results in second end 156 moving between a first position that is spaced from workpiece 30 and a second position in which clamp arm 90 drives upper pressure foot 80 into firm engagement with a portion of workpiece 30 (FIG. 1) that is supported on radiused surface 84 of lower pressure foot 75 so as to hold workpiece 30 at a predetermined coordinate position.
Advantageously, positioning-bores 25 of riser 7 may be located at varying fixed distances from the bottom surface of seat plate 21 , e.g., between one-hundred and five-hundred millimeters, etc., in about five millimeter to about thirty-five millimeter increments, more or less. In this way, positioning-bores 50 and 60 of modular positioning blade 9 may be located at varying fixed distances from the bottom surface of seat plate 21 , e.g., three-hundred, three-hundred and twenty, four-hundred and thirty, five-hundred and forty millimeters, etc., by simply adjusting riser mount 32 upwardly or downwardly relative to top portion 24 of riser 7 .
Additionally, the vertical and horizontal location of positioning-bores 50 and 60 , may be more finely adjusted by utilizing an alternative modular positioning blade 9 , as shown in FIGS. 4-9. In this way, radiused surface 84 of pressure foot 75 may be precisely and accurately positioned vertically and/or horizontally in space for supporting and clamping workpiece 30 at a known position above the top surface of platform 12 . Modular system and fixture for positioning and clamping a workpiece 5 may be used not only to clamp and maintain workpiece 30 at a known height, but also can be modified to adjust the horizontal location of workpiece 30 relative to riser 7 by merely adjusting the relative positions of modular blade 9 on riser 7 , clamp assembly 11 on clamp mount 34 of modular blade 9 , and/or pressure feet 75 and 80 on locator arm 36 and clamp arm 90 , respectively. For example, FIG. 13 shows one possible orientation of pressure feet 75 , 80 that can be selected while maintaining modular positioning blade 9 in one position. FIG. 14 represents the use of additional “NC” blocks that are positioned on portions of pressure fee 75 , so as to further provide an alternative position for clamping work piece 30 . Also, as shown in FIG. 16, a rough locator arm 175 and/or piloting pin 180 may be installed on the back side of modular positioning blade 9 in order to initially locate and pilot an edge of workpiece 30 into position for engagement by pressure feet 75 , 80 . It will be understood that rough locator arm 175 and/or piloting pin 180 may be assembled to modular positioning blade 9 , via mounting bores 48 and positioning-bores 50 located through transition portion 38 . Of course, with the use of each additional embodiment of modular positioning blade 9 , a plurality of precisely and accurately defined locations of pressure feet 75 , 80 can be achieved without the need for manufacturing custom fixturing or tools to suit that purpose.
ADVANTAGES OF THE INVENTION
Numerous advantages are obtained by employing the present invention.
More specifically, a modular system and apparatus for positioning and clamping a workpiece is provided which avoids all of the aforementioned problems associated with prior art devices.
In addition, a modular system and apparatus for positioning and clamping a workpiece is provided which does not require well trained and technically sophisticated personnel to properly operate.
Furthermore a modular system and apparatus for positioning and clamping a workpiece is provided which reduces the cost and complexity associated with the accurate positioning of a workpiece, such as a portion of an automobile.
Also, a system and apparatus for positioning and clamping a workpiece is provided which incorporates a modular design that allows for fine adjustments of the position of a workpiece through the selection of easily identifiable, standardized modular blades that are easily assembled to accommodate a plurality of required workpiece locations, as well as, a design that provides for multiple clamped positions by simple adjustments to the location of a assembly or pressure feet on a modular blade.
It is to be understood that the present invention is by no means limited only to the particular constructions herein disclosed and shown in the drawings, but also comprises any modifications or equivalents within the scope of the claims.
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The a modular system for locating and clamping a workpiece in space is provided that includes positioning blade including a riser mount having a plurality of first mounting-bores and a plurality of first positioning-bores. A clamp mount is provided on the blade that includes a plurality of second mounting-bores and a plurality of second positioning-bores. The first positioning-bores have a predetermined positional relationship to the second positioning-bores. A locator arm is also provided on the blade, and has a plurality of third positioning-bores where the third positioning-bores comprise a predetermined position relative to the first positioning-bores and the second positioning-bores. A system for positioning and clamping a workpiece is also provided that includes in combination the foregoing positioning blade mounted on structure for elevating the workpiece, e.g., a riser, and structure for clamping the workpiece. A kit for forming a variety of fixtures for positioning and clamping a workpiece is also provided that includes a plurality of position determining modules where each module includes a positioning blade having a different set of positional locations for its positioning-bores.
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This invention relates to the art of glass fiber reinforced plastics and more particularly to a reinforced plastic material with flame retardant additive capable of being formed into large rigid panels.
The invention is particularly applicable to material which is in the form of large panels for use as traffic signs or other traffic control structures and will be described with particular reference thereto, although it will be appreciated that the invention has broader applications and can be used whereever panels having high physical strength and good flame retardancy characteristics are required.
In the past, traffic signs and other traffic control products have been fabricated from thick sheets of aluminum. Aluminum has good strength characteristics, is light in weight and has good corrosion resistance. However, the price of aluminum fluctuates widely and on a square footage basis is frequently much more expensive than the equivalent price of glass fiber reinforced plastic material. Additionally, aluminum has a significant scrap value and is increasingly becoming the subject of theft by vandals who remove the traffic signs from their installed positions and sell the material as scrap. A further problem with aluminum signs is that they deform excessively when shot by vandals or passing hunters.
Proposals have been made in the past to substitute fiberglass reinforced plastic panels for aluminum. While many fiberglass reinforced panels have been successful in commercial sign applications, the Federal and State governments have been very reluctant to use fiberglass reinforced panels in traffic signs, one of the principal reasons being that most fiberglass reinforced plastic materials, if heated to an ignition temperature, vigorously burn, inviting torching of the signs by vandals.
While efforts have been made to reduce the flammability of the fiberglass materials employed, heretofore additives to the fiberglass resin which would reduce the flammability also reduced the physical strength characteristics of the resultant panel to the point where the panels were unsatisfactory for traffic sign use.
While flame or burn resistance is of prime importance, other physical characteristics of the panel are necessary if they are to adequately function in traffic signs, namely the ability to withstand high (85 mph) wind loads, resistance to vandalism, good weatherability, easy fabrication, no panel warpage, no delamination or migrating constituent and the capability of being recycled. Any one of these properties by itself is not unusual in glass fiber reinforced plastics but to have all of these properties in combination is a prime necessity in traffic control signs.
SUMMARY OF THE INVENTION
The present invention provides a reinforced plastic material which can be readily made into large flat panels which overcomes all of the above referred to problems and provides a panel having good physical and mechanical characteristics coupled with high flame retardancy characteristics.
In accordance with the present invention, a glass fiber reinforced plastic material with flame retardant additive is provided comprised of a cured mixture of a general purpose polyester resin, a halogenated polyester resin, catalyst, at least one monomer cross-linking agent, one or more inorganic fire retardant fillers and glass fibers.
These ingredients, in accordance with the invention, are present in a resinous composition in the following general proportion in parts by weight:
general purpose polyester resin 42.5 to 56.5
halogenated polyester resin 14.5 to 18.5
cross linking monomer 12.0 to 22.0
inorganic fire retardant filler 15.0 to 25.0
Basis 100 weight parts of this resinous composition, there is further combined with such composition up to about 3 weight parts of catalyst combination, together with from about 20 to about 30 weight parts of reinforcing fiberglass.
The material provides exceptionally strong, smooth, warp free fiberglass reinforced plastic sheets with fire retardant property. Production of a sheet having all these characteristics was simply not possible previously. Resins and fillers which improve flame retardancy usually resulted in panel warp and low mechanical properties in a thin sheet. Numerous formulations, tests and revisions were required to discover the correct mix of ingredients and proportions of ingredients which interact to provide all the required characteristics here.
It is the primary object of the present invention to provide a fiberglass reinforced plastic sheet material having high strength, dimensional stability, tough impact resistance, freedom from warpage, weather and corrosion resistance and flame retardant property.
It is another object of the present invention to provide a traffic sign material having low initial cost and low scrap value.
It is another object of the present invention to provide a fiberglass reinforced plastic substitute for aluminum sheet traffic sign material having good flame retardancy characteristics.
It is a further object of the present invention to provide fiberglass reinforced plastic sheet material having good adhesion characteristics such that it will accept and retain paints and adhesive bonded reflective materials and the like.
Another object of the present invention is to provide a traffic sign material which will not deform excessively when shot at with firearms.
Other objects, features and advantages of the present invention will become apparent from the detailed description of the preferred embodiment which follows.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In preparing the glass fiber reinforced plastic material with flame retardant additive there will first be produced the resinous composition. A principal constituent of this composition is an unsaturated polyester resin, which may also be referred to herein for convenience as the "general purpose" resin. This general purpose resin can be prepared from monomeric ingredients including maleic constituency, e.g., maleic anhydride, phthalic constituency such as phthalic acid and a glycol. For best physical properties in the plastic material it is advantageous that the glycol used be at least a C 3 glycol such as propylene glycol. Also, for preparing panels that will have retarded warp, it is advantageous to have the maleic constituency predominate over the phthalic constituency. Preferably, for best mechanical and physical properties in the final product, a general purpose resin will be selected that has a maleic to phthalic ratio of about 2 to 1. It is further most desirable to select a general purpose resin based upon propylene glycol, although higher molecular weight glycols can be included. It is further contemplated that those of lower molecular weight than propylene glycol can be included if the propylene or higher molecular weight glycols are present in great excess over those of lower molecular weight. The resin will contribute from about 42.5 weight parts to about 56.5 weight parts, to the 100 weight parts of the resinous composition. Use of less than about 42.5 weight parts is undesirable for obtaining best mechanical properties of finished product, while greater than about 56.5 weight parts can require deleterious cutback in amounts of further ingredients, such as those included for flame retardancy. Preferably, for a best balance of all ingredients plus the good mechanical properties contributed by the resin, such is present in an amount of about 49-50 weight parts, basis 100 weight parts of the resinous composition.
The next critical ingredient present in the resinous composition is the halogenated polyester resin. The halogens of this resin will most typically be chlorine and bromine or their mixture. Preferably for best flame retardance characteristic of the final product, bromine is the halogen of choice. Usually, the halogenated polyester resin selected will contain from about 20 to 25 weight percent of halogen. It is important for best flame retardance property of the final product that the polyester resin selected contribute at least 3.3 weight parts of halogen, and more preferably about 3.5 weight parts of bromine or more, per 100 weight parts of resinous composition. The halogenated polyester resin should be present in an amount contributing from about 14.5 weight parts up to about 18.5 weight parts, to the 100 weight parts of resinous composition. Use of less than about 14.5 weight parts can enhance mechanical properties of the final product, but at sacrifice to flame retardance characteristics, while the contrary is observed when greater than about 18.5 weight parts of the halogenated polyester resin is employed. Preferably, for best flame retardance property combined with enhanced mechanical properties, the polyester resin will be present in amount of about 16-17 weight parts, basis 100 weight parts of the resinous composition.
The next necessary ingredient for the resinous composition is the cross-linking monomer or "cross-linking agent." It is to be understood that a certain amount of monomer will typically be contributed to the resinous composition through the selection of the general purpose resin or the halogenated polyester resin or both. Commercially available resins of these types can be expected to contribute monomer to the final resin mixture. But for complete copolymerization as well as enhanced viscosity control, it is necessary to supply additive crosslinking agent to the resinous composition. An acrylic monomer will be used with methyl methacrylate monomer being preferred. It is also most advantageous for best processing control, although not critical, to include styrene monomer. The monomer cross-linking agent will contribute from about 12 weight parts up to about 22 weight parts to the resinous composition, basis 100 weight parts. When both the acrylic monomer as well as styrene monomer are present a fairly even balance between the two monomers is preferred for economy and efficient process control. Thus, when about 12 weight parts of agent is present, there will most always be contributed to this amount 6 weight parts of acrylic monomer and 6 weight parts of styrene monomer. Less than about 12 weight parts of total monomer is undesirable for achieving best viscosity control. On the other hand, greater than about 22 weight parts is unnecessary to affect efficient copolymerization and can detract from the presence of the flame retardant ingredients in sufficient amounts. When a monomer combination is present in the more elevated quantities, the styrene can predominate, for economy. Thus, about 12 weight parts of styrene plus about 10 weight parts of acrylate can be useful.
Another critical ingredient for the resinous composition is the inorganic fire retardant filler. Many such inorganic fire retardant fillers are known and, as will be recognized by those skilled in the art, can find use in the present invention. One group of such fillers of particular interest are the fillers that release water for fire retardancy, such as epsom salts. These water-releasing fillers, also termed herein "hydrous fillers" may include hydrated alumina. For the fire retardant filler, alumina trihydrate is preferred, whereby hydrated alumina is often merely referred to herein for convenience as "alumina trihydrate." The hydrated alumina is advantageously silicon treated before use, for example with a silane or a polysiloxane. For best fire retardance property, it is preferred that the hydrated alumina be a silane treated hydrated alumina.
The fire retardant filler should contribute to the resinous composition an amount from about 15 weight parts to about 25 weight parts, both basis 100 weight parts of such composition. The presence of less than about 15 weight parts will be insufficient to provide desirable flame retardance characteristic for the composition. The use of greater than about 25 weight parts can detract from the most desirable physical properties of the composition. When a combination of fire retardant filler is used and such combination includes a hydrous filler, the hydrous filler will generally be present in an amount of about 20 weight parts or less. It is preferred to use a hydrous filler in conjunction with a second inorganic filler.
The second filler will most always be present to achieve consistent flame retardant property in the final product. The second filler can be an antimony compound such as antimony oxide. Although not intending to be bound to any specific substance, the second filler will often be referred to herein as antimony trioxide. However, the use of other antimony substances are contemplated, e.g., sulfides of antimony as well as antimony salts of or acids such as antimony butyrate. It is preferred for best burn resistance to use the oxide. When present, the antimony compound should contribute from about 1 to about 5 weight parts, basis 100 weight parts resinous composition. A use of greater than about 5 weight parts is uneconomical while less than about 1 weight part will be insufficient for enhancing flame retardance. As mentioned before, the second inorganic filler will be used along with the hydrous filler and in combination there will most always be present about 1-weight parts of the second filler together with about 15-20 weight parts of the hydrous filler.
The general purpose resin, the halogenated polyester resin, the monomer cross-linking agent and the inorganic fire retardant filler then complete the critical ingredients for the 100 weight parts basis of the resinous composition. However, other critical ingredients are further combined with such resinous composition. One of these further critical ingredients is the catalyst component. As used, this component will supply catalyst, often in combination, which can add as much as about 3 weight parts of catalyst onto 100 weight parts of the resinous composition. Although any number of a variety of catalysts may be used, as will be well recognized by one skilled in the art, it has been found most advantageous to employ a combination of catalysts. Of particular interest is the combination of cumene hydroperoxide and t-butyl peroctoate. Typically, about a 50 weight percent excess of the t-butyl peroctoate will be used in the preferred combination.
Another critical ingredient for the reinforced material, but not contributing to the 100 weight parts of resinous composition, is the fiberglass reinforcing material. The fiberglass will usually be supplied as bundled filaments chopped to short lengths on the order of 1.5 to 2.5 inches or so. It is preferable for best dispersion of the chopped fiberglass in the resinous composition that a coated fiberglass be used. Such reinforcing material will add from about 20 to about 30 weight parts, added to the 100 weight parts of the basis resinous composition. Preferably for best physical properties of finished articles, about 24-26 weight parts of fiberglass reinforcing material is added.
In addition to the ingredients for the resinous composition, plus the other critical ingredients, additional substances are useful, some of which will most always be present. These however, will be employed in addition to the foregoing discussed ingredients.
One such additional ingredient is wetting agent. Although such agent can be present in only a very minor amount, such amount may be all that is needed for providing complete filler dispersion in the resinous composition. For purposes of the present invention, a hydrophobic wetting agent is used. It is present in the composition to contribute an amount from about 0.01 to 0.1 weight part, basis 100 parts of the composition. A use of less than about 0.01 weight part will simply be insufficient to contribute to best filler dispersion while greater than about 0.1 weight part is uneconomical.
Another additional ingredient most always included is an ultraviolet light (U.V.) stabilizer substance. It is to be understood that the discussion herein with reference to such substance is in conjunction with its use beyond that which may be contributed by the general purpose resin and/or halogenated polyester resin. These resins, as commercially prepared, will often contain some minor amount of U.V. stabilizer substance, e.g., 0.2 to 0.5 weight percent, basis weight of the individual resin. Taking into account that each of the general purpose resin and halogenated polyester resin can contribute up to about 0.5 weight percent of ultraviolet light stabilizer substance, there is preferably added an additional amount of such substance, such that the total of all such contributions will provide up to about 2 weight parts of stabilizer, basis 100 weight parts of the resinous composition. Greater than about 2 weight parts will simply be uneconomical and not contribute further desirable ultraviolet light stabilization. When additional stabilizer is used, it will usually be supplied in an amount of at least about 0.25 weight part to contribute sufficient enhancement and stabilization to the resinous composition.
In addition to the foregoing, the composition may further include optional ingredients such as pigments, which should be non-metallic for best fire retardance property, as well ad dyes, optical brighteners, anti-oxidants and additional fillers, e.g., clay filler including reinforcing fillers, and the like. When such ingredients are employed, it is desirable that they not contribute greater than about 8 weight parts or so of the composition, basis 100 weight parts of resinous composition.
The following example shows a way in which the invention has been practiced, but should not be construed as limiting the invention. In the example, all parts are parts by weight, unless otherwise specified.
EXAMPLE
The following ingredients, in the weight parts as shown, are blended together:
______________________________________Unsaturated Polyester Resin* 49.5Halogenated Polyester Resin** 16.5Methyl Methacrylate Monomer 6.0Styrene Monomer 8.0Benzotriazole 0.25Wetting Agent+ 0.1Cumene Hydroperoxide 0.8______________________________________ *RCI-98-498 resin from Reichhold Chem. Co. **Koppers 6131 Resin containing 23 weight percent bromine. +Byk Mallinckrodt BYK980
The resins, then the monomers are initially blended together. As blending continues, there is then admixed to this blend the benzotriazole U.V. stabilizer and next the wetting agent.
As mixing continues, the temperature of the mixture is raised to about 95° F. and the following ingredients are added, parts being parts by weight:
______________________________________Alumina Trihydrate* 16Antimony Oxide 4______________________________________ *Silane-treated, SOLEM SB335 HYFLEX.
The full blend is subjected to high shear mixing, under vacuum, to remove entrained air and gases. The mixture is then ready for addition of a first catalyst, 0.8 parts by weight of cumene hydroperoxide, and, a second catalyst, t-butyl peroctoate, which is added in amount contributing an additional 1.25 parts to the full blend. The resulting catalyzed resin is then ready for further processing. Such processing will usually be for the preparation of resin panels using a continuous carrier film, or on a belt. More specifically, with this catalyzed resin it is first deposited on a carrier film. Glass fibers are then placed on the resin layer, there being used in this application 25 weight parts of such fibers per 100 parts of the fully blended resin mixture. The resulting composite, on the carrier film, is passed between a roller and in contact with a second moving film, whereby the composite travels forward between the carrier film and the second film. It proceeds through a heating zone to cure the resin while so confined. After proceeding through the heating zone, the cured resin can be separated from its enclosure by bending each film away from the resin. The emerging cured resin can then be cut into suitable sizes to be subsequently used as panels.
Preferred ingredient proportions and ranges of proportions have been set forth. Of course, changing the proportion of one ingredient, even within the ranges set forth, may require adjustment of the proportions used of other ingredients.
The invention has been described with reference to the preferred embodiment. Obviously, modifications and alterations will occur to others upon the reading and understanding of this specification. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalent thereof.
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A strong, fiberglass reinforced plastic material with fire retardant additive for use as a traffic sign blank material is described. The material is formed from a well balanced mixture of unsaturated polyester resin, halogenated polyester resin, inorganic fire retardant filler, monomer cross-linking agent and fiberglass reinforcement.
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RELATED APPLICATIONS
[0001] This application claims the benefit of 35 U.S.C. 119(e) to U.S. Provisional Patent Application Ser. No. 62/005,035 filed on May 30, 2014.
FIELD OF THE INVENTION
[0002] This invention relates to a vehicle cross-support member which in a most preferred embodiment includes a plurality of axially-joined elongated members of different materials for optimizing strength and rigidity, whilst minimizing manufacturing costs. The invention further relates to a method of manufacturing the vehicle cross-support member, most preferably in a vehicle assembly line, involving axially engaging the longitudinal sections using most preferably interference fit.
BACKGROUND OF THE INVENTION
[0003] In the automobile industry, vehicle cross-support members, which is also known as crossbeams, cross car beams, and other similar components (collectively referred hereinafter as “vehicle cross-support members” or “cross-support members”) are utilized as part of the vehicular body structure. The vehicle cross-support member normally spans between or fastened to a pair of laterally disposed vertical pillars, or A-pillars, in the region generally below the windscreen and a cowl top, and between a forward engine compartment and a rearward passenger compartment, so as to extend in a direction transverse to the length of an automobile. As part of a motor vehicle body, the cross-support member provides for cross car stiffness and rigidity against for example side load impacts.
[0004] Located forwardly of the driver and the front-row passenger, the cross-support member also supports or provides mounting surfaces for various vehicle components, including an instrument panel, a glove and/or storage compartment, a center console, a dashboard and a steering column member.
[0005] In view of the various forces and loads which may be placed on or transferred to the cross-support member during vehicle operation, it is an important consideration in the design and manufacture of a vehicle that the cross-support member possesses or provides for improved Noise, Vibration and Harshness (“NVH”) performance, stiffness, strength and load path. Commercially, it is also of significant consideration that the cross-support member permits more standardized and customizable assembly and installation in vehicles of differing performance requirements and price points, without significantly increasing mechanical or manufacturing complexities.
SUMMARY OF THE INVENTION
[0006] One possible non-limiting object of the present invention is to provide a vehicle cross-support member for placement in a generally transverse orientation to a length of a vehicle, and which is designed for permitting improved and more cost-effective assembly and installation without significantly compromising NVH performance, and structural rigidity and strength.
[0007] Another possible non-limiting object of the present invention is to provide a vehicle cross-support member for placement in a generally transverse orientation to a length of a vehicle, and which may be configured to incorporate components made with different materials, while avoiding significant increases to manufacturing cost or complexity.
[0008] Another possible non-limiting object of the present invention is to provide a method for preparing a vehicle cross-support member, and which may readily be configured and installed in vehicles of differing performance and price points in an automobile assembly line.
[0009] In view of the disadvantages of previously known devices, the present invention provides in one simplified aspect a vehicle cross-support member positionable in a generally transverse orientation to a length of a vehicle, the vehicle cross-support member comprising first and second longitudinal sections coupled at respective axial joint end portions most preferably by interference fit.
[0010] In one aspect, the present invention provides a vehicle cross-support member positionable in a generally transverse orientation to a length of a vehicle, the vehicle cross-support member comprising first and second adjacent longitudinal sections coupled at respective axial joint end portions by interference fit, the first longitudinal section comprising in the respective axial joint end portion a pair of longitudinally spaced annular ridge members and a peripheral engagement surface portion extending therebetween; and the second longitudinal section defining in the respective axial joint end portion a generally hollow interior with an interior surface profile sized to frictionally engage the peripheral engagement surface portion.
[0011] Preferably, each said longitudinal section comprises an elongated tubular member defining a generally hollow interior, the tubular member having a cross-section shape selected from the group consisting of a circle, an ellipse, a triangle, a square, a hexagon, and an octagon. Each said longitudinal section is preferably formed as an extruded tubular member prepared with a material comprising aluminum, steel, magnesium and/or carbon fiber.
[0012] Preferably, each said longitudinal section comprises a vehicle attachment end portion located at an axial end distal to the axial joint end portion, the vehicle attachment end portion being shaped for direct or indirect attachment to a lateral structural member of the vehicle.
[0013] Preferably, the first and second longitudinal sections are formed as passenger side and driver side sections, respectively, the passenger side and driver side sections being positionable in the vehicle proximal to a front passenger compartment and a driver compartment, respectively. The passenger side and driver side sections preferably comprise elongated steel and aluminum tubular members, respectively, each said elongated tubular member having a circular cross-section, wherein the passenger side section has a length greater than that of the driver side section, and wherein the passenger side section has an outer diameter less than that of the driver side section.
[0014] In one embodiment, the axial joint end portion of the second longitudinal section is provided with a joint engagement barrel defining the hollow interior. The joint engagement barrel may be provided as an integral component of the axial joint end portion, or in the alternative, a separate component to be secured or welded to the axial joint end portion. When provided as a separate component, the second longitudinal section defines in the joint end portion an axially open end sized to longitudinally receive the joint engagement barrel, and the second longitudinal section is welded to the joint engagement barrel. For more secure welding, the second longitudinal section and the separate joint engagement barrel comprise the same material. Most preferably, in the assembled arrangement, each of the two axial ends of the joint engagement barrel is in abutting contact with an associated one of the annular ridge members.
[0015] Preferably, the annular ridge members comprise compression beads. To prevent relative rotational movement between the first and second longitudinal sections, one or both of the annular ridge members comprise one or more stop tabs sized to be received in associated longitudinally recessed slots defined by the rims located in the axial ends of the joint engagement barrel.
[0016] In one embodiment, the first longitudinal section comprises a first generally hollow tube and a second tube sized to be partially received longitudinally in the interior of the first tube, the second tube comprising an outwardly extending rim located distal to the first tube, wherein in the assembled arrangement, the second tube is longitudinally received in the hollow interior of the joint engagement barrel in frictional engagement therewith, and the joint engagement barrel is in abutting contact with the outwardly extending rim and an axial end of the first tube.
[0017] In another aspect, the present invention provides a method for manufacturing the cross-support member, method comprising forming a first one of said annular ridge members at a pre-determined longitudinal position in the axial joint end portion of the first longitudinal section to define an insertion portion; longitudinally inserting the insertion end portion into the hollow interior such that the axial joint end portion of the second longitudinal section abuts against the first annular ridge member, the interior surface frictionally engaging the outer peripheral surface of the insertion portion; and forming the other said annular ridge member in abutting contact with the axial end portion of the second longitudinal section.
[0018] In yet another aspect, the present invention provides a vehicle cross-support member for positioning in a generally transverse orientation to a length of a vehicle, the cross-support member comprising a jointed portion extending longitudinally from a first end to a second end, wherein the jointed portion comprises a first elongated member and a second elongated member mechanically coupled to the first elongated member, the first elongated member comprising a first body portion extending longitudinally from the first end to an axially open socket end portion, wherein the socket end portion comprises an inwardly tapering sidewall portion and a reduced diameter engagement barrel integral with the tapering sidewall portion, the engagement barrel extending longitudinally from the tapering sidewall portion to define an axially open end and an inner engagement surface, and the second elongated member comprising a second body portion extending longitudinally from the second end to a mating end portion, wherein the mating end portion comprises: an insertion rod sized for fitted placement into the axially open end, the insertion rod comprising an outer engagement surface for frictional engagement with the inner engagement surface in a mechanically coupled position; an annular seating flange extending generally outwardly from the insertion rod for seated engagement with an inner surface of the tapering sidewall portion; and an annular abutment flange formed adjacent to the insertion rod, the abutment flange being engageable with the engagement barrel to limit axial movement of the mating end portion inwardly through the axially open end, wherein in the mechanically coupled position, said frictional engagement between the insertion rod and the engagement barrel fixedly secures the first and second elongated members in a weldless connection.
[0019] In yet another aspect, the present invention provides a vehicle cross-support member for positioning in a generally transverse orientation to a length of a vehicle, the cross-support member comprising a jointed portion extending longitudinally from a first end to a second end, wherein the jointed portion comprises a first elongated member and a second elongated member coupled to the first elongated member, the first elongated member comprising a first body portion extending longitudinally from the first end to an axially open socket end portion, wherein the socket end portion comprises an inwardly tapering sidewall portion defining an axially open end, and the second elongated member comprising a second body portion extending longitudinally from the second end to a mating end portion, wherein the mating end portion comprises an insertion rod assembly having: an insertion rod comprising an outer engagement surface and a pair of longitudinally spaced annular abutment flanges, wherein the outer engagement surface extends between the abutment flanges; and an engagement barrel comprising an inner engagement surface frictionally engaging the outer engagement surface to fixedly retain the engagement barrel and the insertion rod in a mechanically coupled position, wherein the abutment flanges bear against the engagement barrel to limit axial movement thereof relative to the insertion rod, wherein the mating end portion is received into the axially open end with a periphery of the engagement barrel being coupled to the inwardly tapering sidewall portion adjacent to the axially open end to thereby fixedly secure the first and second elongated members.
[0020] In yet another aspect, the present invention provides a vehicle cross-support member for positioning in a generally transverse orientation to a length of a vehicle, the cross-support member comprising a jointed portion extending longitudinally from a first end to a second end, wherein the jointed portion comprises a first elongated member and a second elongated member mechanically coupled to the first elongated member, the first elongated member comprising a first body portion extending longitudinally from the first end to an axially open socket end portion, and the second elongated member comprising a second body portion extending longitudinally from the second end to a mating end portion, the mating end portion being sized for fitted placement within the socket end portion in frictional engagement therewith in a mechanically coupled position, wherein in the mechanically coupled position, said frictional engagement between the socket end portion and the mating end portion fixedly secures the first and second elongated members.
[0021] The socket end portion preferably comprises an inwardly tapering sidewall portion and an engagement barrel coupled to the sidewall portion, the engagement barrel extending longitudinally to define an axially open end and an inner engagement surface, and the mating end portion comprises an outer engagement surface and an annular abutment flange disposed adjacent to the outer engagement surface, the outer engagement surface being sized for the frictional engagement with the inner engagement surface in the mechanically coupled position, wherein the abutment flange abuts against the engagement barrel to limit axial movement thereof relative to the mating end portion.
[0022] In one embodiment, the engagement barrel is integral with the tapering sidewall portion to extend longitudinally therefrom to define the axially open end, the abutment flange being engageable with the engagement barrel adjacent to the axially open end to limit axial movement of the mating end portion inwardly therethrough, and the mating end portion further comprises an annular sealing flange extending generally outwardly from the insertion rod for seated engagement with an inner surface of the tapering sidewall portion.
[0023] In an alternative embodiment, the tapering sidewall portion defines an axially open aperture, the engagement barrel being received into the aperture with a periphery of the engagement barrel being welded to the tapering sidewall portion adjacent to the aperture, and the mating end portion comprises a pair of the abutment flanges bearing against the engagement barrel to limit axial movement thereof relative to the outer engagement surface.
[0024] Preferably, each said first and second elongated members comprises a hollow tubular body having a lateral cross-sectional profile selected from the group consisting of a circle, an ellipse, a square, a triangle, a rectangle, a parallelogram, a trapezoid, a pentagon, a hexagon and an octagon. It is to be appreciated that each of the first and second elongated members are not strictly restricted to having a single uniform cross-sectional profile, and may include a plurality of longitudinal sections each having a different or same cross-sectional profile. More preferably, each said first and second elongated members is formed as a generally cylindrical tubular member, and the inner and outer engagement surfaces comprise a substantially identical radius to effect an interference fit therebetween in the mechanically coupled position.
[0025] In one embodiment, the engagement barrel comprises a rim disposed adjacent to the axially open end, the rim defining one or more longitudinally recessed slots, and the abutment flange comprises one or more retention tabs each positioned to be received in an associated one of the recessed slots to prevent rotation of the engagement barrel relative to the insertion rod. Alternatively, the engagement barrel may include a rim defining one or more longitudinally recessed slots, one of the abutment flanges bearing against the rim, wherein the one abutment flange comprises one or more retention tabs each positioned to be received in an associated one of the recessed slots to prevent rotation of the engagement barrel relative to the insertion rod.
[0026] To prevent relative movement between the engagement barrel and the insertion rod, the outer engagement surface preferably defines a surface opening or an inwardly oriented depression, and the inner engagement surface comprises a retention member sized to be at least partially received in the opening or depression.
[0027] Each said seating and abutment flanges preferably comprises a compression bead integrally formed on the mating end portion by applying generally longitudinal compression thereon. For added resistance or strength against potential relative axial movement of the engagement barrel during operation, each of the flanges may include two or more integrally formed compression beads.
[0028] It is to be appreciated that the first and second elongated members are not particularly limited to being prepared with any specific material or substance. Preferably, the elongated members are prepared with a metal or alloy material selected to impart structural rigidity, stiffness and strength to the vehicle cross-support member. In one embodiment, each said first and second elongated members comprises independently of each other one or more of aluminum, steel, magnesium and carbon fiber.
[0029] In a more preferred embodiment where the engagement barrel is integral with the inwardly tapering sidewall portion, the first elongated member comprises aluminum, and the second elongated member comprises steel, wherein the first elongated member is for positioning proximal to a driver side compartment of the vehicle, and the second elongated member is for positioning proximal to a front passenger compartment of the vehicle. In an alternative preferred embodiment where the engagement barrel is coupled or welded to the inwardly tapering sidewall portion, the first elongated member and the engagement barrel each comprises aluminum, and the second body portion and the insertion rod each comprises steel, wherein the first elongated member is for positioning proximal to a driver side compartment of the vehicle, and the second elongated member is for positioning proximal to a front passenger compartment of the vehicle.
[0030] In one embodiment, one or both of the first and second elongated members comprise an attachment bracket for securing the vehicle cross-support member to a lateral structural member of the vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] Reference may now be had to the following detailed description taken together with the accompanying drawings in which:
[0032] FIG. 1 is a perspective view of a motor vehicle cross-support member assembly which includes a vehicle cross-support member in accordance with a preferred embodiment of the present invention, and which is shown as coupled to a number of associated vehicle components of the cross-support member assembly;
[0033] FIG. 2 is an elevational view of the cross-support member assembly shown in FIG. 1 ;
[0034] FIG. 3 is a partial cross-sectional view of a driver side longitudinal tube section of the cross-support member shown in FIG. 1 ;
[0035] FIG. 4 is a partial cross-sectional view of a passenger side longitudinal tube section of the cross-support member shown in FIG. 1 ;
[0036] FIG. 5 is a perspective end view of a joint engagement barrel of the cross-support member shown in FIG. 1 ;
[0037] FIG. 6 is a partial cross-sectional view of the passenger side longitudinal tube section and the joint engagement barrel shown in FIGS. 4 and 5 , respectively;
[0038] FIG. 7 is a sectional perspective view of the passenger side longitudinal tube section and the joint engagement barrel shown in FIGS. 4 and 5 , respectively;
[0039] FIG. 8 is an elevation view of the passenger side longitudinal tube section and the joint engagement barrel shown in FIGS. 4 and 5 , respectively;
[0040] FIG. 9 is a partial cross-sectional view of the cross-support member shown in FIG. 1 ;
[0041] FIG. 10 is a partial top view of the cross-support member assembly shown in FIG. 1 ; and
[0042] FIG. 11 is a partial cross-sectional view of a vehicle cross-support member in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] Reference is made to FIG. 1 which shows a perspective view of a motor vehicle cross-support member assembly 10 which includes an aluminum-steel hybrid joint cross-support member 12 in accordance with a preferred embodiment of the present invention. In the construction shown, the cross-support assembly 10 includes the aluminum-steel hybrid joint cross-support member 12 ; a pair of lateral A-pillar attachment members 14 a , 14 b ; transversely spaced central column support members, 16 a , 16 b ; a steering column mounting assembly 18 ; and cowl top mounting brackets 20 a , 20 b . As shown in use, the cross-support member 12 is secured in a position with axial vehicle attachment end portions 32 , 52 coupled to the A-pillar attachment members 14 a , 14 b , respectively.
[0044] As will be described in greater detail below, the hybrid joint cross-support member 12 incorporates a three-piece construction which broadly includes a driver side longitudinal tube section 30 , a passenger side longitudinal tube section 50 and a joint engagement barrel 70 . For greater clarity, FIG. 2 shows an elevation view of the cross-support member assembly 10 .
[0045] Reference is made to FIG. 3 which shows a partial cross-sectional view of the driver side tube section 30 . The tube section 30 includes a longitudinally elongated, hollow tubular aluminum sidewall 31 of substantially uniform diameter and thickness along the length, and which extends axially from the vehicle attachment end portion 32 towards a beveled joint engagement end portion 34 . FIG. 3 shows best the joint engagement end portion 34 as having an inwardly tapered sidewall which defines an end joint engagement aperture 36 . The aperture 36 is formed as having reduced internal and external diameters compared to those of the remaining tubular sidewall 31 . As will be described, the joint engagement aperture 36 is sized to receive therein in a mated fit manner both end portions of the passenger side tube section 50 and the joint engagement barrel 70 .
[0046] Although not strictly limited, the driver side section 30 preferably has a length between about 30 cm and about 150 cm; an outer diameter between about 3 cm and about 15 cm; and a thickness between about 0.1 cm and about 1 cm. The joint engagement aperture 36 preferably has an inner diameter between about 2 cm and about 12 cm.
[0047] Reference is now made to FIG. 4 which shows a partial cross-sectional view of the passenger side tube section 50 . The tube section 50 includes a longitudinally elongated, hollow tubular sidewall 51 of generally uniform diameter and thickness, and which is made with a material different from that of the sidewall 31 , or namely steel. The tubular sidewall 51 extends axially from the vehicle attachment end portion 52 towards a mating end portion 54 . The mating end portion 54 includes a tubular barrel engagement sidewall 60 extending from a first annular compression bead 56 of enlarged diameter located adjacent to the sidewall 51 . The mating end portion 54 further includes a second annular compression bead 58 longitudinally spaced from the first compression bead 56 , such that the barrel engagement sidewall 60 extends between the compression beads 56 , 58 . As will be described, the outer peripheral surface of the barrel engagement sidewall 60 is sized to frictionally engage an interior surface of the joint engagement barrel 70 .
[0048] As best shown in FIG. 7 , the second compression bead 58 includes a plurality of annularly spaced engagement tabs 62 , 64 , 66 extending towards the first compression bead 56 for effecting interlocking engagement with the joint engagement barrel 70 as will be described below.
[0049] The passenger side tube section 50 preferably has a length between about 50 cm and about 180 cm; an outer diameter between about 2 cm and 10 cm; and a thickness between about 0.05 cm and about 0.5 cm. Each of the compression beads 56 , 58 preferably extends annularly between about 0.1 cm and about 1 cm from an outer surface of the sidewalls 51 , 60 , and are longitudinally spaced between about 0.5 cm and about 10 cm. The barrel engagement sidewall 60 most preferably have an outer diameter and thickness identical to those of the sidewall 51 . The sidewall 60 may however incorporate differing dimensions depending on the dimensions of the joint engagement barrel 70 .
[0050] FIG. 5 shows best a perspective end view of the joint engagement barrel 70 . The barrel 70 includes a generally cylindrical body having a sidewall 71 which defines a hollow interior 72 extending between first and second axially open ends 74 , 76 . The joint engagement barrel 70 is specifically made with the same aluminum material used for forming the driver side tube section 30 . At the first open end 74 , the sidewall 71 defines a plurality of longitudinally recessed slots 78 , 80 , 82 . The slots 78 , 80 , 82 are annularly spaced along the periphery of the open end 74 , and as will be described, are used for effecting interlocking engagement with the passenger side tube section 50 .
[0051] The joint engagement barrel 70 preferably has a length between about 0.5 cm and about 10 cm; an outer diameter between about 3 cm and 12 cm; and a thickness between about 0.1 cm and 1 cm.
[0052] For assembly, the passenger side tube section 50 is initially provided as a blank steel tube. The compression bead 56 is first formed at a pre-determined longitudinal position on the blank steel tube, delineating between the sidewalls 51 , 60 . The barrel engagement sidewall 60 is axially inserted into the hollow interior 72 through the first open end 74 of the joint engagement barrel 70 using a press or hydraulic equipment, until the periphery of the second open end 76 abuts against the pre-formed compression bead 56 . The passenger side tube section 50 is pressed to form the second compression bead 58 to abut against the periphery of the first open end 74 , such that the joint engagement barrel 70 is in abutting contact with both the compression beads 56 , 58 , with the interior surface of the joint engagement barrel 70 frictionally engaging the barrel engagement sidewall 60 . As shown in FIGS. 6 to 8 , peripheral portions of the second compression bead 58 longitudinally aligned with the recessed slots 78 , 80 , 82 are lanced to form the engagement tabs 62 , 64 , 66 , so as to be received in an associated one of the recessed slots 78 , 80 , 82 , and effect interlocking engagement between the passenger side tube section 50 and the joint engagement barrel 70 to prevent relative rotation therebetween.
[0053] To join the driver side and passenger side tube sections 30 , 50 , the barrel engagement sidewall 60 with the joint engagement barrel 70 frictionally engaged thereto is axially inserted through the joint engagement aperture 36 , such that an outer peripheral surface of the barrel 70 is proximal to, or in contact with the periphery of the aperture 36 . The joint engagement end portion 34 is welded to the joint engagement barrel 70 using metal inert gas welding to form the cross-support member 12 as a single integral unit.
[0054] Although not strictly limited, as shown in FIGS. 1 and 2 , the driver side tube section 30 has a length less than that of the passenger side tube section 50 , the ratio of the lengths of the tube sections 30 , 50 being between about 0.55 and about 0.85. FIG. 10 best shows the driver side tube section 30 secured on an upper portion of the central column support member 16 a offset in a vehicle towards the driver side.
[0055] The applicant has appreciated that the hybrid joint cross-support member 12 may provide for improved cost-efficiency in that the driver side tube section 30 with increased load requirements could be constructed with aluminum materials of greater strength (and higher costs), while the passenger side tube section 50 , with lesser load requirements, could be prepared separately with less expensive steel materials. Such construction may allow for an improved component design with more optimal balance between performance and cost.
[0056] It is to be noted that while the driver side and passenger side tube sections 30 , 50 are described as being prepared with aluminum and steel, respectively, other materials, such as carbon fiber, magnesium and other suitable metal alloys, may be selected, depending on the required specifications of the vehicle in which the cross-support member 12 is to be mounted. For instance, in a performance vehicle with greater demands for reduced weight, and increased vehicle rigidity and handling, the tube sections 30 , 50 may be constructed with more costly carbon fiber and aluminum, respectively. For more secure axial engagement, the tube section 30 and the joint engagement barrel 70 are preferably made with the same material.
[0057] The applicant has also appreciated that the hybrid joint cross-support member 12 may provide for more efficient and versatile assembly and mounting in a vehicle assembly line. For instance, the cross-support member 12 may be adopted for assembly and installation in a vehicle assembly line designed for manufacturing both lower cost and higher cost vehicles, by providing pre-fabricated driver side and passenger side tube sections of different materials to be assembled and installed in different combinations, depending on the specifications of each particular vehicle manufactured in the assembly line.
[0058] Reference is now made to FIG. 11 which shows a partial cross-sectional view of an aluminum-steel hybrid joint cross-support member 112 in accordance with an alternative embodiment of the present invention. In contrast to the cross-support member 12 , the joint cross-support member 112 incorporates a two-piece construction which broadly includes a driver side longitudinal tube section 130 and a passenger side longitudinal tube section 150 .
[0059] The driver side tube section 130 is substantially similar to the tube section 30 in that it includes a longitudinally elongated, hollow tubular aluminum sidewall 131 extending from a vehicle attachment end portion (not shown) towards a beveled seating portion 138 . The driver side tube section 130 differs from the tube section 30 in that an integrally-formed joint engagement barrel portion 170 extends from the seating portion 138 . The barrel portion 170 includes a cylindrical sidewall 171 defining a hollow interior extending from that of the remaining portion of the driver tube section 10 to an axially open end 176 . Similar to the sidewall 71 , the sidewall 171 defines a plurality of longitudinally recessed slots (not shown) annularly spaced along the periphery at the open end 176 for effecting interlocking engagement with the passenger side tube section 150 .
[0060] The passenger side tube section 150 is similar to the tube section 50 in that a longitudinally elongated, hollow tubular sidewall 151 is provided to extend from an axial vehicle attachment end portion (not shown) towards a mating end portion 154 . The mating end portion 154 includes a tubular barrel engagement sidewall 160 , a first annular compression bead 156 located between the sidewalls 151 , 160 and a second annular compression bead 158 longitudinally spaced from the first compression bead 156 distal to the sidewall 151 . The second compression bead 158 differs from the bead 58 in that the bead 158 extends at an obtuse angle from the barrel sidewall 160 to better conform to an inner surface of the seating portion 138 as will be described. As also will be described, the first compression bead 156 includes a plurality of annularly spaced engagement tabs (not shown) extending towards the second compression bead 158 to effect interlocking engagement with the driver side tube section 130 .
[0061] For assembly, the compression bead 156 is first formed at a pre-determined longitudinal position on a blank hollow steel tube to be formed as the passenger side tube section 150 , with the compression bead 156 delineating between the sidewalls 151 , 160 . The mating end portion 154 is axially inserted through the open end 176 to effect an interference fit between the outer peripheral surface of the barrel engagement sidewall 160 and the inner surface of the sidewall 171 , until the periphery of the open end 176 abuts against the first compression bead 156 . The second compression bead 158 is then formed in the hollow interior of the driver side tube section 130 , such that the bead 158 is in seated engagement with the seating portion 138 . The annular portions of the first compression bead 156 longitudinally aligned with the recessed slots defined by the sidewall 170 are lanced to form the engagement tabs inserted into associated recessed slots to prevent relative rotational movement between the tube sections 130 , 150 during operation.
[0062] It is to be noted that for increased rigidity and strength in the engagement between the driver side and passenger side tube sections, each of the compression beads may be increased in size or number, provided that such modifications do not interfere with the construction, assembly or operation of the cross-support member. For added resistance against relative rotational movement in the frictional engagement between the joint engagement barrel/barrel portion and the mating end portion, the inner surface of the joint engagement barrel/barrel portion may be modified to include inwardly extending projections shaped for complementary engagement with projection receiving indentations defined by the outer peripheral surface of the mating end portion. Such projections and indentations are preferably introduced after fully engaging the mating end portion and the joint engagement barrel/barrel portion, using for example half shearing or lancing.
[0063] It is to be noted that the driver side and passenger side sections are not strictly limited to the co-axial arrangement in the fully assembled form as shown in FIGS. 1 , 2 and 9 to 11 . In an alternative embodiment, the driver side tube section 130 may be modified such that the longitudinal axis of the integral joint engagement barrel portion 170 is offset from that of the remaining portion of the driver side tube section 130 . By way of a non-limiting example, the driver side tube section 130 or the beveled seating portion 138 may be modified to include an axially offset portion. Furthermore, with the cross-support member 12 , the joint engagement end portion 34 may be modified to define the joint engagement aperture 36 with the origin offset from the longitudinal axis of the driver side tube section 30 .
[0064] While the invention has been described with reference to preferred embodiments, the invention is not or intended by the applicant to be so limited. A person skilled in the art would readily recognize and incorporate various modifications, additional elements and/or different combinations of the described components consistent with the scope of the invention as described herein.
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There is provided in a preferred embodiment a vehicle cross-support member for positioning in a generally transverse orientation to a length of a vehicle, the cross-support member including a jointed portion extending from a first end to a second end, wherein the jointed portion includes a first elongated member and a second elongated member mechanically coupled to the first elongated member. The first elongated member includes an axially open socket end portion, and the second elongated member includes a mating end portion sized for fitted placement within the socket end portion in frictional engagement therewith in a mechanically coupled position.
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This is a continuation of application Ser. No. 08/685,453, filed Jul. 19, 1996 now U.S. Pat. No. 5,720,683.
FIELD OF THE INVENTION
The invention relates to an apparatus for separating woody material from plant fibers and, more particularly, to a method for decorticating shive from flax straw to yield flax fibers by subjecting the flax straw to processing sections, each having sets of fluted rollers which are rotated at different rotation rates from adjacent sets of rollers to bend and pull the shive and thereby strip shive from the flax fibers.
BACKGROUND OF THE INVENTION
Various methods of decorticating flax straw, that is, separating the woody shive material from the flax plant fibers, have been proposed. Apart from retting and chemical treatment processes, most systems for mechanically working flax straw rely on some sort of scutching or a beating or flailing action as the primary mechanism to break up the woody material and dislodge the same from associated fibers. Examples of machines utilizing scutching or beating action in removing shive are disclosed in U.S. Pat. Nos. 2,418,694 and 2,741,894.
The problem with beating flax straw to break loose the shive material is that the beating action can also damage or break the fibers and thereby shorten the fibers separated from the shive. In many applications for these fibers, long fibers can be necessary for strength purposes such as in papermaking, preparation of fiberboard-types of materials, production of textiles, and reinforcing other fibers, plastic or composite material, and thus the shorter fibers produced by prior methods of decortication are undesirable. In addition to longer fibers, it is also economically desirable to be able to process high rates of flax straw through decorticating machines with relatively low power requirements.
SUMMARY OF THE INVENTION
According to the invention, an apparatus for separating woody material from plant fibers is disclosed which includes the provision of a plurality of woody material bending regions with the plant material being fed to a first and then a second one of the bending regions as bending and pulling surfaces are moved through the bending regions. The bending and pulling surfaces move through the regions at different operating speeds so that the bending and pulling surfaces in adjacent bending regions will pull on the plant material to separate the fibers from the woody material. As the bending and pulling surfaces primarily impart a pulling or stripping force on the fiber along its length where the fiber has its most strength, the woody material can be dislodged and stripped away lengthwise with minimal damage or breakage of the fiber. In addition, if the friction of being pulled over the bending and pulling surfaces becomes too large at the removal point of the woody material, the woody material will overcome the pulling force and the plant material will not be pulled and will cease its relative motion and move between the bending and pulling surfaces in a region until it is once again to a point where it can be pulled and removal of woody material can be accomplished. In this manner, damage such as by breaking of the plant fiber is limited.
The step of providing bending regions may include the step of providing first and second sets of fluted rollers having bending and pulling radially extending flute surfaces. The plant material is fed to the first bending region between the first set of fluted rollers and then the second bending region between the second set of fluted rollers. The method utilizing fluted rollers allows very high flow rates of plant material to be processed with relatively low power requirements compared to processes which primarily rely on mechanically working and beating or flailing of the plant material to break loose the woody material.
The step of separating fibers from woody material may include the step of causing the plant to undergo back and forth bending and pulling as the bending and pulling flute surfaces engage the plant material as they move through their respective bending regions to crimp and break woody material and to strip the woody material from the plant fibers. By back and forth bending of the woody material, areas of weakness are created which when subjected to pulling forces will allow the woody material to be stripped from the plant fibers.
The method may further include the steps of feeding plant material to a third one of the bending regions after it is moved through the second bending region and causing the third region bending and pulling surfaces to move through the third region at an operating speed different than the operating speed of the first and second region bending and pulling surfaces. Preferably, the bending and pulling surfaces are caused to move through the first, second and third bending regions at progressively increasing operating speeds. In this manner, the plant material will be pulled between the bending regions such as by the second region bending and pulling surfaces from the first region and by the third region bending and pulling surfaces from the second region to strip the woody material from the plant fibers.
Preferably, the first, second and third bending regions are provided together as a first plant material processing section with additional processing sections being provided for feeding plant material successively to each of the processing sections. The plant material can be fed to five processing sections at a rate of at least 10,000 pounds per hour and yielding as fiber output from the final processing section in the range of 55-60% of fiber purity. Thus, the method of the present invention has increased processing rates while still yielding relatively high percentages of fiber as output over prior decorticating methods.
Another aspect of the invention is a method for decorticating shive from flax straw to yield flax fibers, including the steps of providing sets of upper and lower fluted rollers, with the upper and lower rollers arranged in a set to provide an area therebetween where the flutes of the upper rollers overlap with the flutes of the lower rollers as the rollers are rotated, rotating sets of fluted rollers at different predetermined rotation rates, feeding flax straw to the flute overlap areas between the upper and lower rollers, bending the shive of the flax in the fluted overlap areas by engagement with the roller flutes while limiting damage to the flax fibers, and pulling bent shive from one set of rollers to the next as a result of the different rotation rates of the roller sets to strip the shive from the flax and produce flax fibers.
Preferably, the step of providing sets of fluted rollers includes providing a first set of feed rollers, a second set of intermediate feed rollers and a third set of high speed rollers with the flax being fed successively from the first set to the second set to the third set of rollers. The rotating step may include rotating the feed rollers at a rate of approximately 60-110 revolutions per minute (rpm), the intermediate speed rollers at a rate of approximately 1000-1750 rpm, and the high speed rollers at a rate of approximately 2000-3500 rpm.
The method may include the step of providing a set of upper and lower crush rollers, feeding the flax to the crush rollers, producing a thin mat of compressed flax, and feeding the thin flax mat to the first set of rollers.
The method may include the steps of providing removable flutes on the fluted rollers and removing worn flutes on the rollers and replacing the removed flutes with new flutes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a machine which can be used to carry out the method of the present invention and shows a machine frame for supporting sets of fluted roller assemblies through which plant material travels;
FIG. 2 is a side elevational view of the machine of FIG. 1 including an optional scutching unit provided at the outlet end of the machine;
FIG. 3 is an enlarged fragmentary view of optional crush feed rollers and the first processing section of FIG. 2;
FIG. 4 is a block diagram of the method according to the present invention where the plant material is first fed to a crushing area and then to a plurality of processing sections each having varying speed sets of rollers and then to the scutching area;
FIG. 5A is a front elevational view of one of the roller assemblies and a removable flute before it is mounted to the roller;
FIG. 5B is a view similar to FIG. SA with the flute attached to the roller;
FIG. 6 is a front elevational view of the drive system for one of the sets of feed rollers; and
FIG. 7 is a front elevational view of the drive system for one of the sets of intermediate or high speed rollers.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A machine 10 is depicted in FIG. 1 which can carry out the method of separating woody material from plant fibers in accordance with the present invention. The machine 10 includes a framework 12 for supporting sets of roller assemblies 14 and their associated drives 16.
Referring to FIGS. 2-4, the method in accordance with the invention includes arranging the roller assemblies 14 in sets so that they define the woody material bending regions 18 between upper and lower rollers 14a and 14b in a set. The plant material 20 is then fed through these bending regions 18, as best seen in FIG. 3. The method herein utilizing the machine 10 is ideally suited for decorticating flax straw to yield flax fibers, although it will be recognized that other plant material from which it is desired to separate woody material from the plant fibers can also be processed by way of the method of the present invention.
To separate the woody material from the plant fibers, the roller assemblies 14 are provided with bending or pulling surfaces or flutes 22 thereon. The rollers 14 in a set are arranged so that the bending and pulling surfaces 22 move through the bending regions 18 in an overlapping manner, thereby bending the plant material 20 in the bending region 18. The bending and pulling surfaces 22 are caused to move through their respective bending regions 18 at different predetermined operating speeds so that the plant material 20 is pulled from the slower moving sets of roller assemblies 14 to the faster moving roller sets. In this fashion, the woody material on the exterior of the plant material 20 is bent creating areas of weakness with the woody material then being gripped by the surfaces 22 and pulled from one set of rollers 14 to the next to strip the woody material off of the fibers leaving a relatively long length of unbroken fibers as the final product. This is a significant improvement over prior methods which mechanically work the straw, such as by beating and flailing the straw to break loose the shive material as in those processes the fiber length was typically much shorter than that produced by way of the present method. In addition, the present method does not require any pretreatment of the flax straw such as by field retting and has been found to work well with straw in a wide variety of conditions.
More particularly, the sets of roller assemblies 14 include a set of low speed, smaller diameter feed rollers 24, intermediate speed, larger diameter rollers 26 and high speed large diameter rollers 28 which make up a single processing section of the machine 10. Preferably, the intermediate speed rollers 26 and the high speed rollers 28 are of substantially equal diameters. As can be seen in FIG. 2, five such processing sections are provided in the machine 10.
As the flax straw material 20 is fed from one processing section to the next, shive is progressively removed from the fiber by the bending and stripping action, as previously described. The woody shive falls out of the machine 10 between the processing sections and is conveyed away with the fiber being carried forward to the end of the machine 10 and out from the last processing section. With the decorticating method herein, the percentage of fiber obtained from flax straw has been found to be in the range of 55 to 60 percent fiber purity. To obtain even higher percentages of fiber, the fiber material from the machine 10 can then be fed to a scutching unit 30 which gently mechanically works the fibers to dislodge remaining portions of shive left on the fibers without damage to the fibers. Utilizing the scutching unit can increase fiber purity up to around 80 percent. Field retting of the straw and exercising control over the straw moisture content can also assist in increasing fiber purity. Adjustment of the roller spacing and speed of the machine 10 can also help in obtaining higher purity percentages.
For determining fiber purity, a twenty (20) gram sample can be taken from the processed fiber. The sample can then be ground in 2 mm lengths in a Willey Grinding Mill. The ground sample is weighed and placed in a mini-cyclone separator. A vacuum cleaner is used to provide air flow for separating shive and fiber and as the sample is mixed, fiber is separated by way of air classification. As the shive particles are heavier, they remain in the mixer with the fiber being carried by the air flow and removed from the flow by a mini-cyclone and routed to a different sample container. After removal of fiber from the shive, the remaining shive is weighed and a purity percentage of fiber is calculated using the weight of the measured weight of the shive and the sample weight.
As previously mentioned, it is preferred that the feed rollers 24 are operated at a predetermined operating speed that is lower than the predetermined operating speed for the intermediate speed rollers 26 which, in turn, is lower than the predetermined operating speed for the high speed rollers 28. In this manner, flax 20 is pulled from between the bending region 18a between the feed rollers 24a and 24b to the bending region 18b between the intermediate speed rollers 26a and 26b. Similarly, the flax 20 is pulled from the bending region 18b between the intermediate speed rollers 26a and 26b to the bending region 18c between the high speed rollers 28a and 28b. Preferably, the feed rollers are rotated at a rate of approximately 60-110 rpm, the intermediate speed rollers 26 at a rate of approximately 1000-1750 rpm, and the high speed rollers at a rate of approximately 2000-3500 rpm to achieve the pulling and stripping action between sets of roller assemblies 14.
Thus, it is apparent that flax material 20 introduced to the roller assemblies 14 will be bent in a back and forth fashion in the bending regions 18 over and between the surfaces of the flutes 22 of roller assemblies 14 which will produce areas of weakness in the exterior woody shive material of the flax 20. Then, as the flax 20 is caused to be pulled between sets of rollers 14, the woody shive material will tend to dislodge from the fiber at the areas of weakness thus stripping the shive from the flax fibers. In addition, as the flax 20 will tend to be reoriented as it is fed between the roller assemblies 14 through the bending regions 18 to travel in a transverse direction across the flutes 22, in other words, so that the flax straw 20 is arranged lengthwise in a direction normal to the axes of the roller assemblies 14, the pulling force between sets of roller assemblies 14 will act on the fibers along their length where the fiber has its most strength, thus limiting any damage or breaking of the fibers tending to shorten the fiber length. Moreover, the fibers are sufficiently flexible so as to bend around the flutes 22 without tearing such as can occur when they are subjected to a beating or flailing action or impacted with a sharp edge as in many prior decorticating methods.
As described earlier, the flax straw 20 will tend to orient itself so that it travels along its length in a direction substantially normal to the axis of the roller assemblies 14. In some applications, it may be desirable to provide a set of crush rollers 32 before the processing sections to form a flax straw mat and to provide protection against foreign objects. The crush rollers 32 are driven by a crush roller drive 33 and can be spring loaded together to define a mat forming nip area 34 therebetween so that when flax straw 20 is introduced to the nip area 34, a thin straw mat will be produced and the shive material will be compressed to make it more brittle and prone to breakage as it is fed through the bending regions 18. The machine 10 utilizing elongate roller assemblies 14 can handle increased processing rates of flax straw 20, e.g., 10,000 lbs./hr., versus other methods used by prior decorticating machines. After the flax material 20 has been fed through the processing sections and scutching unit 30, the fiber is collected and can be shaken to remove any loose shive whereupon it is then ready for baling.
Turning to FIGS. 5A and 5B, the preferred construction of the roller assemblies 14 will now be described. While the preferred assembly of the flutes 22 is described herein, it will be manifest that many other means for forming the roller assemblies 14, including their flutes 22 could be utilized. The roller assemblies 14 can each have a shaft 36 having an enlarged diameter cylindrical mounting portion 38 with smaller diameter stub shaft portions 40 and 42 extending from either end 38a and 38b thereof. On the cylindrical mounting portion 38, a number of short cylindrical spacer members 44 are mounted as by welding. The spacer members 44 are each provided with notches or slots 46 formed in one end face at their outer periphery. In addition, a pair of annular discs 48 and 50 are mounted between the innermost spacer members 44a and 44b on the cylindrical mounting portion 38 approximately mid-way between either end 38a and 38b thereof. The annular disc 48 includes locating slots 51 which extend from the outermost periphery radially inwardly towards the center. The disc 50 includes capturing apertures (not shown) which are spaced around the annular body of the disc 50 and in alignment with the slots 51 of disc 48.
The flutes 22 each include an elongate portion 52 which extends substantially along the entire length of the large diameter mounting portion 38. Depending from the bottom edge of the elongate portion 52 are a plurality of flange hooks 54 which fit into the peripheral slots 46 of the spacer members 44. To fix the circumferential position of the flutes 22, the central flange hook 54a is provided with a lowered tab 56 which can be slid into one of the apertures in annular disk 50, as seen in FIG. 5B. Similarly, the end flanges 54b and 54c can be provided with respective tabs 58 and 60 for mounting in apertures (not shown) of end locking caps 62 and 64, respectively. In one form, the end caps 62 and 64 are welded to the ends 38a and 38b of the cylindrical mounting portion 38. In another form, the end caps 62 and 64 are press fit or threaded on the ends 38a and 38b. In this manner, the flutes 22 can be removably secured onto the spacer members 44 providing roller assemblies 14 with a plurality of circumferentially spaced flutes 22 which can be removed once worn and replaced with new flutes 22.
As previously mentioned, the roller assemblies 14 include respective drives 16. As shown in FIG. 1, the drives 16 are mounted on drive mounting platforms 66 and 68 of the framework 12 on either side of the roller assemblies 14. More specifically and referring to FIG. 6, a feed roller assembly drive system 70 is shown including a motor 72 mounted atop a speed or gear reducer housing 74. A drive shaft 76 extends from the housing 74 into gearing housing 78 in which gearing (not shown) is provided for transmitting the rotary power from the drive shaft 76 to opposite or counter rotary motion of a counter shaft 80 to be imparted to upper feed roller 24a.
The framework 12 includes upper and lower mounting beams 82 and 84 extending lengthwise on either side of the sets of roller assemblies 14. The ends 38a of the cylindrical mounting portions 38 of the shafts 36 are mounted in bearing housings with upper bearing housing 86 attached to the upper beam 82 and lower bearing housing 88 attached to the lower beam 84.
To drive the upper and lower feed rollers 24a and 24b with opposite rotary motion and at the same speed so as to move their respective flutes 22 through the bending region 18 defined in the overlap area of the flutes 22 and thereby bend and pull on the flax straw 20 fed therethrough, the drive shaft 76 and counter shaft 80 are coupled to respective intermediate shafts 90 and 92 which, in turn, are coupled to the stub shafts 40 of the lower feed roller 24b and the upper feed roller 24a, respectively. Due to the relatively small diameters of the feed rollers 24 and the larger displacement between the drive shaft 76 and counter shaft 78, the counter shaft 80 is offset from the axis of the upper roller 24a which it drives. In other words, the counter shaft 80 is displaced vertically higher from the axis of the upper roller 24a, and therefore, the intermediate shaft 92 is inclined downwardly from the counter shaft 80 to the stub shaft 40 of the upper roller 24a. Since it is important that the rollers 24a and 24b rotate with equal speeds in opposite directions, the intermediate shaft 92 is coupled at respective ends 92a and 92b thereof to the counter shaft 80 and the stub shaft 40 of the upper roller 24a by way of flexible couplings that are CV or constant velocity joints 94 and 96, respectively, as are known. On the other hand, the drive shaft 76 is aligned and coaxial with the shaft of the lower feed roller 24b so that more rigid couplings 98 and 100 can be used between the drive shaft 76 and one end 90a of the intermediate shaft 90 and the other end 90b of the intermediate shaft 90 and the stub shaft 40 of the lower roller 24b.
The drive system 102 for the intermediate and high speed rollers 26 and 28 are mounted on the frame platform 68 on the opposite side of the roller assemblies 14. Motors 104 for the intermediate and high speed rollers 26 and 28 are substantially the same and the motors 104 for the intermediate speed rollers 26 are arranged in staggered relation from the motors 104 for the high speed rollers 28 on the frame platform 68. Otherwise, the remainder of the drive system 102 is substantially identical for either the intermediate speed rollers 26 or high speed rollers 28 so that only the drive system for the intermediate speed rollers 26 will be described herein.
Referring to FIG. 7, the motor 104 is arranged horizontally on the platform 68 with its drive shaft 106 coupled to secondary shaft 108 by way of shaft coupling 110. The secondary drive shaft 108 drives gears (not shown) in gear housing 112 to transmit the rotary power from the drive shaft 106 to counter rotary motion of counter shaft 114 which is imparted to upper intermediate rollers 26a.
Similar to the ends 38a of the mounting portion 38 of the shafts 36 on the side of the feed roller drive system 70 which are supported in bearing housings 86 and 88, the other ends 38b of the mounting portion 38 of the shaft 36 on the side of the intermediate and high speed drive systems 102 are supported in upper and lower bearing housings 116 and 118, respectively.
The following is a description of the drive system 102 and shafting for the intermediate speed rollers 26 (which is substantially the same as that of the high speed rollers 28), with the differences from the feed roller drive system 70 and shafting being due to the difference in diameters between the feed rollers 24 and the intermediate and high speed rollers 26 and 28 and the speeds at which they are driven. To drive the upper and lower intermediate speed rollers 26a and 26b with opposite rotary motion and at the same speed so as to move their respective flutes 22 through the bending regions 18b defined in the overlap areas of the flutes 22 and thereby bend and pull on the flax straw 20 fed therethrough, the secondary drive shaft 108 and counter shaft 114 are coupled to respective intermediate shafts 120 and 122 which, in turn, are coupled to the stub shafts 40 of the lower intermediate speed rollers 26b and the upper intermediate speed rollers 26a, respectively. Due to the larger diameters of the intermediate speed rollers 26 and the smaller displacement between the secondary shaft 108 and counter shaft 114, the counter shaft 114 is offset from the axis of the upper rollers 26a which it drives. In other words, the counter shaft 114 is displaced vertically lower from the axis of the upper roller 26a, and therefore, the intermediate shaft 122 is inclined upwardly from the counter shaft 114 to the stub shaft 40 of the upper roller 26a. Since it is important that the rollers 26a and 26b rotate with equal speed in opposite directions, the intermediate shaft 122 is coupled at respective ends 122a and 122b thereof to the counter shaft 114 and the stub shaft 40 of the upper rollers 26a by way of flexible couplings that are CV or constant velocity joints 124 and 126, as are known. On the other hand, the secondary shaft 108 is aligned and coaxial with the shaft of the lower intermediate speed roller 26b and high speed roller 28b so that more rigid couplings 128 and 130 can be used between the secondary shaft 108 and one end 120a of the intermediate shaft 120 and the other end 120b of the intermediate shaft 120 and the stub shaft 40 of the lower rollers 26b and 28b.
While there have been illustrated and described particular embodiments of the present invention, it will be appreciated that numerous changes and modifications will occur to those skilled in the art, and it is intended in the appended claims to cover all those changes and modifications which fall within the true spirit and scope of the present invention.
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A method for separating woody material from plant fibers is disclosed which includes the provision of a plurality of woody material bending regions with the plant material being fed to a first and then a second one of the bending regions as bending and pulling surfaces are moved through the bending regions. The bending and pulling surfaces move through the regions at different operating speeds so that the bending and pulling surfaces in adjacent bending regions will pull on the plant material to separate the fibers from the woody material. As the bending and pulling surfaces primarily impart a pulling or stripping force on the fiber along its length where the fiber has its most strength, the woody material can be dislodged and stripped away lengthwise with minimal damage or breakage of the fiber. The step of providing bending regions can include the step of providing first and second sets of fluted rollers having bending and pulling radially extending flute surfaces. The plant material is fed to the first bending region between the first set of fluted rollers and then the second bending region between the second set of fluted rollers. Preferably, a third bending region is also provided and the bending and pulling flutes are caused to move through the first, second and third regions at progressively increasing operating speeds.
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BACKGROUND OF THE INVENTION
The present invention relates to apparatus and method for treating carbon fiber fabrics and particularly to a disintegrating apparatus for a carbon fiber fabric obtained by using a multifilament yarn, namely, an apparatus for discretely separating carbon filaments bonded together with a sizing agent.
In molding a composite material which contains a woven texture of carbon fibers obtained by weaving a multifilament yarn, as a reinforcing member in a matrix resin, a step of disintegrating the filaments of the multifilament yarn as a step which precedes the molding step is known from Japanese Patent Laid Open No. 231073/1987. It is also disclosed therein to effect the disintegrating operation using ultrasonic wave. By the method using ultrasonic wave it is possible to greatly improve the strength of the composite material after molding, and the use of ultrasonic wave permits the individual filaments to be disintegrated in a more discrete state and also permits the effect of the method to be exhibited in a more satisfactory manner.
In order to practise the above method economically on an industrial scale it is necessary to use an apparatus for disintegrating the carbon fiber fabric continuously. This apparatus must be able to disintegrate the carbon fiber fabric efficiently and uniformly throughout the fabric into each constituent filament as completely as possible. Moreover, it is inevitably required that the cost of the apparatus itself and the running cost be low and that the operation as well as maintenance and control be easy.
It is the first object of the present invention to provide an apparatus particularly suitable for practising the disintegrating step using ultrasonic wave and capable of satisfying the above-mentioned requirements.
As to a sizing agent, if a fabric with a sizing agent adhered to the weaving yarn is impregnated with a matrix resin, the matrix resin is difficult to permeate the weaving yarn because a bundle of several hundred to several ten thousand filaments which constitute the weaving yarn is in a bonded state with the sizing agent. Therefore, it is desirable to remove the sizing agent from the fabric before the matrix impregnation.
As means for removing a sizing agent from a carbon fiber or glass fiber fabric there are known a heat setting method wherein the sizing agent is burnt off and a method wherein the sizing agent is removed using a solvent. In the heat setting method, however, there easily occur shift in weave and napping because the fabric is exposed to a high temperature, and if the sizing agent after decomposition and carbonization remains on the fiber surface, the reinforcing effect will be deteriorated markedly. The method using a solvent is also disadvantageous in that it usually requires the use of an expensive solvent so the cost is high and danger is involved therein and that the equipment required is large-sized.
Usually, therefore, a resin of the same sort as the matrix resin is used as the sizing agent to thereby omit the sizing agent removing step.
However, it is actually very troublesome to change the sizing agent according to the kind of the matrix resin used. Thermosetting resins typified by epoxy resins have heretofore been mainly used as the matrix of composite fiber-reinforced materials, but recently, in addition to epoxy and other thermosetting resins, various matrix resins have come to be used, including thermoplastic resins such as polyester, nylon and polyether ether ketone. Providing many kinds of sizing agents for such various matrix resins causes an increase of economic burden and gives rise to complicated problems in production management and inventory management. Such problems can be overcome if it is possible to inexpensively provide reinforcing yarn fabrics from which sizing agents have been removed. To this end it is necessary to find out a simple method for removing a sizing agent from a fiber-reinforced fabric.
It is the second object of the present invention to provide method and apparatus for removing a sizing agent from a reinforcing yarn fabric easily and efficiently.
SUMMARY OF THE INVENTION
The apparatus of the present invention disintegrates the constituent yarn of a carbon fiber fabric by the application of ultrasonic wave thereto in water. It also functions to remove an emulsion type sizing agent effectively from a carbon fiber fabric with the sizing agent adhered thereto by the application thereto of ultrasonic wave in water.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side view schematically showing an example of the apparatus of the present invention;
FIG. 2 illustrates a fragmentary portion of FIG. 1, on an enlarged scale, with the guide plate for the carbon fiber fabric being inclined relative to the water surface; and
FIG. 3 illustrates the apparatus of FIG. 1, similarly to that shown in FIG. 2, with the guide plate for the carbon fiber fabric being convexly curved towards the oscillator side thereof.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described below with reference to the drawing.
The apparatus of the present invention includes a water vessel 2, an ultrasonic wave oscillator 3 immersed in the water vessel 2, a guide plate 4 opposed in water to the oscillator 3, and a conveyor means 7 for conveying a carbon fiber fabric 20 continuously along an oscillator-side face 4a of the guide plate 4.
The ultrasonic wave oscillator 3 is mounted rotatably about an axis which is perpendicular to the oscillator-side face 4a of the guide plate 4, and means 3a for rotating the oscillator about the said axis is provided, whereby it is made possible for the apparatus to effect a more uniform disintegration of yarn.
Further, by inclining the oscillator 3-side face 4a of the guide plate 4 with respect to the water surface of the water vessel 2 as shown in FIG. 2, or by forming it as a curved surface which is convex on the oscillator side as shown in FIG. 3, it is made possible for the apparatus to effect the yarn disintegrating operation more efficiently and uniformly.
A carbon fiber fabric 20a to be disintegrated is conveyed by the conveyor means 7 and passes the ultrasonic wave oscillator 3 side of the guide plate 4. At this time, ultrasonic wave is applied to the thus-passing carbon fiber fabaric now indicated at 20b, so that the fabric 20b is brought into pressure contact with the guide plate 4 by virtue of the acoustic pressure and thereby spread out flatewise. In this state, the ultrasonic wave acts on the multifilament yarn which constituents the fabric, whereby the yarn is disintegrated. During this application of ultrasonic wave, the carbon fiber fabric 20b is held in a flatewise spread state in water and backed up by the guide plate 4, so the ultrasonic wave is applied to the fabric surface efficiently and uniformly. In the present invention the ultrasonic wave oscillator is employable in the frequency range of 20 to 50 KHz, preferably 26 to 28 KHz.
The thus yarn-integrated fabric, now indicated at 20c, is drawn out from the water vessel 2 continuously by the conveyor means 7 and wound up through a drying device 8 provided as necessary.
By using a carbon fiber fabric with an emulsion type sizing agent adhered thereto as the above carbon fiber fabric, the emulsion type sizing agent is removed effectively.
The "emulsion type sizing agent" as referred to herein indicates a sizing agent prepared by incorporating a surfactant into a water-insoluble sizing resin followed by dispersion in water. Examples of such water-insoluble sizing resin include known epoxy resins such as glycidyl ether type, e.g. bisphenol A diglycidyl ether, bisphenol F diglycidyl ether, phenol novolak polyglycidyl ether and cresol novolak polyglycidyl ether, glycidyl amine type, e.g. N,N-diglycidyl dianiline and N,N,N'N'-tetraglycidyl diaminodiphenylmethane, and mixtures thereof, as well as known polyamide resins and polyester resins.
As preferred examples of the surfactant are mentioned nonionic surfactants, particularly polyoxyethylene ethers. Concrete examples include polyoxyethylene octylphenyl ether, polyoxyethylene nonylphenyl ether, polyoxyethylene lauryl ether, polyoxyethylene cetyl ether, polyoxyethylene stearyl ether and polyoxyethylene oleyl ether.
In some particularly use there may be added an ester type lubricant such as, for example, oleyl oleate, stearyl oleate, lauryl oleate, oleyl stearate, oleyl laurate, or oleyl palmitate.
The carbon filament yarn comprising carbon filaments bonded together with the sizing agent exemplified above is woven into a fabric by a conventional method. Conditions for the radiation of ultrasonic wave to the thus-woven fabric are as described above.
By radiating ultrasonic wave to the fabric immersed in water, the emulsion type sizing agent adhered to the yarn is removed into water. The percent removal of the sizing agent reaches equilibrium in a certain time in proportion to the radiation time of ultrasonic wave. In the actual operation, the radiation time is determined according to the kind of the sizing agent used, the proportion of the emulsifier used, etc. It is also preferable that a water-soluble organic solvent (e.g. alcohol or ketone) be mixed in water in a proportion not more than 10 vol. %, depending on the kind of the sizing agent used.
The apparatus of the present invention will now be explained in more detail with reference to FIG. 1. The numeral 1 denotes a fabric feeder for feeding a carbon fiber fabric 20a to be disintegrated; numeral 2 denotes a disintegrating water vessel; numeral 3 denotes an ultrasonic wave oscillator disposed within the disintegrating water vessel 2; numeral 4 denotes a guide plate constituted by a glass plate; numeral 5 denotes a guide supporting frame which supports the guide plate 4 in opposed relation to the ultrasonic wave oscillator; numeral 6 denotes a water depth adjusting weir plate; numeral 7 denotes a delivery belt; numeral 8 denotes a drying device; and numeral 9 denotes a take-up unit for taking up the fabric after disintegration indicated at 20c.
The fabric feeder 1 is provided with a roller device 1a for feeding out the carbon fiber fabric 20a to be disintegrated and a motor 1b with a reduction gear for rotating the roller device 1a. In an electric control box 10 is incorporated an electric circuit, which makes control so that the rotating speed of the roller device 1a is synchronized with the speed of the delivery belt 7.
The water surface in the disintegrating water vessel 2 is at a level defined by the upper edge of the water depth adjusting weir plate 6, and in order to keep the water in the vessel clean, tap water is supplied from a water supply port 2a at all times and is discharged from a drain port 2b. The water supply port 2a is located away from the fabric feeder 1, namely, on the outlet side of the carbon fiber fabric 20, while the drain port 2b is located on the inlet side, so a water flow is created in the direction opposite to the advancing direction of the fabric 20 in the water vessel 2, whereby the water in the area where the ultrasonic wave oscillator 3 is located is kept clean.
A height-adjustable guide roller 2c is attached to an upper edge portion of the inlet of the disintegrating water vessel 2. The carbon fiber fabric is weak against bending, so by adjusting the height of the guide roller 2c the fabric 20a being conveyed from the fabric feeder 1 to the guide plate 4 is prevented from a undergoing a large bending force and the fabric 20b is conveyed along the oscillator-side face (underside), indicated at 4a, of the guide plate 4.
The fabric 20a fed into the water vessel 2 is conducted below the guide plate 4 and conveyed along the underside of the guide plate. The water fabric 20 has a certain width and the degree of radiation of ultrasonic wave differs between the central portion and the side portions of the fabric, thus causing a difference in strength of the disintegrating action, so there is a fear of the yarn being disintegrated non-uniformly. In the illustrated apparatus of the present invention, in order to ensure a uniform disintegrating effect, the ultrasonic wave oscillator 3 is mounted on a rotary shaft 3c and the rotary shaft 3c is rotated at a rate of two revolutions per minute by means of a motor 3a with a reduction gear 3d through a belt transmission gear 3e.
The oscillation frequency and output of the ultrasonic wave oscillator 3 used in the illustrated apparatus are 28 KHz and 1.2 KW, respectively. Since water acts as a load against the oscillator, the oscillator is allowed to oscillate efficiently to minimize the load. To this end, it is better to determine the mounting water depth of the oscillator 3 so as to cause resonance of water. In the ultrasonic wave oscillator 3 with an oscillation frequency of 28 KHz, its mounting water depth is set at 162 mm as an integer multiple of 1/2 wave length. The water depth for passing of the fabric 20b is set at a depth corresponding to an odd multiple of 1/4 wave length from the water surface where the acoustic pressure of ultrasonic wave is maximum. In the illustrated apparatus, the guide plate 4 is mounted in a depth position of 13.5 mm. In order that the mounting water depth of the ultrasonic wave oscillator 3 and that of the guide plate 4 can be adjusted, a height adjuster (not shown) using a bolt, etc, is attached to each of the weir plate 6 and the guide supporting frame 5.
The carbon fiber fabric 20 has a coarse weave density (3 pcs./cm or so in both longitudinal and transverse directions) because the yarn width expands upon radiation of ultrasonic wave. Therefore, if the fabric 20b is allowed to pass under water or along the water surface without using the guide plate 4 and subjected to the radiation of ultrasonic wave, it will become irregular in shape, not affording a uniformly disintegrated fabric. To avoid this problem the guide plate 4 is provided and the fabric 20b is allowed to pass the oscillator side of the guide plate. Upon radiation of ultrasonic wave from the ultrasonic wave oscillator 3 during passing of the fabric, the fabric 20b is brought into close contact with the guide plate 4 by virtue of an acoustic pressure acting upwards, so that the ultrasonic wave is radiated uniformly to the fabric 20b, thus affording a uniformly disintegrated fabric 20c.
If the guide plate 4 is mounted in parallel with the water surface, the air dissolved in water will form air bubbles upon radiation of ultrasonic wave, which air bubbles adhere to the guide plate 4 and also to the fabric 20b, resulting in that the fabric assumes a non-uniformly disintegrated state. To avoid this inconvenience, that is, to let the air bubbles formed escape from below the guide plate 4, the guide plate is slightly inclined so that the delivery side of the fabric 20b is higher.
In the presence of the guide plate 4, the ultrasonic wave radiated from the ultrasonic wave oscillator 3 is reflected by the guide plate 4 and then directed to the fabric 20b. At the same time, the guide plate 4 itself also oscillates to cause oscillation of the fabric 20b which is in close contact with the guide plate. If the fabric 20b is allowed to pass the oscillator side of the guide plate 4, the uniformity of disintegration and the disintegration efficiency will be improved remarkably by a synergistic effect of the above actions.
Even if the fabric 20b is allowed to pass along the side face of the guide plate 4 opposite to the oscillator side, there will be attained a certain effect. But the ultrasonic wave will be attenuated because it passes through the guide plate 4 and the fabric 20 will try to rise under the action of the acoustic pressure so it is necessary to provide rollers 5a, 5a for suppressing such rising tendency of the fabric. However, when the fabric 20 passes over the guide plate 4, it will undulate vertically, so that the ultrasonic wave radiation effect is apt to become non-uniform and the effect of disintegration is inferior to that obtained when the fabric is allowed to pass along the underside of the guide plate 4.
The material of the guide plate 4 for improving the disintegration efficiency is, for example, glass, plastic or aluminum. A transparent plate is suitable because it is possible to check the state of the fabric 20b being disintegrated continuously. Particularly, a glass plate is suitable because of a small attenuation factor of ultrasonic wave.
The disintegrated fabric 20c which has passed the underside of the guide plate 4 is pulled up from the water vessel 2 by the delivery belt 7. The fabric 20a to be disintegrated before the radiation of ultrasonic wave is coarest in weave density, taking into account the expansion of the yarn width when disintegrated, so there will occur a shift in weave if the delivery belt 7 and the fabric feeder 1 are not equal in speed. To prevent such shift in weave, the speed of the delivery belt 7 and that of the fabric feeder 1 are synchronized by the electric circuit incorporated in the electric control box 10. It is a driving motor 7a for the delivery belt 7 that keeps constant the speed of the fabric 20b which passes the radiation area of ultrasonic wave. The fabric feeder 1 and the take-up unit 9 are controlled in interlock with the speed of the delivery belt 7 to prevent tension from being exerted on the fabric 20 which tension would cause a shift in weave.
The disintegrated fabric 20c after the ultrasonic treatment contains a large amount of water, so if it is directly subjected to drying, it will take a considerable time. In view of this point the illustrated apparatus employs as the delivery belt 7 a mesh belt manufactured by Aramid to drain off as large an amount of water as possible before the disintegrated fabric 20c enters the drying device 8. Like the adjustable roller 2c, the delivery belt 7 is also adjustable its height on the front end side (the guide plate 4 side) to mitigate the bending of the fabric 20c at the edge portion of the guide plate 4.
Then, the disintegrated fabric 20c is fed to the drying device 8, in which it is dried by hot air of far infrared ray at a temperature not higher than the boiling temperature of water. The drying device 8 is provided with guide belts 8a, which are also mesh belts to permit drying of the disintegrated fabric 20c from above and below.
The fabric 20c thus dried is wound onto a roller 9a of the take-up unit 9.
According to the apparatus of the present invention described above, the multifilament yarn of the carbon fiber fabric can be disintegrated into the constituent filaments and there can be obtained a uniformly disintegrated fabric; besides, the working efficiency is high, the apparatus structure is simple, and the operation, maintenance and control are easy.
EXAMPLE 1
A commercially available multifilament carbon yarn (3,000 filaments, TEX 198 g/km) was treated with a sizing agent (1) shown in Table 1 below. Therefore, it was woven into a plain weave having a weight of 200 g/m 2 by means of a Rapier loom.
TABLE 1______________________________________ Sizing Agent (1) Sizing Agent (2)______________________________________Resin Bisphenol A type Bisphenol A type epoxy resin epoxy resinEmulsifier Polyethylene glycol Polypropylene glycolEmulsifier 80% 27%content insizing agent______________________________________
To the fabric thus obtained was radiated ultrasonic wave at the frequency of 28 KHz for a certain time using the apparatus shown in FIG. 1. Through this sizing agent removing step the sizing agent contained in the fabric was removed 100%.
EXAMPLE 2
The same treatment as that described in Example 1 was performed using a sizing agent (2) shown in Table 1. As a result of radiation of ultrasonic wave for a certain time the sizing agent contained in the fabric was removed 50%.
COMPARATIVE EXAMPLE
A fabric obtained using the same sizing agent as that shown in Example 2 was merely passed through the water vessel 2 and not subjected to the radiation of ultrasonic wave. As a result, the percent removal of the sizing agent was 30%.
Upon comparison between the above Example 2 and Comparative Example it is apparent that without radiation of ultrasonic wave only a small portion of the sizing agent is removed, while by the radiation of ultrasonic wave there is removed a larger amount of the sizing agent.
According to the method of the present invention, an emulsion type sizing agent can be removed from a reinforcing yarn fabric easily and effectively. Thus, by applying the method of the present invention to a fabric which has been obtained by bonding a multifilament yarn using a sizing agent followed by weaving, it is possible to remove the sizing agent from the reinforcing yarn fabric easily and effectively without the fear of damage to the fabric during the sizing agent removing step. Thus, according to the present invention it is possible to obtain reinforcing yarn fabrics capable to being impregnated with various matrix materials easily and sufficiently.
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An apparatus for disintegrating a carbon fiber fabric. The apparatus includes a water vessel containing water, with an ultrasonic wave oscillator immersed in the water and a guide plate for the fabric being located in opposed relation to the oscillator. A conveyor is provided for continuously conveying the carbon fiber fabric along the side of the guide plate facing the oscillator. Sound waves generated by the oscillator function to press the carbon fiber fabric against the guide plate in a manner as to cause the fabric to be disintegrated under the effects of the ultrasonic waves.
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BACKGROUND
[0001] Baseball is played on a field comprised of an outfield and an infield, with most of the action taking place on the infield. The infield is in the shape of a diamond, with first base, second base, third base, and home plate located in sequence at each point of the diamond. A player must progress counterclockwise from base to base to score a run. The team with the most runs at the end of the game wins. There is an equal distance between each adjacent base, but this distance varies depending on baseball league. For major league and most male adult baseball leagues, distance between adjacent bases is 90 feet. For “little league,” the distance between adjacent bases may be about 60 feet, with some other leagues also having varying sizes between 60-90 feet between adjacent bases.
[0002] Although baseball is a favorite pastime of many people, baseball's popularity combined with a finite number of permanent baseball fields can result in an unmet demand for full-sized baseball fields, where, for example, two or more baseball teams may have to share one baseball field for practice purposes. An insufficient number of fields may, among other negative results, limit practice time and thereby inhibit team progress and player development. To try and ameliorate this problem, when a playing surface exists with sufficient open space, coaches and/or players may set up makeshift infields using items on hand such as branches, coats, etc., as bases, or may use a portable set of bases. The accuracy of the layout of such infields, however, often depends to a large degree on fallible human judgment. The resulting inaccurate and imprecise measurements of such makeshift diamonds can lead to team practices that fail to sufficiently replicate real-game conditions, thus negatively impacting the judgments and expectations of players, and also lead to poor playing habits.
[0003] To attempt to achieve greater accuracy of base positions, some coaches, parents, and/or players may use string or tape to measure out the distance to each base one at a time—an often time-consuming process. Moreover, such string may become entangled with itself, other objects, and even players, as the string in some cases remains on the playing surface during play. In addition, such string must be removed from the playing surface by manual means, such as winding up the string on a reel by hand, which can be burdensome. Furthermore, some prior art devices attempting to set up an infield using strings or measuring tapes, whether requiring hand-reeling or not, may require substantial concentration and time. In addition some such devices may require the purchase of a “measuring ball base,” if not a whole new set of bases.
[0004] Thus there exists a need for an infield measuring and aligning device that may function quickly, conveniently, and accurately, thereby maximizing quality practice time for players and for coaches.
SUMMARY
[0005] A conveniently portable device for measuring and aligning the bases of an infield quickly and accurately. Although the device may allow measuring of distances to all bases simultaneously, it may nevertheless be in the form of a single, integrated unit that is portable and operable by a single person. In one embodiment, the device may be comprised of at least four marking pieces, four of which may be base marking pieces for marking the respective positions of the home plate, first base, second base, and third base of an infield, which marking pieces may attach to at least one other marking piece so that together they form the integrated unit. For example, irrespective of the shape of the base marking pieces (whether square-shaped or other), the positions of the base marking pieces may be radially arranged while in the form of the integrated unit (and in one embodiment, with at least a part of each base marking piece forming an outer part of the integrated unit), with each base marking piece oppositely-positioned from another base marking piece and adjacent to two other base marking pieces. More specifically, for example in one embodiment the second base marking piece may be positioned opposite from the home base marking piece, and adjacent to the first base marking piece and the third base marking piece, and with similar positional relationships between the other base marking pieces (e.g., the first base marking piece may be positioned opposite from the third base marking piece and adjacent to the home base marking piece and the second base marking piece).
[0006] One embodiment of the device may improve accuracy further by measuring distances to at least some of the base marking pieces from a central reference point, located in about the center of the infield diamond. Thus, in addition to utilizing base marking pieces, the device marking pieces may comprise a center marking piece for marking the position of the central reference point. In one embodiment, each base marking piece may attach to the center marking piece. For example, in one embodiment, the second base marking piece may be located on the side of the center marking piece opposite from the home base marking piece, and adjacent to the first base marking piece and the third base marking piece. The marking pieces may all be secured to the playing surface by, in one embodiment, apertures in each marking piece through which a stake may be inserted to secure a marking piece to a surface.
[0007] In one embodiment, the marking pieces, even when detached from any marking piece, may nevertheless be connected to at least one other marking piece by some connecting means such as, for example, a cord (e.g., nylon bands in one embodiment). Moreover said connecting means may be extensible and retractable by, for example, coils around which the cords may be reeled. One embodiment of the device, the connecting means may extend from one base marking piece to an oppositely-situated base marking piece, or from a base marking piece to an adjacent base marking piece, or from at least a base marking piece to a center marking piece (depending on the particular embodiment), in order to more accurately gauge the positions and alignments of all the bases together. In one embodiment incorporating cords, the total unwindable, extensible lengths of the cords may be the substantially correct distances for properly laying out the bases of the diamond. In another embodiment, the cords may include markings indicating proper measurements for different sizes of an infield (e.g., major league baseball, softball, and/or little league, etc.). Once unwound, the cords may be re-wound, and this capability to retract fully may assist in the marking pieces quickly and conveniently re-attaching compactly together to form the easily portable single unit. Such a single unit may have various shapes according to embodiment but in one embodiment may be in the shape of a square, with each base marking pieces comprising a corner of the square.
[0008] One objective of the device and method is to facilitate laying out the bases of an infield accurately, quickly, and conveniently in several simple steps. Specifically, in one embodiment, a first step may be to separate one base marking piece until it lies a certain distance (i.e., a first distance) away from its oppositely-positioned base marking pieces for setting up the infield, which first distance corresponds to the correct distance between oppositely-situated or positioned bases of an infield so that bases may be accurately laid at the opposite end points of said first distance.
[0009] Next, the proper positions of the base marking pieces adjacent to the oppositely-positioned base marking pieces laid out, can be determined by measuring the correct distance between each base marking piece and its adjacent base marking pieces for setting up an infield (i.e., the second distance or base-to-adjacent base total length), the second distance being the correct distance between adjacent bases of an infield. For example, two second distances may be measured from the first-laid base marking piece to its two adjacent base marking pieces, and from the base marking piece oppositely-positioned from said first-laid out base marking piece to said piece's two adjacent base marking pieces—which adjacent base marking pieces for both of the oppositely-positioned bases are the same adjacent base marking pieces, one adjacent base marking piece on either side of the axis formed by the first-laid base marking piece and the oppositely situated base marking piece—by connecting said second distances so that the end points of each second distance separately extending from the first laid base marking piece to both adjacent pieces, and the end points of each second distance separately extending from the base marking piece oppositely-positioned from the first laid base marking piece to either adjacent base marking piece, touch. Once the proper positions for base marking positions have been determined and marked by, for example, accurately measuring the first distance(s) and second distances between base marking pieces, the bases of an infield may be placed in the positions indicated and the marking pieces may be reattached together to form the single unit device, and removed from the playing surface.
[0010] Other embodiments of the device may involve variations of the aforementioned process. For example, in one embodiment incorporating a center marking piece, and where each base marking piece may be attached and connected to the center marking piece, the additional steps of detaching each base marking piece from the center marking piece may be taken. For example, a step may still be to separate one (first laid) base marking piece from the rest of the central unit so that it lies a first distances from its oppositely-positioned piece, but in this particular embodiment this might be accomplished by separating (i.e., detaching) both the first laid and the oppositely-positioned base from the center marking piece so that they remain a first distance apart from one another, and each being separated from the center marking piece substantially half the first distance (i.e., the center-to-base total length). In one embodiment, this may include the additional steps of inserting stakes through apertures in the oppositely-positioned base marking pieces and securing them to the ground in the correct positions a first distance apart from one another. More specifically as an example, the piece for marking the position of home plate (i.e., the home plate or home base marking piece) might be separated from the center piece and secured to the ground. Then the base marking piece opposite from the home plate (or home base) marking piece or from the area where the home base marking piece was detached—i.e., in one embodiment, the second base marking piece—may also be detached from the center marking piece and moved a first distance from the home base marking piece and secured to the ground.
[0011] In one embodiment of the device incorporating unwindable nylon cord as the connecting means, which able to wrap or be reeled around coils housed within the marking pieces, the cord connecting one base marking piece to its oppositely-positioned base marking piece (for example, connecting the second base marking piece to the home base marking piece) may be unwound and extended to a first distance for correctly laying out an infield. In one particular embodiment also incorporating unwindable nylon cord as the connecting means but also comprising the center marking piece, separate unwindable reeled cords connecting one base marking piece to the center marking piece and said one base marking piece's oppositely-positioned base marking piece to the center marking piece may both be unwound and extended substantially half of the first distance, and then stakes may then be inserted through the apertures in the oppositely-positioned base marking pieces securing them to the ground, and then the center marking piece may also be secured to the ground using a stake (although the order of these steps may vary). In another embodiment where all four base marking pieces are connected to the center marking piece in a similar manner, the two other base marking pieces adjacent to the first detached oppositely-positioned bases may also be separated from the center marking piece, and the respective unwindable cords may unwound and extended the correct distance and the base marking pieces secured to the ground in a similar manner. In one embodiment, the cords may be comprised of nylon and may extend to the desired distance and retract due to spring coil mechanisms. In one embodiment, the position of the coil may lock (which may be accompanied in one embodiment by an audible click), preventing a coil from automatically retracting the nylon cord once the cord has extended to the desired distance.
[0012] In the embodiment incorporating a center marking piece, once the marking pieces have all been separated the proper distances and have been placed in the proper positions using both a central reference point and adjacent reference points, and the marking pieces secured to the ground (which in one embodiment may occur when each coil is in a locked position and the cords taut), each base (including home plate) may be placed in a proper position to set up an infield. More specifically, based on the position of the home base marking piece, the home plate may be placed (in one embodiment) underneath the home base marking piece. Similarly, a second base may be placed in its proper position based on the second plate making piece. Based on the positions of the first and third base marking pieces, the first and third bases respectively may then be placed in their proper positions. Each base may also be further accurately aligned with the dimensions of the infield, using in one embodiment adjacent outer marking piece cords.
[0013] The base marking pieces may then be removed from the infield playing surface. In one embodiment, this may be accomplished by removing each stake from the aperture of each base marking piece and then reattaching each piece to the center marking piece to form a single unit. The center marking piece (for embodiments incorporating such a feature) may also be removed from the playing surface by removing the stake from its aperture. In one embodiment, the reattaching process may be facilitated by spring coil mechanisms that cause the cords connecting the marking pieces to automatically retract without requiring manual winding.
[0014] The order of steps for setting up a temporary infield using the device may vary depending on embodiment and/or preference. For example, the order of marking pieces that are detached, or reattached, or secured to the ground first may of course vary. In addition, in one embodiment each base may be placed in its proper location after each base marking piece is or less than all base marking pieces are properly positioned (e.g., after each base marking piece is secured to the ground), rather than after all the base marking pieces have been properly positioned. Moreover, configurations and materials used for the various components of the device may vary. For example, specific positions of the reeled coils within the device may vary in different embodiments.
[0015] It is also anticipated that the device and different embodiments thereof may be used in different manners that will be apparent to those skilled in the art(s) to which the device pertains. For example, although the device may permit a single person to accurately set up a baseball diamond quickly and easily in several steps, several persons may also cooperate to use the device to set up a baseball diamond in a more expeditious manner. Thus, the capability of the base marking pieces to simultaneously mark the positions of the bases may be beneficial to some device users.
[0016] Various means and methods may be used to keep the marking pieces in a certain desired position of a playing surface (depending, for example, on whether the playing surface is an outdoor grassy area or different type of playing surface). However, in the embodiment incorporating pointed objects to be inserted through apertures to secure the marking pieces to an outdoor ground playing surface, such securing means may vary. For example, the size of the stakes (and the apertures) may vary, but might in some embodiments have a width ranging from ¼″ to ⅜″.
[0017] Size and dimensions of the device and of marking pieces may also of course vary. In one embodiment the single unit may be relatively lightweight, portable by one person, relatively compact, and its outer surface may be comprised of durable material. In addition, in one embodiment, the cords connecting each base marking piece to adjacent base marking pieces may be beneficial for accurate alignment purposes. For example and not by way of limitation, in one embodiment the cords connecting adjacent bases may be used as a reference point for spraying base running lines on the infield playing surface.
[0018] The above description and listed alternative embodiments are considered that of some embodiments only. It is understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and not intended to limit scope. Alterations and modifications of the device described herein, and such further applications of the principles said device, are contemplated as would occur to those skilled in the art(s) to which the device pertains.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is an overheard perspective view of a device for setting up an infield, the device being in the form as an integrated unit.
[0020] FIG. 2 is an overhead perspective view of the device in FIG. 1 , with one base marking piece separated from the rest of the unit.
[0021] FIG. 3 is a cutaway overhead view of the device in FIG. 1 .
[0022] FIG. 4A is an overhead view of the device in FIG. 1 , with marking pieces in the form as an integrated unit, demonstrating a first step of setting up an infield.
[0023] FIG. 4B is an overhead view of the device in FIG. 1 , with a home base marking piece separated, demonstrating a second step of setting up an infield.
[0024] FIG. 4C is an overhead view of the device in FIG. 4B , with a second base marking piece separated, demonstrating a third step of setting up an infield.
[0025] FIG. 4D is an overhead view of the device in FIG. 4C , with a first base marking piece separated, demonstrating a fourth step of setting up an infield.
[0026] FIG. 4E is an overhead view of the device in FIG. 4D , with a third base locating piece in an extended position, demonstrating final steps of setting up an infield.
[0027] FIG. 4F is an overhead view of an embodiment of a device for setting up an infield that comprises a center marking piece connected to two oppositely-positioned base marking pieces.
[0028] FIG. 4G is an overhead view of an embodiment of a device for setting up an infield that comprises two connected oppositely-positioned base marking pieces, without a center marking piece.
DETAILED DESCRIPTION
[0029] “Cord” is herein defined as any flexible length material that may be wrapped on a spool or reel and that may be used for measuring distance. “Coil” is defined as an object such as a reel around which a cord may wind or be gathered, possibly in concentric rings or spirals. “Stake” is defined as an object that may secure a locating piece to a surface such as the ground. “Base” is defined as a base of any type of infield (e.g., baseball, softball, etc.), and any infield size, and may include home plate. “Separate” is broadly defined as substantially separate, and includes when pieces are detached yet still connected by for example, a connecting means. For example, a marking piece might be attached to another marking piece by a connecting means so that some surfaces of the marking pieces are contiguous, yet the marking piece might also become separate from the other marking piece so that no surfaces of the marking pieces are contiguous yet still the marking pieces may be connected by the connecting means.
[0030] Turning to the drawings, FIG. 1 illustrates an embodiment of a device 5 for laying out an infield 54 ( FIG. 4E ), which embodiment 5 may be in the form of an integrated unit and, in the particular embodiment described herein, may be in the shape of a square. The square-shaped single-unit embodiment of the device 5 may have four base marking pieces 6 , 7 , 8 , 9 located in each corner of the square: a piece for marking the position of home base 6 , a piece for marking the position of second base 7 , a piece for marking the position of first base 8 , and a piece for marking the position of third base 9 . The base marking pieces 6 , 7 , 8 , 9 may be configured to attach together as a single, integrated unit 5 , and to separate from one another, and to reattach together to form the integrated unit 5 . Each piece for marking a base/plate may have an aperture 10 , 11 , 12 , 13 —a home base marking piece aperture 10 , a second base marking piece aperture 11 , a first base marking piece aperture 12 , and a third base marking piece aperture 13 . In the embodiment shown, each aperture 10 , 11 , 12 , 13 may be located near the outer perimeter of the corresponding marking piece 6 , 7 , 8 , 9 .
[0031] As shown in FIG. 2 , in the center of the embodiment of the device 5 may be a piece for marking the center of the infield 14 , and in the center of the center marking piece 14 may also be a center marking piece aperture 15 . Each of the base marking pieces 6 , 7 , 8 , 9 may separate from the rest of the device 5 , and in the particular embodiment shown, may separate from the center marking piece 14 . For example, as shown in FIG. 2 , the second base marking piece 7 may separate from the center marking piece 14 . However, even when separated from the center piece 14 , the second base marking piece 7 may still be connected to the center piece 14 by means of a center piece cord 16 (a second base marking piece center cord 16 ). In addition, the second base marking piece 7 may also be connected to the adjacent corner marking pieces 8 , 9 (in this case, i.e., the first base marking piece 8 and the third base marking piece 9 ) by means of adjacent marking piece cords 17 , 18 —one cord 17 running from the second base marking piece 7 to the first base marking piece 8 (a first-second adjacent cord 17 ), and another cord 18 running from the second base marking piece 7 to the third base marking piece 9 (a second-third adjacent cord 18 ).
[0032] Each cord connecting one marking piece to another marking piece may be retractable and extensible by means of coils. More specifically, as illustrated in FIG. 3 , in the embodiment of the device shown, there may be spring coil mechanisms 23 , 24 , 25 , 26 strategically placed to connect the center marking piece 14 to each base marking piece 6 , 7 , 8 , 9 through respective center cords 29 , 16 , 30 , 31 . Similar spring coil mechanisms 19 , 20 , 21 , 22 may allow each base marking piece 6 , 7 , 8 , 9 to connect to an adjacent base marking piece 6 , 7 , 8 , 9 via adjacent piece cords 17 , 18 , 27 , 28 , and allow said cords 17 , 18 , 27 , 28 to retract or extend (by for example, the winding of the cords 17 , 18 , 27 , 28 about the coils 19 , 20 , 21 , 22 to be in a reeled position, and the unwinding of the cords 17 , 18 , 27 , 28 ). In one embodiment of the device 5 , there may be a setting where the cords 29 , 16 , 30 , 31 , 17 , 18 , 27 , 28 retract automatically into the coils 23 , 24 , 25 , 26 , 19 , 20 , 21 , 22 until/unless signaled to stop winding. The aforementioned features and components may assist the embodiment of the device 5 shown to set up an infield quickly and accurately, and in several relatively simple steps, as follows.
[0033] First, as shown in FIG. 4A , the embodiment of the device 5 may be easily portable in a compact single-unit configuration, with all of the base marking pieces 6 , 7 , 8 , 9 attached together to form an integrated unit, and transported to an open playing surface 32 having sufficient size for a temporary infield. Second, as shown in FIG. 4B , the home base marking piece 6 may be separated from the center marking piece 14 (and the other marking pieces 7 , 8 , 9 ), and a stake 33 may be placed through the home base marking piece aperture 10 , securing the home base marking piece 6 to the playing surface 32 . The home base marking piece 6 may still be connected, however, to the center marking piece 14 through a center cord 29 (a home base marking piece center cord 29 ), and connected to the first base marking piece 8 via an adjacent piece cord 28 (a home-first adjacent cord 28 ), and connected to the third base marking piece 9 via another adjacent piece cord 27 (a home-third adjacent cord 27 ).
[0034] Third, as shown in FIG. 4C , the second base marking piece 7 , oppositely-positioned from the home base marking piece 6 , may also be separated and pulled away from the center marking piece 14 . The second base marking piece 7 may also still be connected to the center marking piece 14 through the second base marking piece center cord 16 , and connected to the first base marking piece 8 via first-second adjacent piece cord 17 , and connected to the third base marking piece 9 via second-third adjacent piece cord 18 . Once the second base marking piece 7 has been extended a desired distance from the home plate piece 6 for accurately laying out an infield 54 , which distance in one embodiment might be signaled by the second base marking piece center cord 16 being extended substantially to its full length, the spring coil mechanism 24 shown in FIG. 3 may (in one particular embodiment) enter a locked position, causing the cord 16 to no longer automatically retract. Similarly, the home base marking piece 6 may be located the desired distance from the center marking piece 14 , which distance might be reached in one embodiment when the cord 29 connecting the home base marking piece 6 with the center marking piece 14 (which may also be referred to as the home base marking piece center cord 29 ) substantially reaches its full length, which in one particular embodiment may cause the spring coil mechanism 23 associated with the home base marking piece center cord 29 to lock, and causing that cord 29 to cease automatically retracting. In this configuration, the second base marking piece 7 and the oppositely-positioned home base marking piece 6 may be located a proper distance from each other for setting up an infield (referred to herein as a first distance). Another stake 34 may be placed through the second base marking piece aperture 11 , thus securing the second base marking piece 7 to the playing surface 32 . With the second base marking piece 7 extended the desired distance from the home base marking piece 6 , and the home base marking piece center cord 29 and the second base marking piece center cord 16 both extended the desired distances (with might be for each half or substantially half of the first distance), the center marking piece 14 may also be secured to the playing surface 32 , by placing another stake 35 through the center marking piece aperture 15 .
[0035] Fourth, as shown in FIG. 4D , the first base marking piece 8 may be separated from the center marking piece 14 in a direction perpendicular to the direction in which the home base marking piece 6 and the second base marking piece 7 were extended. However, the first base marking piece 8 may still be connected to the center marking piece 14 via a first base marking piece center cord 30 , to the home base marking piece 6 via an adjacent cord 28 (which may also be referred to as the home-first adjacent cord 28 ), and to the second base marking piece 7 via the first-second adjacent cord 17 . Once the first base marking piece 8 is extended the desired distance away from the center marking piece 14 , which might occur in one embodiment where the cord 30 connecting the first base marking piece 8 with the center marking piece 14 reaches its full length, the spring coil mechanism 25 (shown in FIG. 3 ) associated with the cord 30 connecting the first base marking piece 8 with the center marking piece 14 may in one embodiment cause that cord 30 to cease automatically retracting.
[0036] Similarly, once the first base marking piece 8 is extended away from the home base marking piece 6 and the second base marking piece 7 the desired distances, which might occur in one embodiment when the home-first adjacent cord 28 and the first-second adjacent cord 17 both reach their full lengths, the spring coil mechanisms 22 , 19 (as shown in FIG. 3 ) associated with the home-first adjacent cord 28 and the first-second adjacent cord 17 , respectively, may cause those cords 28 , 17 to cease automatically retracting. With the first base marking piece 8 extended the desired distance from the center marking piece 14 , and the desired distances from the home base marking piece 6 and the second base marking piece 7 (at which point, in one particular embodiment all the cords 30 , 28 , 17 connecting the first base marking piece 8 may be taut), the first base marking piece 8 may also be secured to the playing surface 32 by placing another stake 36 through the first base marking piece aperture 12 .
[0037] Fifth, as shown in FIG. 4E , the aforementioned basic process for extending and placing the first base marking piece 8 in the proper position may be repeated for the third base marking piece 9 . Specifically, the third base marking piece 9 may be separated from the center marking piece 14 in a direction perpendicular to the direction in which the home base marking piece 6 and the second base marking piece 7 were extended, and in the opposite direction from the first base marking piece 8 . As with the other base marking pieces 6 , 7 , 8 , the third base marking piece 9 may still be connected to the center marking piece 14 via a third base marking piece center cord 31 , and connected to the home base marking piece via an home-third adjacent cord 27 , and to the second base marking piece via the second-third adjacent cord 18 . The third base marking piece 9 may be extended away from the center marking piece 14 the desired distance, in one particular embodiment, where the third base marking piece center cord 31 reaches its full length, at which point the spring coil mechanism 26 ( FIG. 3 ) associated with the third base marking piece center cord 31 may also cause that cord 31 to cease automatically retracting. In addition, once the third base marking piece 9 is extended away from both the home base marking piece 6 and the second base marking piece 7 the desired distances, which might occur in one particular embodiment when the home-third adjacent cord 27 and the second-third adjacent cord 18 reach their full lengths, the spring coil mechanisms 21 , 20 (as shown in FIG. 3 ) associated with those cords 27 , 18 may cause those cords 27 , 18 to cease automatically retracting. (In one embodiment, this setting might be signaled to the user by an audible click.) With the third base marking piece 9 extended the desired distances from the center marking piece 14 , the home base marking piece 6 , and the second base marking piece 7 (at which point in one embodiment all the cords 31 , 27 , 18 connecting the third base marking piece 9 may be taut), the third base marking piece 9 may also be secured to the playing surface 32 by placing another stake 37 through the third base marking piece aperture 13 .
[0038] Next, a set of bases 39 , 40 , 41 , including a home plate 38 , may be laid on the playing surface 32 to set up an infield 54 . First, a home plate 38 may be positioned under the home base marking piece 6 . In one embodiment, proper alignment of the home plate 38 may be achieved by positioning the base 38 so that the bottom corner 42 of the home plate 38 touches the stake 33 inserted within the home base marking piece aperture 10 . Additional proper alignment of the home plate 38 may be achieved in one embodiment by positioning the bottom right edge 46 so that it is aligned with the home-first adjacent cord 28 , and positioning the bottom left edge 47 so that it is aligned with the home-third adjacent cord 27 .
[0039] Second, a second base 39 may be positioned under the second base marking piece 7 , and accurate alignment may be achieved in one embodiment by positioning the second base 39 so that its top corner 43 touches the stake 34 in the second base marking piece aperture 11 . Additional proper alignment of the second base 39 may be achieved in one embodiment by positioning the second base top right edge 48 so that it is aligned with the first-second adjacent cord 17 , and positioning the second base top left edge 49 so that it is aligned with the second-third adjacent cord 18 .
[0040] Third, a first base 40 may be positioned under the first base marking piece 8 , and accurate alignment may be achieved in one embodiment by positioning the first base 40 so that its right corner 44 touches the stake 36 in the home base marking piece aperture 12 . Additional proper alignment of the first base 40 may be achieved in one embodiment by positioning the first base top right edge 50 so that it is aligned with the first-second adjacent cord 17 (i.e., the cord running from the first base marking piece 8 to the second base marking piece 7 ), and positioning the first base bottom right edge 51 so that it is aligned with the home-first adjacent cord 28 (i.e., the cord running from the first base marking piece 8 to the home base marking piece 6 ).
[0041] Finally, a third base 41 may be positioned under the third base marking piece 9 , with accurate alignment being achieved in one embodiment by positioning the third base 41 so that its left corner 45 touches the stake 37 in the home base marking piece aperture 13 . Additional proper alignment of the third base 41 may be achieved in one embodiment by positioning the third base top left edge 52 so that it is aligned with the second-third adjacent cord 18 (i.e., the cord running from the third base marking piece 9 to the second base marking piece 7 ) and positioning the third base bottom left edge 53 so that it is aligned with the cord 27 running from the third base marking piece 9 to the home base marking piece 6 .
[0042] With each of the bases 39 , 40 , 41 (including home plate 38 ) laid out on the playing surface 32 , and properly aligned and in the proper positions to set up an infield 54 , the device 5 may be removed from the playing surface 32 by removing each of the stakes 33 , 34 , 36 , 37 from the playing surface 32 and respective apertures 10 , 11 , 12 , 13 , retracting each cord 17 , 18 , 27 , 28 , 29 , 16 , 30 , 31 into each respective coil 19 , 20 , 21 , 22 , 23 , 24 , 25 , 26 , and reattaching each of the base marking pieces 6 , 7 , 8 , 9 to the center marking piece 14 into the device 5 again, in the form of an easily portable single unit. In the embodiment described herein, this process may be accomplished without manual winding and without less likelihood that the cords 17 , 18 , 27 , 28 , 29 , 16 , 30 , 31 will become entangled. In one particular embodiment, the coils 19 , 20 , 21 , 22 , 23 , 24 , 25 , 26 may be reengaged to a setting of automatically retracting the cords 17 , 18 , 27 , 28 , 29 , 16 , 30 , 31 by first attempting to extend the cords 17 , 18 , 27 , 28 , 29 , 16 , 30 , 31 further outward. In such a manner, the bases 39 , 40 , 41 (including home plate 38 ) may be properly and precisely laid out and aligned to set up a temporary infield 54 on a playing surface 32 .
[0043] FIG. 4F illustrates another embodiment a device, or alternative embodiment 105 for laying out an infield 54 , which may also be in the form of an integrated unit. This square-shaped integrated-unit embodiment of a device 105 may also be comprised of a center marking piece 114 and four base marking pieces 106 , 107 , 108 , 109 : a piece for marking the position of home plate 106 , a piece for marking the position of second base 107 , a piece for marking the position of first base 108 , and a piece for marking the position of third base 109 . The alternative embodiment 105 may be used to accurately mark the positions of infield bases 38 , 39 , 40 , 41 in much the same manner and steps as the embodiment of the device 5 described above, but one difference being that the alternative embodiment 105 may omit from its design cords and coils connecting the center marking piece 114 to one pair of oppositely-positioned bases such as (in the embodiment shown) the first base marking piece 108 and the third base marking piece 109 . After the proper distance between the home base marking piece 106 and the oppositely-positioned second base marking piece 107 is determined by measuring the distance from the center marking piece 114 to the second base marking piece 107 using the center-second cord 116 , and the distance from the center marking piece to the home base marking piece 106 using the center-home cord 129 , the proper locations can be determined of the first base marking piece 108 and the third base marking piece 109 , which lie adjacent to the oppositely-situated second base marking piece 107 and home base marking piece 106 . The proper location of the first base marking piece 108 may be indicated by the home-first adjacent cord 128 and the first-second adjacent cord 117 , and the proper location of the third base marking piece 109 may be determined by the home-third adjacent cord 127 and the second-third adjacent cord 118 . As a variant for marking the positions of first base 40 and oppositely-positioned third base 41 , the configurations of the first base marking piece 108 and the third base marking piece 109 (and related components) may be interchangeable with the home base marking piece 106 and the second base marking piece 107 (and related components) in other embodiments.
[0044] FIG. 4G illustrates another embodiment a device, or alternative embodiment 205 for laying out an infield 54 , which may also be in the form of an integrated unit 205 , but without a center marking piece 114 , 14 (as shown in FIGS. 4E and 4F ). This embodiment of a device 205 may also be comprised of at least four base marking pieces 206 , 207 , 208 , 209 : a piece for marking the position of home plate 206 , a piece for marking the position of second base 207 , a piece for marking the position of first base 208 , and a piece for marking the position of third base 209 . The embodiment 205 may be used to accurately mark the positions of infield bases 38 , 39 , 40 , 41 in much the same manner and steps as the embodiment of the devices 5 , 105 described above, with one difference being that the embodiment 205 , instead of having two separate nylon cords 116 , 129 (shown in FIG. 4F ) extending from a center piece 114 to oppositely-situated base marking pieces 106 , 107 to each measure more or less the half of the correct distance between the oppositely-situated bases 38 , 39 , the embodiment of a device 205 may instead have one length of flexible material 216 extending a first distance between oppositely-positioned home plate base marking pieces 206 and second base marking piece 207 . After the proper distance between the oppositely-positioned home base marking piece 206 and the second base marking piece 207 is determined in this manner, and the home base marking piece 206 and the second base marking piece 207 are secured to the ground/playing surface 32 , the proper locations can now be determined for the first base marking piece 208 and the third base marking piece 209 , which may lie adjacent to the second base marking piece 207 and its oppositely-situated home base marking piece 206 . As with the aforementioned embodiment of the devices 105 ( FIG. 4F ), the proper location of the first base marking piece 208 may be indicated by the home-first adjacent cord 228 and the first-second adjacent cord 217 , and the proper location of the third base marking piece 209 may be determined by the home-third adjacent cord 227 and the second-third adjacent cord 218 (which may be extended a second distance). In an alternative embodiment, the positions of oppositely-positioned bases first base 40 and third base 41 may be marked first, by interchanging the configurations of the first base marking piece 208 and the third base marking piece 209 (and related components) with the home base marking piece 206 and the second base marking piece 207 (and related components).
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A device and a method for accurately laying out the bases of an infield, said device comprising marking pieces that attach to one another to form a single integrated unit. Base marking pieces forming the integrated unit may mark the positions of the bases of an infield. The marking pieces may be connected, which connecting means may assist in measuring distances between marking pieces, which measured distances may determine proper positions of the base marking pieces. After bases are laid out and an infield set up, the marking pieces may re-attach to again form the integrated unit.
In one embodiment, accuracy may be increased by utilizing a center reference point marked by a center marking piece. The center marking piece may be connected to some base marking pieces, and in one embodiment the base marking pieces may attach to the center marking piece and together form the integrated unit.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S. patent application Ser. No. 13/360,227, filed Jan. 27, 2012, which is a divisional application of U.S. patent application Ser. No. 12/784,016, filed May 20, 2010 (issued on Feb. 28, 2012 as U.S. Pat. No. 8,122,887), which is a divisional application of U.S. patent application Ser. No. 10/564,998 (issued on Jun. 15, 2010 as U.S. Pat. No. 7,735,487), which received a 371 filing date of Jun. 6, 2006 and is a 371 filing of PCT/NZ2004/000165, filed on Jul. 27, 2004. These applications claim priority from New Zealand Application No. 527313, which was filed on Jul. 30, 2003. All of these references are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to patient interfaces particularly though not solely for use in delivering Continuous Positive Airways Pressure (CPAP) therapy to patients suffering from obstructive sleep apnoea (OSA). In particular the present invention relates to forehead rest pads on patient interfaces.
[0004] 2. Description of the Related Art
[0005] In the art of respiration devices, there are well known variety of respiratory masks which cover the nose and/or mouth of a human user in order to provide a continuous seal around the nasal and/or oral areas of the face such that gas may be provided at positive pressure within the mask for consumption by the user. The uses for such masks range from high altitude breathing (i.e., aviation applications) to mining and fire fighting applications, to various medical diagnostic and therapeutic applications.
[0006] One requisite of such respiratory masks has been that they provide an effective seal against the user's face to prevent leakage of the gas being supplied. Commonly, in prior mask configurations, a good mask-to-face seal has been attained in many instances only with considerable discomfort for the user. This problem is most crucial in those applications, especially medical applications, which require the user to wear such a mask continuously for hours or perhaps even days. In such situations, the user will not tolerate the mask for long durations and optimum therapeutic or diagnostic objectives thus will not be achieved, or will be achieved with great difficulty and considerable user discomfort.
[0007] U.S. Pat. No. 5,243,971 and U.S. Pat. No. 6,112,746 are examples of prior art attempts to improve the mask system. U.S. Pat. No. 5,570,689 and PCT publication No. WO 00/78384, and U.S. Pat. No. 6,119,693 are examples of attempts to improve the forehead rest.
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to attempt to provide a patient interface which goes some way to overcoming the abovementioned disadvantages in the prior art or which will at least provide the industry with a useful choice.
[0009] Accordingly in a first aspect the present invention consists in a device for delivering a supply of gases to a user comprising:
[0010] a patient interface, in use in fluid communication with said supply of gases,
[0011] a forehead rest engaging said interface including a deformable resilient member configured to in use rest against the face of a patient, said deformable resilient member when compressed in use creating a uniformly and gradually increasing force, while evenly distributing the pressure on the area of the forehead of said patient that contacts said resilient member.
[0012] Preferably said deformable resilient member has a top surface and a base connected by two side walls, said side walls being thin and in use are compressible.
[0013] Preferably said top surface is substantially thicker than said side walls.
[0014] Preferably said top surface includes additional support at its centre to limit its collapse.
[0015] Preferably said side walls are capable of folding under compression.
[0016] Preferably said deformable resilient member is moulded from silicone.
[0017] Alternatively said deformable resilient member is extruded from silicone.
[0018] In a second aspect the present invention consists in a device for delivering a supply of gases to a user comprising:
[0019] a patient interface, in use in fluid communication with said supply of gases,
[0020] a forehead rest engaging said interface including a deformable resilient member configured to in use rest against the face of a patient, said deformable resilient member being of a hollow conical shape where in use and under compression the top part of said hollow cone deforms or the side walls of said cone deform.
[0021] Preferably said deformable resilient member is moulded from silicone.
[0022] Alternatively said deformable resilient member is extruded from silicone.
[0023] In a third aspect the present invention consists in a device for delivering a supply of gases to a user comprising:
[0024] a patient interface, in use in fluid communication with said supply of gases,
[0025] a forehead rest engaging said interface, an adjustable deformable resilient member mounted on said forehead rest, said adjustable deformable resilient member configured to in use rest against the face of a patient, said resilient member is height adjustable such that said patient can adjust the distance between said forehead rest and the face of said patient.
[0026] Preferably said adjustable deformable resilient member is at least one adjustable strap attached and adjustable on said forehead rest.
[0027] Alternatively said adjustable deformable resilient member is a member rotatably mounted on said forehead rest.
[0028] In the alternate form the adjustable deformable resilient member being rotatable relative to said forehead rest
[0029] In a further form said resilient member has two ends, one of the resilient member being fixed to the forehead rest, the other end of the strap is free, said free end capable of sliding relative to said forehead rest, said sliding of free end of strap allowing said user to adjust the height between said forehead rest and said forehead of said user.
[0030] Preferably said forehead rest includes a plurality of recesses, the free end of the strap including a slideable sleeve, said slideable sleeve sliding relative to said forehead rest and slideably moving said strap to adjust the height of said resilient member, said sleeve also capable of being fixed into any one of the recesses, said recesses allowing varying degrees of height adjustment.
[0031] Preferably said forehead rest also including an aperture, said fixed end of strap fixed to said forehead rest by engaging into said aperture.
[0032] Preferably said strap includes a plurality of protrusions at each end, said protrusions at said fixed end of said strap engaging with said aperture to fix said strap to said forehead rest, said protrusions at said free end of said strap engaging with said sleeve to connect said strap to said sliding sleeve.
[0033] Preferably said forehead rest is substantially T shaped, said forehead rest comprising two lateral arms extending outward from a vertical arm, said resilient member attached to at least one lateral arm of said forehead rest.
[0034] Alternatively said forehead rest is substantially I shaped.
[0035] In a further form said strap has a fixed end and a movable end, said fixed end fixed to the forehead rest, said movable end is arranged on said forehead rest to form a substantially circular shape that provides a cushioning effect should a force be applied.
[0036] Preferably said movable end of said strap being threaded through an aperture in the arm to form said circular shape, said movable end of said strap being adjustable on said forehead rest to allow a user to adjust the size of the circular shape created by said strap.
[0037] Preferably said strap includes a plurality of spaced apart apertures on the strap, said forehead rest including a protrusion extending outward from said forehead rest, said protrusion capable of engaging with any one of said apertures on said strap to fix the movable end of said strap and fix the size of said circular shape, said plurality of spaced apart holes on strap allowing a user to adjust the size of said circular shape.
[0038] Preferably said forehead rest includes a holding sleeve, said holding sleeve holding said strap in a substantially correct orientation relative to the forehead rest and protrusion on said forehead rest.
[0039] Preferably said forehead rest is a substantially I shaped piece.
[0040] In another form said strap is arranged on said forehead rest to form two arced sections relative to said forehead rest, said arced sections resting against a user's head and providing a cushioning effect.
[0041] Preferably said forehead rest includes at least one aperture, said strap curled through said aperture to form a middle section extending in the opposing direction to said arced sections.
[0042] Preferably said strap is folded back on itself to form said middle section, said strap having two ends, both ends of said strap fixed to opposing ends of said forehead rest.
[0043] Preferably said forehead rest includes a lip at each end of said forehead rest, said rest comprising an abutment at each end of said strap, said abutment engaging with said lip to fix each end of said strap to said forehead rest.
[0044] Preferably said forehead rest includes a pair of apertures said strap curling through both said apertures to form said middle section and arced sections.
[0045] Preferably said middle section can be pulled through or pushed through said aperture or apertures in order to increase or decrease the size of said arced sections.
[0046] Preferably said strap includes a plurality of spaced apart notches along the edge of said strap, said notches capable of engaging with said aperture or apertures to hold said middle section in place, said notches providing incremental positions for the middle section to be held and said notches providing incremental sizes of said arced sections.
[0047] Preferably said strap has notches along both edges of said strap to provide for better grip and engagement with said aperture or apertures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] One preferred form of the present invention will now be described with reference to the accompanying drawings,
[0049] FIG. 1 is a block diagram of a humidified continuous positive airway pressure (system) as might be used in conjunction with the present invention,
[0050] FIG. 2 is an illustration of the nasal mask in use according to the preferred embodiment of the present invention,
[0051] FIG. 3 shows a perspective view of the mask with cushion,
[0052] FIG. 4 is a cutaway view of the mask showing the cushion,
[0053] FIG. 5 is a cutaway view of the periphery of the outer membrane,
[0054] FIG. 6 is a cutaway view of the periphery of the mask body portion,
[0055] FIG. 7 shows a prior art forehead rest in isolation,
[0056] FIG. 8 shows a section view of the prior art forehead rest of FIG. 7 ,
[0057] FIG. 9 shows a perspective view of the forehead rest cushion of FIG. 7 ,
[0058] FIG. 10 is a section of a further prior art forehead rest cushion,
[0059] FIG. 11 is a section of perspective view of the forehead rest cushion of FIG. 10 ,
[0060] FIG. 12 is a back view showing the slots in the forehead rest for each cushion to lock into,
[0061] FIG. 13 is a perspective view of a first embodiment of a forehead rest cushion of the present invention,
[0062] FIG. 14 is a perspective view of a second embodiment of a forehead rest cushion of the present invention,
[0063] FIG. 15 is an alternative perspective view of the forehead rest cushion of FIG. 14 ,
[0064] FIG. 16 is a section of the forehead rest cushion of FIG. 14 ,
[0065] FIG. 17 is a side view of a third embodiment of a forehead rest cushion of the present invention,
[0066] FIG. 18 is an alternative perspective view of the forehead rest cushion of FIG. 17 ,
[0067] FIG. 19 is a section view of the forehead rest cushion of FIG. 17 ,
[0068] FIG. 20 is a perspective view of a fourth embodiment of a forehead rest cushion of the present invention,
[0069] FIG. 21 is a section of the forehead rest cushion of FIG. 20 ,
[0070] FIG. 22 is a perspective view of a fifth embodiment of a forehead rest cushion of the present invention,
[0071] FIG. 23 is a sixth embodiment of a forehead rest cushion of the present invention,
[0072] FIG. 24 is a seventh embodiment of a forehead rest cushion of the present invention,
[0073] FIG. 25 is a perspective view of an eighth embodiment of a forehead rest cushion of the present invention,
[0074] FIG. 26 is a perspective view of a ninth embodiment of a forehead rest cushion of the present invention,
[0075] FIG. 27 is a perspective view of a tenth embodiment of a forehead rest cushion of the present invention, where the forehead rest cushion is adjustable to a user's requirements,
[0076] FIG. 28 is a perspective view of an eleventh embodiment of a forehead rest cushion of the present invention, this embodiment also being incapable of being adjusted by the user,
[0077] FIG. 29 is a perspective view of a twelfth embodiment of the forehead rest cushion of the present invention, where the forehead rest cushion is adjustable,
[0078] FIG. 30 is a perspective view of a thirteenth embodiment of a forehead rest cushion of the present invention, this embodiment also being adjustable,
[0079] FIG. 31 is a perspective view of a fourteenth embodiment of a forehead rest cushion of the present invention,
[0080] FIG. 32 is a perspective view of a fifteenth embodiment of a forehead rest cushion of the present invention, and
[0081] FIG. 33 is a perspective view of a sixteenth embodiment of a forehead rest cushion of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0082] The present invention provides improvements in the delivery of humidified gases therapy. In particular a patient interface is described which is more comfortable for the user to wear and reduces leakage as compared with the prior art. It will be appreciated that the patient interface as described in the preferred embodiment of the present invention can be used in respiratory care generally or with a ventilator but will now be described below with reference to use in a humidified CPAP system. It will also be appreciated that the present invention can be applied to any form of patient interface including, but not limited to, nasal masks, oral masks and mouthpieces.
[0083] With reference to FIG. 1 a humidified Continuous Positive Airway Pressure (CPAP) system is shown in which a patient 1 is receiving humidified and pressurised gases through a patient interface 2 connected to a humidified gases transportation pathway or inspiratory conduit 3 . It should be understood that delivery systems could also be VPAP (Variable Positive Airway Pressure) and BiPAP (Bi-level Positive Airway Pressure) or numerous other forms of respiratory therapy. Inspiratory conduit 3 is connected to the outlet 4 of a humidification chamber 5 which contains a volume of water 6 . Inspiratory conduit 3 may contain heating means or heater wires (not shown) which heat the walls of the conduit to reduce condensation of humidified gases within the conduit. Humidification chamber 6 is preferably formed from a plastics material and may have a highly heat conductive base (for example an aluminium base) which is in direct contact with a heater plate 7 of humidifier 8 . Humidifier 8 is provided with control means or electronic controller 9 which may comprise a microprocessor based controller executing computer software commands stored in associated memory.
[0084] Controller 9 receives input from sources such as user input means or dial 10 through which a user of the device may, for example, set a predetermined required value (preset value) of humidity or temperature of the gases supplied to patient 1 . The controller may also receive input from other sources, for example temperature and/or flow velocity sensors 11 and 12 through connector 13 and heater plate temperature sensor 14 . In response to the user set humidity or temperature value input via dial 10 and the other inputs, controller 9 determines when (or to what level) to energise heater plate 7 to heat the water 6 within humidification chamber 5 . As the volume of water 6 within humidification chamber 5 is heated, water vapour begins to fill the volume of the chamber above the water's surface and is passed out of the humidification chamber 5 outlet 4 with the flow of gases (for example air) provided from a gases supply means or blower 15 which enters the chamber through inlet 16 . Exhaled gases from the patient's mouth are passed directly to ambient surroundings in FIG. 1 .
[0085] Blower 15 is provided with variable pressure regulating means or variable speed fan 21 which draws air or other gases through blower inlet 17 . The speed of variable speed fan 21 is controlled by electronic controller 18 (or alternatively the function of controller 18 could carried out by controller 9 ) in response to inputs from controller 9 and a user set predetermined required value (preset value) of pressure or fan speed via dial 19 . Nasal Mask
[0086] According to a first embodiment of the present invention the patient interface is shown in FIG. 2 as a mask. It will be appreciated the patient interface could equally be a nasal mask, full face, oral mask or mouth piece, endotracheal tube or cannula by way of example. The mask includes a hollow body 102 with an inlet 103 connected to the inspiratory conduit 3 . The mask 2 is positioned around the nose of the user 1 with the headgear 108 secured around the back of the head of the patient 1 . The restraining force from the headgear 108 on the hollow body 102 and the forehead rest 106 ensures enough compressive force on the mask cushion 104 , to provide an effective seal against the patient's face.
[0087] The hollow body 102 is constructed of a relatively inflexible material for example, polycarbonate plastic. Such a material would provide the requisite rigidity as well as being transparent and a relatively good insulator. The expiratory gases can be expelled through a valve (not shown) in the mask, a further expiratory conduit (not shown), or any other such method as is known in the art.
Mask Cushion
[0088] Referring now to FIGS. 3 and 4 in particular, the mask cushion 1104 is provided around the periphery of the nasal mask 1102 to provide an effective seal onto the face of the user to prevent leakage. The mask cushion 1104 is shaped to approximately follow the contours of a patient's face. The mask cushion 1104 will deform when pressure is applied by the headgear 1108 to adapt to the individual contours of any particular user. In particular, there is an indented section 1150 intended to fit over the bridge of the user's nose as well as a less indented section 1152 to seal around the section beneath the nose and above the upper lip.
[0089] In FIG. 4 we see that the mask cushion 1104 is composed of a inner foam cushion 1110 covered by an outer sealing sheath 1112 . The inner cushion 1110 is constructed of a resilient material for example polyurethane foam, to distribute the pressure evenly along the seal around the user's face. The inner cushion 1110 is located around the outer periphery 1114 of the open face 1116 of the hollow body 1102 . Similarly the outer sheath 1112 may be commonly attached at its base 1113 to the periphery 1114 and loosely covers over the top of the inner cushion 1110 .
[0090] In the preferred embodiment shown in FIGS. 3-6 the bottom of the inner cushion 1110 fits into a generally triangular cavity 1154 in the hollow body 1102 . The cavity 1154 is formed from a flange 1156 running mid-way around the interior of the hollow body.
[0091] The outer sheath 1112 fits in place over the cushion 1110 , holding it in place. The sheath 1112 is secured by a snap-fit to the periphery 1114 of the hollow body. In FIGS. 5-6 the periphery 1114 is shown including an outer bead 1158 . The sheath 1112 includes a matching bead 1159 , whereby once stretched around the periphery, the two beads engage to hold the sheath in place.
Forehead Rest
[0092] A prior art nasal mask 102 including a forehead rest 106 is shown in FIGS. 2 and 7 . The forehead rest 106 may move freely in proximity to the mask body 102 and user, but with no lateral movement or may be permanently fixed or adjustably fixed.
[0093] Referring to FIG. 7 , at the top end 142 (around the user's forehead) of the bridge member 136 harnessing slots (not shown) are provided which allow straps from the headgear to be inserted to secure the mask to the headgear. For the user's comfort one or more resilient cushions 140 are provided on the T-piece of the forehead rest 142 the top end of the bridge member 136 , to rest on the forehead of the user. The cushion 140 is constructed by injection moulding or extruding, from silicone or any foam materials as is known in the art for providing cushioning. In FIG. 7 a second cushion 143 is shown at the other end of the section 142 .
Forehead Rest Cushion
[0094] Referring now to FIGS. 8 and 9 the prior art forehead rest cushion 140 is illustrated. The cushion 140 , in cross section, includes an outer curved member 210 and a inner curved member 212 both of which are attached at each end to a straight base member 214 . The inner curved member 212 is a substantially similar curved shape to the outer curved member 210 . The inner member 212 and outer member 210 may be coterminous, the inner member may attach to the outer member 210 or both may attach to the base 214 separately.
[0095] When the cushion 140 comes into contact with the user's face the outer curved member 210 deforms as more pressure is applied to the cushion towards the face. This comprises of the first mode of deformation. Once the outer curved member 210 deforms enough to contact the inner curved member a second mode of deformation occurs.
[0096] As will be appreciated if the outer curved member is flatter than the second curved member 212 the first mode requires less force. The relative curvature and thickness of each can be varied to give a characteristic first mode and second mode. Once in the second mode of deformation extra force is required to deform both the first curved member 210 and the second curved member 212 . This configuration described above results in more even deformation force across the load bearing surface of the cushion 216 and also results in a more progressive force of cushioning when the cushion 120 is deformed.
[0097] A further prior art embodiment of a forehead rest cushion is shown in FIGS. 10 and 11 . This forehead rest cushion 140 has an outer curved member 220 attached at either end to a straight base member 222 . A inner inverted curved member 224 is inverted with respect the outer curved member 220 and is attached at either end two points on the 226 , 228 on the outer curved member 220 . The inner inverted curved member is lower in overall height than the outer curved member 220 such that a first mode of deformation occurs when the outer curved member 220 is deformed. A second mode of deformation occurs when the inner inverted curved member 224 contacts the base member 222 . The outer curved member 220 and the inner inverted curved member 224 deform simultaneously. The forces across the load bearing surface 230 are further distributed by virtue of a generally quadrilateral member 232 including as one side the base member 222 which attaches over the inner inverted curved member 220 approximately at its ends and at its load bearing point 234 . The quadrilateral member 232 provides additional stiffness and reduces lateral deformation.
[0098] These prior art forehead rests have a base member that includes a flange 240 which engages with a slot 2138 in the forehead rest 106 to lock the forehead rest cushion in place. The flange 240 first slides through aperture 2139 as seen in FIG. 12 .
[0099] In the preferred forms of the forehead rest cushion of the present invention will now be described with reference to FIGS. 13 to 26 , 31 and 32 . With each of the embodiments as described in relation to these figures the forehead rest cushion or pad allows for a controlled compression of the cushion. Each cushion is capable of being compressed under a force and will return to its original position (as shown in the Figures) when the force ceases.
[0100] A first embodiment of the forehead rest cushion is shown in FIG. 13 . This forehead rest cushion 300 has a flange 301 that is able to be attached to a forehead rest, such as that rest 106 shown in FIG. 7 or 12 . The flange 301 slides through the aperture 2139 in the T-piece 2140 of the forehead rest 106 . The cushion 300 is substantially rectangular in shape with an upper wall 302 and lower wall 303 , with the flange being attached to the lower wall 303 . The side walls are corrugated or concertinaed such that these walls 304 , 305 collapse when a force is placed on the upper wall 302 . As described above, as the cushions are made from a plastics material, such as silicone or foam, the folds forming the side walls will return to the original form when any compression force ceases.
[0101] FIG. 14 shows a second embodiment of a forehead rest cushion of the present invention. This forehead rest cushion 306 is a cushion that is in the general shape of a parabolic cone. The cushion has an open top 307 that can be seen in FIG. 15 , this open top 307 allows the edge 308 of the cushion 306 to roll inwards when the top of the cone shaped cushion is compressed, or a force placed air on. This cushion may be attached to a forehead rest, such as the T-piece forehead rest as shown in FIGS. 7 and 12 by any appropriate means, for example, gluing or the like and may include a flange such as that described above with reference to FIG. 13 .
[0102] In alternative embodiments any of the forehead rest cushion of the present invention as shown in the Figures may have an alternative attachment mechanism such as an arrow head type barb or protrusion, which fits into apertures on the forehead rest. Alternatively, any of the cushions may be provided with an aperture in place of the flange that is able to be slid about an arm of the forehead rest.
[0103] A third embodiment of the forehead rest cushion of the present invention is shown in FIGS. 17 , 18 and 19 . This cushion 309 has a conical body 310 with a flattened circular top 311 . This cushion is either injection moulded, extruded, or stamped from a sheet of material and is preferably made of a thermoplastic elastomer, silicone or foam. Again, when a force is applied to the top 311 the inner areas of the top roll inwards down towards the top of the cone body 310 . For example, as shown in FIG. 19 in a section view when a force A is placed on the top 311 the inner area of the top 311 moves downwards and the outer areas, shown as 311 ′, move upwards or simply adjust to the shape of the area of user's forehead it abuts.
[0104] Reference is now made to FIGS. 20 and 21 where the force embodiment of the forehead rest cushion of the present invention is shown this forehead rest cushion 312 is of a hemispherical shape and also allows for a two stage cushioning when a force is placed upon it. The cushion 312 has a hemispherical body 313 suspended above a platform 314 and also has a flange 315 allowing the cushion 312 to be slotted into an aperture in a forehead rest, such as that described above. The hemispherical body 313 is suspended above platform 314 on small supports 316 , 317 . This cushion 312 is preferably moulded from a thermoplastics material, silicone or foam.
[0105] A fifth embodiment of the forehead rest cushion is shown in FIG. 22 . The cushion 318 is shaped in the form of an “M” or generally rectangular with a recess 319 formed in the top wall 320 of the cushion 318 . Therefore, two inner vertical walls 321 , 322 are formed parallel to the outer vertical walls 323 , 324 . When a force is applied to the upper wall 320 the recessed part 319 and vertical walls 322 , 321 are pushed downwards towards the lower wall 325 . When the apex 326 of the recessed part 319 hits the lower wall 325 the cushion may still be compressed, but at a different rate of force such that the compression of this cushion 318 is a two stage compression. The recess 319 in the middle of the cushion 318 therefore provides more uniform pressure across the top wall 320 of the cushion. As with other forms as described above this forehead cushion 318 is supplied with a flange 327 attached to the lower wall 325 allowing the cushion 318 to be attached to the forehead rest.
[0106] Reference is now made to FIG. 23 where a sixth embodiment of the forehead rest cushion of the present invention is shown. This cushion 328 is of a similar form to that described in relation to FIG. 13 , but its top or upper wall 329 is curved and the side walls 330 , 331 merely form one corrugation or fold. When a force is placed upon the upper wall 329 the side walls 330 , 331 fold in upon themselves. Again, this cushion has a flange 332 attached to its lower wall 333 to allow the cushion 328 to be attached to the forehead rest.
[0107] A seventh embodiment of the forehead rest cushion as shown in FIG. 24 , this cushion is very similar in form to that of the prior art cushion as shown in FIG. 8 but its upper wall 335 is split in two and its inner wall 336 is horizontal in nature and not curved. Again, this cushion 334 has a flange 337 that allows it to be attached to a forehead rest. This cushion provides a two stage compression where the inner wall provides stability to the cushion 334 .
[0108] The eighth embodiment of the forehead rest cushion of the present invention is shown in FIG. 25 . This cushion 318 has a base member 319 having a flange similar to as described above in relation to the prior art cushions. The flange 340 allows the cushion 338 to be attached to a forehead rest. Two vertical walls 341 , 342 extend upwards nearer the centre of the base member 339 , and a curved upper member in the shape of a partial oval is attached above the vertical walls 341 , 342 . When a force is placed on the curved upper member 343 the vertical walls 341 , 342 initially support the force placed on the upper member 343 . The outer edges 344 , 345 of the upper member 343 are able to freely roll inwards to give further controlled support to the cushion 338 .
[0109] A ninth embodiment of the forehead rest cushion of the present invention is shown in FIG. 26 . This cushion 346 has a base member 347 and a flange attached to it to enable the cushion to be attached to a forehead rest. Extending outwards and upwards from the edges of the base member 347 are arms 349 , 350 . These arms 349 , 350 are curved inwardly towards one another and may overlap. When a force is placed on the upper 350 arm, the arm 350 moves down towards the lower arm 349 . If enough force or a continued force is provided to the upper arm 350 , the upper arm 350 will continue to compress against and push the lower arm 349 towards the centre of the cushion 346 and the base member 347 . These independent inwardly rolled arms 349 , 350 allow for a two stage compression that is controlled when a force being placed on the upper arm 350 .
[0110] A fourteenth embodiment forehead rest cushion of the present invention is shown in FIG. 31 . This cushion 351 has a similar shape to the prior art cushion of FIG. 9 and includes a base member 354 and a flange 353 which engages with a slot 2138 in the forehead rest to lock the forehead rest cushion in place. The flange 353 slides through and fixes in the aperture 2139 as seen in FIG. 12 . The cushion 351 is substantially rectangular in shape but with an upper wall 352 that is slightly curved at its edges where it meets the side walls 355 , 356 of the cushion. The upper wall is thicker in width than the side walls 355 , 356 to provide additional strength and control to the cushion. Furthermore, the relative thickness of the upper wall 352 compared to the side walls 355 , 356 prevents the cushion 351 from caving in. This helps provide a uniform pressure on the user's forehead.
[0111] A further embodiment of a forehead rest cushion is shown in FIG. 32 . This cushion 357 is exactly the same shape as that cushion of FIG. 31 , but this cushion has an additional curved short wall 358 extending below and following the contour of the upper wall 359 . This short wall 358 provides for additional support to the upper wall 359 when a force is placed upon it.
[0112] FIGS. 27 to 30 and 33 illustrate forehead rest cushions that can be adjusted to a user's preference. Firstly referring to FIG. 27 a rotating substantially circular or cam shaped cushion 360 rotatably mountable between two legs 361 , 362 , which are each attached and extend outwards from the forehead rest or mask base, for example, one on either side of the T-piece as shown in FIG. 12 . As the cushion 360 rotates in the direction of Arrow B the offset is increased or decreased.
[0113] FIG. 28 shows a further embodiment of the cushion of FIG. 27 . This cushion 363 additionally has a plurality of fixed attachments 364 , similar to the flange on the cushions described above. Each of these can be attached to the forehead support in turn to provide an adjustable cushion.
[0114] A twelfth embodiment of a forehead rest cushion of the present invention is shown in FIG. 29 . This cushion 365 is effectively a strap or flexible elongate member (preferably made of a flexible plastics material) attached to one arm 366 of a T or to an I piece of a forehead rest. In the case of a T-shaped forehead rest, such as that shown in FIG. 12 , two cushions of this type would be provided one for each of the two arms of the T-shaped forehead rest. The strap 365 is provided with a pair of protrusions 367 , 368 at each of its ends 369 , 370 such that a recess is formed between each set of protrusions. Each end 369 , 370 is fixed to the arm 366 by appropriate means, such as a sleeve 371 or aperture 372 on the arm 366 . In particular, the upper end 369 of the strap 365 is fixed to the arm 366 in the aperture 372 and the lower end 370 is slideably adjustable by way of a slideable sleeve 371 capable of sliding and being fixed into any one of a number of recesses 373 formed on the edge 374 of the arm 366 .
[0115] A further embodiment of an adjustable forehead rest cushion is shown in FIG. 30 . This adjustable cushion 375 is a strap or flexible elongate member where a first end 376 of its two ends 376 , 377 is fixed to an arm 379 (similar to that arm 366 described above). The second end 377 of the two ends is threaded about and around such that a substantial part of the strap forms a circular shape that provides a cushioning effect should a force be placed upon it. The second end 377 after being threaded through an aperture 381 in the arm 379 , and possibly an further holding sleeve 380 formed on the arm 379 , is fixed to the other side of the arm 379 , for example by pressing a protrusion 382 through a hole 383 formed in the strap 375 . The size of the circular cushion formed can be adjusted as a plurality of spaced apart holes are provided in the strap and the strap can be pulled through the arm and the protrusion 382 fixed in each hole dependent on the requirements of the user.
[0116] Yet still a further embodiment of an adjustable forehead rest cushion is shown in FIG. 33 , where a double loop strap 384 is formed into two arced cushions 385 , 386 . Each of the apexes of the arced cushions 385 , 386 would in use rest against a user's forehead to provide additional comfort while wearing a mask or interface similar to that described above. The strap 384 has abutments 387 , 388 formed at each end that fit under lips 389 , 390 formed in an arm 391 (such as, a one T-piece arm of the forehead rest as described above in relation to FIG. 12 , or an I shaped forehead rest as is known in the prior art and particularly described in New Zealand patent application number 524439 of Fisher & Paykel Healthcare Limited). The middle section 392 of the strap 384 has a plurality of notches 393 cut in each of its edges. The strap 384 is threaded through two apertures formed in the middle of the arm 391 , such that a substantial portion of the middle section 392 extends out from the arm 391 in an opposing direction to the arced cushions 385 , 386 . The middle section 393 can be pulled further through the arm or to pushed back through the apertures in the arm using the notches 393 as incremental positions for the middle section to be held in, to decrease or increase the size of the arced cushions 385 , 386 .
[0117] The forehead rest cushion embodiments shown in FIGS. 27 to 30 and 33 are all user adjustable. In particular the forehead rest cushions shown in these figures are height adjustable and allow the user to adjust the amount cushioning the forehead rest cushions can provide. The height of the forehead rest cushion is the distance between the forehead rest 106 and the face or forehead of the user. The height adjustable forehead rest cushion allows a user to adjust the distance between the forehead rest and the lace of the patient. This allows a user to adjust the amount of cushioning provided by the forehead rest cushion.
[0118] In other forms of the forehead rest cushion of the present invention the cushion may be an inflatable member that can be manually inflated using a syringe or a hand or finger operated compression pump, or automatically inflated using a compressible reservoir or the like.
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A patient interface that is comfortable for a user to wear is disclosed. The patient interface includes a forehead rest and cushion. In particular the cushion includes a deformable resilient member that when compressed creates a uniformly and gradually increasing force while evenly distributing the pressure on the forehead of the patient.
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RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional patent application No. 61/334,639 filed May 5, 2010, which is herein incorporated in its entirety by reference.
TECHNICAL FIELD
[0002] The invention relates to slings used with lifters to mobilize a disabled person. More particularly, the invention relates to a rigid sling system whose constituent sections may be slid under the individual and interlocked while the person is in a sitting position, e.g. in a wheelchair, embracing, as opposed to lifting, the individual into a sling and ready to become engaged to any lifting device via adjustable straps.
BACKGROUND
[0003] Due to the lack of mobility, a handicapped person is dependent on others. In addition to creating difficulties in completing daily tasks, this dependency also creates hardships for those around them. The lack of mobility and the feeling of burdening others have long term physical and mental effects on both the handicapped person and those around them.
[0004] Regardless of the means (e.g. lifter), a type of sling is used to move a disabled person from one point to another. At present, a variety of slings have been designed and are being employed. Existing slings are either too bulky or there is a need to position the disabled person into them, which requires some manual lifting of the subject, or they are made of a type of fabric or strap supports which makes these slings flexible. The flexibility of these slings combined with the compressibility of the disabled person's body requires a long vertical range of movement for the lifting devices to do the actual lifting, resulting in limitations in the usefulness of these types of slings. These slings also exert lateral pressure on the individual's body causing discomfort and possibly affecting circulation in the contact area.
[0005] What is needed, therefore, are means to eliminate the disadvantages of the existing slings for lifting a disabled person. The use of a rigid sling system that can be slid comfortably and safely under the disabled person with minimal effort from a lay person and secures the subject without inserting lateral pressure while requiring minimal lifting of the subject is highly desirable. Hence this invention provides a practical solution.
SUMMARY
[0006] One embodiment of the invention provides a durable, rigid, lightweight sling system with its constituent sections easily able to slide under a disabled person, then interlock and support the person. All the constituent pieces that come in contact with the person's body are coated with hypoallergenic material. In addition, it is designed to be used for toilet and bathing purposes.
[0007] Another embodiment of the invention provides a rigid sling system with a lifting device to use minimal vertical movement to separate the person from the place they are sitting. It also eliminates the lateral forces on the user, thus making the whole process easier and more comfortable.
[0008] In another embodiment, the use of such a sling system does not require another individual to lift the disabled person into the sling. Rather, the assistant may place this sling system easily and safely under the subject while the subject is sitting in a wheelchair, car, couch, bed, or office chair. This may be accomplished by simply pushing the disabled person to one side, which will position the buttocks and thigh so the proper section of the sling may be slid under the proper area. This process will be repeated for the opposite side. After both sections are in position and assembled, the sling is ready for use. Note that this assisting person could be almost anyone, man, woman, or young adult.
[0009] In another embodiment, when the sling system is used to transfer a disabled person to a car or any other place and one wishes to remove it from under the person, just undo the locking system to detach the left and the right sections of the sling and slide out the constituent sections safely and easily, confident that it can be readily used as needed.
[0010] In another embodiment, no tools are required for assembling or disassembling of the sling system. When the sling system sections are detached, it may be transported or stored anywhere without occupying much space.
[0011] The features and advantages described herein are not all-inclusive and, in particular, many additional features and advantages will be apparent to one of ordinary skill in view of the drawings, photos, specification, and claims. Moreover, it should be noted that the language used in the specification has been principally selected for instructional purposes, and not to limit the scope of the inventive subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS AND PHOTOS
[0012] FIG. 1 is a block diagram illustrating a front view of the two piece sling system, ready to be attached to a lifting device configured in accordance with one embodiment.
[0013] FIG. 2A is a block diagram illustrating a front view of a right section of the sling system configured in accordance with one embodiment.
[0014] FIG. 2B is a block diagram illustrating a front view of a left section of the sling system configured in accordance with one embodiment.
[0015] FIG. 3A is a block diagram illustrating a top view of a grip member 63 of FIG. 3B .
[0016] FIG. 3B is a block diagram illustrating a front view of a back side connector configured in accordance with one embodiment.
[0017] FIG. 3C is a block diagram illustrating a front view of a grip member of FIG. 4C .
[0018] FIG. 3D is a block diagram illustrating a side view of a bracket of FIG. 4C in accordance with one embodiment.
[0019] FIG. 4A is a block diagram illustrating a front view of a right leg support member configured in accordance with one embodiment.
[0020] FIG. 4B is a block diagram illustrating a front view of a right side main frame configured in accordance with one embodiment.
[0021] FIG. 4C is a block diagram illustrating a front view of a front side connector configured in accordance with one embodiment.
[0022] FIG. 5A is a block diagram illustrating a front view of FIG. 5C configured in accordance with one embodiment.
[0023] FIG. 5B is a block diagram illustrating a top view of FIG. 5C .
[0024] FIG. 5C is a block diagram illustrating side view of a back side connector plate of FIG. 3B receiver configured in accordance with one embodiment.
[0025] FIG. 6 is a block diagram illustrating a side view of a left side main frame configured in accordance with one embodiment.
[0026] FIG. 7 is a block diagram illustrating a side view of a right side main frame configured in accordance with one embodiment.
[0027] Photo 1 is a photograph of one embodiment of the sling system being interlocked and connected to a lifter.
[0028] Photo 2 is a photograph of the sling system which has been swung to a position inside a vehicle configured in accordance with one embodiment.
[0029] Photo 3 is a photograph of the right section FIG. 2A and the left section FIG. 2B of the sling system configured in accordance with one embodiment.
[0030] Photo 4 is a photograph of a back side connector FIG. 3B , connecting a left side main frame of FIG. 2B and a right side main frame of FIG. 4B via a back connector receiver of FIG. 5C configured in accordance with one embodiment.
[0031] Photo 5 is a photograph of a front side connector FIG. 4C configured in accordance with one embodiment.
[0032] Photo 6 is a photograph of a front side connector FIG. 4C connecting a right leg support member of FIG. 4A and a left leg support member of FIG. 2B configured in accordance with one embodiment.
DETAILED DESCRIPTION
[0033] One embodiment of the present invention provides a durable, rigid sling system comprised of a right side main frame 82 of FIG. 4B , a left side main frame 42 of FIG. 2B , a back side connector FIG. 3B , a front side connector FIG. 4C , a right leg support FIG. 4A , a left leg support 46 of FIG. 2B , and straps 20 , 22 , 24 , 30 , 34 , 36 , 38 of FIG. 1 , strap 162 of FIG. 7 and their appropriate buckles and hooks. All parts are configured to be assembled or disassembled without tools in accordance with another embodiment of this invention.
[0034] A right side main frame 82 of FIG. 4B , a back side connector FIG. 3B , a right leg support FIG. 4A , and a front side connector FIG. 4C can be grouped using two Carriage bolts-Square neck 40 , 44 of FIG. 2A , and their respective Miniature Clamping knobs 40 A, 44 A of FIG. 2A , and a clamping knob 112 to form the right section FIG. 2A of the sling system. All parts are configured to be assembled or disassembled without tools in accordance with one embodiment of this invention.
[0035] The left side main frame 42 of FIG. 2B and the left leg support 46 of FIG. 2B may be grouped together using a carriage bolt-square neck 48 of FIG. 2B with proper miniature clamping knob 48 A of FIG. 2A to form the left section FIG. 2B of the sling system. These members may be disassembled upon demand. All members are configured to be assembled or disassembled without tools in accordance with one embodiment of this invention.
[0036] When the left section FIG. 2A and the right sections FIG. 2B of the sling system are connected together, it will support the area under the thigh close to the knee, the buttocks and continuing up the back to the area under the shoulder blades and it resembles a legless chair with an opening in the center. This opening at the center serves two purposes: 1) it facilitates the placement of the sling system sections under the disabled person in accordance with one embodiment and 2) the sling system may be used for toilet and bathing purposes in accordance with another embodiment of this invention.
[0037] All the constituent pieces that are subject to come into contact with the body of the disabled person have a hypoallergenic coating in accordance with one embodiment of this invention.
[0038] Referring to FIG. 7 , the constituent portion of the right main frame 82 are a right-long frame 83 and a right-side support 93 . The right long frame 83 is hemmed at both ends, a back hem 160 and a front hem 166 . The front hem 166 has a special form 168 and will receive the right leg support 100 of FIG. 4A . The back hem will receive the right side of a back side connector plate 74 of FIG. 3B . The left side support 150 , in addition to providing a side support for a disabled person, also prevents folding of left-long frame 43 . In the right-side support 93 is a cutout 92 of FIG. 4B for the purpose of securing the right side hanging strap 34 of FIGS. 1 and 7 and the short segment of the safety strap 162 of FIG. 7 . The right main frame 82 and its constituent portions 83 and 93 may be made of a thin flat alloy metal, a reinforced plastic, fiberglass, or some other resilient material having a thickness of about 1.5 mm and a width of at least 5 cm. A front view of the right main frame 82 is shown in FIG. 4B .
[0039] Referring to FIG. 6 , the constituent portions of the left main frame 42 are a left-long frame 43 and a left-side support 150 . The left long frame 42 has a configured front hem 156 to receive a left leg support 46 of FIG. 2B . The back end of the left-long frame 43 is permanently attached to a back connector-receiving member 131 of FIGS. 5A , 5 C. The left side support 150 , in addition to providing a side support for a disabled person, also prevents folding of left-long frame 43 . In the left-side support 150 is a cutout 158 for the purpose of securing the left side hanging strap 30 of FIGS. 1 and 6 and the long segment of the safety strap 38 of FIGS. 1 and 6 . The left main frame 42 and its constituent portions 43 and 150 may be made of a thin flat alloy metal, a reinforced plastic, fiberglass, or some other resilient material having a thickness of about 1.5 mm and a width of at least 5 cm. A front view of the left main frame 42 is shown in FIG. 2B .
[0040] FIGS. 5A and 5B are a front and a top view of FIG. 5C respectively. Referring to FIG. 5C , the back connector receiver member 131 is permanently attached to the back end of the left main frame 42 . It has a guiding member 132 and a latching member 140 . The guiding member 132 has guiding elements 142 , 146 and the latching member 140 has a hook end plate 143 , a push plate 145 for the purpose of unlatching, a counter weight 134 , a stopper 136 and a pivoting pin 138 . FIG. 5B shows that the guiding element 146 has a cutout 144 that serves two purposes. First, it acts as a guide for a notch 64 of a grip member 63 of FIG. 3B to properly pass through and latch on the hook end 143 of the latching element 140 . Second, it secures the grip element 52 of FIG. 3A , preventing the back side connector 74 of FIG. 3B from being disconnected from the receiving member 131 of FIG. 5C when it is in use.
[0041] The front view of the front side connecter is presented in FIG. 4C . The bracket 124 is made of alloy steel with a 2-3 mm thickness. It is about 10 centimeter long and has a width and a shape corresponding to the width and the shape of the leg supports 100 of FIGS. 4A and 46 of FIG. 2B . This bracket 124 has a strap receiving element 113 , three guiding pins 116 , 118 , 134 , a guiding stud 132 , a safety stud 126 , a clamping knob 112 , bar knob 114 , and two walls 87 , 89 of FIG. 3D . The height of the short wall 89 of FIG. 3D is equal to the thickness of the leg supports 100 , 46 of FIGS. 2A , 2 B respectively, and the height of the other wall 87 of FIG. 3D is around 12 mm. The function of this bracket 124 is to connect and align the leg supports 100 , 46 of FIGS. 2A , 2 B respectively. The pin 134 , with a height of around 15 mm, passes through the right side of the bracket 124 and is secured in a way that the top portion of it is used as a guiding element 134 for the right leg support 100 of FIG. 2A , and the bottom portion is used as the pin 91 of FIG. 3D for pivoting front connector-locking system 130 . After placing the right and the left leg supports in their proper place into the bracket 124 to unify them, the locking system 130 should be pivoted counter-clockwise over the leg supports, then the bar knob 114 is hand tightened for safety purposes. The locking system 130 has a handle 86 and two grip elements 88 , 90 of FIG. 3C . The grip element 90 is also used as a pivoting element for the front side-connector locking system.
[0042] FIG. 4A shows the front view of a right leg support 100 . It is made of a thick flat alloy, a reinforced plastic, fiberglass, or some other stiff material, which is about 5 mm thick, 5-6 cm wide and about 20 cm long. The right leg support has a smooth bend 108 in the center along the width. This bend corresponds with the shape of the hem 166 of FIG. 7 and the purpose is to provide a comfort zone under the thigh. It also has an upward curve 96 at the outside end to keep the leg from sliding off. The right leg support 100 has two 6 mm holes 98 , 102 , a 10 mm rounded end groove 104 and a 10 mm bore 108 . After sliding the right leg support 100 through the hem 166 of FIG. 7 , either one of the holes 98 or 102 , in correspondence with the holes 60 , 68 of FIG. 3B may be aligned with the hole 110 of FIG. 4B (depending on the size of the disabled person) and will be secured together by using a 6 mm carriage bolt-square neck 44 and its proper miniature clamping knob 44 A of FIG. 2A . The round groove 104 and the bore 108 will accept the pin 134 and the stud 132 of FIG. 4C respectively upon installation.
[0043] FIG. 2B shows the front view of a left leg support 46 positioned in its proper place into the hem 154 of FIG. 6 using a 6 mm carriage bolt-square neck 48 and its proper miniature clamping knob 44 A of FIG. 2B . The shape of the left leg support 46 of one such embodiment is a mirror image of the right leg support 100 with the exception of having only one 6 mm hole 47 in correspondence with the guiding elements 66 , 68 of FIG. 3B . The round end groove 45 and the bore 41 will accept the pins 118 , 116 of FIG. 4C respectively, upon installation. The back side connector plate 74 is made of a thick flat alloy, a reinforced plastic, fiberglass, or some other stiff material which is about 5 mm thick, 5-6 cm wide, and an appropriate length.
[0044] FIG. 3B presents the front view of the back side connector. It consists of a back side connector plate 74 and a locking system 61 . The back side connector plate has two cutouts 70 and 78 . These cutouts have their respective lead-in notches 72 and 80 at both ends to guide the back strap 24 of FIG. 1 to pass through and seat it into position, or to remove the back strap 24 from the position in accordance with one embodiment of this invention. The plate 74 has two 6 mm holes, 60 and 78 , two guiding elements 66 and 68 , and around its center has a pivoting pin 76 . The constituent elements of the locking system 61 are: a handle 50 , a pivoting arm 62 , and grip elements 52 , 54 of FIG. 3A . FIG. 3A is the top view of grip member 63 of FIG. 3B . Notice that the grip element 52 of FIG. 3A is longer than the other grip element and at its end has a notch 64 of FIG. 3B . The grip member is made of bend resistant alloy steel.
[0045] To install the back side connector FIG. 3B on the right main frame 82 of FIG. 4B the back side connector plate 74 is simply slid into the hem 160 of FIG. 7 , the hole 56 of FIG. 4B is aligned with either holes 60 or 78 of FIG. 3B (in correspondence with the usage of holes 98 or 102 of FIG. 4A for installing the right leg support), then a 6 mm carriage bolt-square neck 40 of FIG. 2A is inserted into the holes and they are secured using miniature clamping knob 40 A of FIG. 2A .
[0046] Referring to FIG. 1 , a right hanging strap 34 is coupled to the right-side support 93 through the cutout 92 of FIGS. 4B , and 7 and from the other end, after passing through a configured ring 26 , is threaded through a buckle 10 having a hooked end shape 10 . It also shows the left hanging strap 30 is coupled to the left-side support 150 of FIG. 6 through the cutout 158 of FIG. 6 , and from the other end, after passing through a configured ring 26 A, is threaded through a buckle 16 having a hooked end shape 16 A.
[0047] FIG. 1 also shows a front hanging strap 15 . The bottom segment 36 of front hanging strap 15 is coupled to the strap receiving element 113 of FIG. 4C and, from the other end, is threaded through a buckle 32 . Two top segments 20 , 22 of front hanging strap 15 are, from one end, secured to the same buckle 32 and, from the other ends, secured to proper configured hooks 14 , 12 respectively. The back support strap 24 , from one end, snaps on the configured ring 26 of the right hanging strap 34 using an eye hook 18 , then through the configured lead-in notches 70 , 80 sit in the cutouts 72 , 78 and, from the other end, snaps on the configured ring 26 A of the right hanging strap 30 using an eye hook 18 A. The long segment of the safety strap 38 is coupled to the lowest end of the left hanging strap 30 and, from the other end, is free. When the sling system is properly positioned under the person and is lifted from the wheelchair, the long segment of the safety belt 38 should be passed from under the person, threaded through the configured buckle 164 of FIG. 7 , then pulled to tighten before removing the wheelchair.
[0048] All straps are made of stretch resistant flexible material, but that are soft upon touch, such as heavy duty polyester.
[0049] For further clarification, if needed, Photos 1 through 6 depict the features and the function of the sections, members, and parts described therein.
[0050] The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. Each and every page of this submission, and all contents thereon, however characterized, identified, or numbered, is considered a substantive part of this application for all purposes, irrespective of form or placement within the application. This specification is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of this disclosure. For example, straps can be logistic, ratchet, or cam strap, etc., the holes of the back connector plate can have other shapes, such as circular, oval, triangular, etc., the locking system may be replaced by a quick release clamp, etc., and the bar knob may be replaced by a double cam clamp, etc. Thus the scope of the embodiments should be determined by the appended claims and their legal equivalents.
[0051] Each of the various embodiments described above may be combined with other described embodiments in order to provide multiple features. Furthermore, while the foregoing describes a number of separate embodiments of the apparatus and method of the present invention, what has been described herein is merely illustrative of the application of the principles of the present invention. Accordingly, this description is meant to be taken only by way of example, and not to otherwise limit the scope of this invention.
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A rigid sling system is provided to ease the lifting of a disabled person by sliding its constituent sections under the subject as opposed to lifting the disabled person into the sling. This sling system is comprised of two sections, a right section and a left section. A right side main frame and its appropriate straps, a back connector, a right leg support, and a front connector with its appropriate straps are constituent members of the right section of the sling system. A left main frame and its appropriate straps, a left leg support are constituent members of the left section of the sling system. The two sections interlock via the connectors and configure to become engaged to a person lifting the sling system.
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RELATED APPLICATION
This is a divisional of application Ser. No. 08/190,654, filed Feb. 2, 1994 now U.S. Pat. No. 5,451,225, which is a continuation in part of Ser. No. 08/075,179 filed Jun. 10, 1993, still pending.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to external fixation devices, and in particular, to fasteners for the wires and pins used with external fixation devices.
2. Description Of the Related Art
External fixation of bone fractures is well known in the art. Many different external fixation devices have been developed, virtually all of which in one form or another use multiple transverse fixation wires or pins which extend through, or are embedded in, respectively, the bone and soft tissue surrounding the bone, and connect, e.g. via nuts and bolts, to various types of supporting elements, such as rings, half-rings, arches or bars.
One of the more common external fixation devices, often referred to as the Ilizarov External Fixator, includes three basic elements: multiple rings (or arches) disposed coaxially about the bone segments to be fixated; transverse wires or pins for fixating the bone segments to the rings (or arches); and distractor mechanisms. The transverse wires are typically secured to the rings by wire fixation bolts and nuts. However effective they may be, these nuts and bolts present problems for both the physician and the patient. The tightening force needed to ensure that the wires remain securely in place often results in bending, or otherwise damaging, the bolts. This results in the loosening of the tensioning of the wires and can cause additional pain and discomfort.
SUMMARY OF THE INVENTION
A fastener for external fixation device wires or pins in accordance with a preferred embodiment of the present invention includes an elongate first fastener member with a shaft and a coupling agent on one end (e.g. a threaded bolt) for coupling to, or engaging, a second fastener member (e.g. a threaded nut). The shaft contains a noncircular bore disposed nonparallelly to the shaft with a minimum radius and a maximum radius (e.g. a transverse, teardrop-shaped hole).
A fastener for external fixation device wires or pins in accordance with an alternative preferred embodiment of the present invention includes an elongate first fastener member with a shaft, a transverse member disposed generally near one end and extending transversely beyond the shaft, and a coupling agent on one end (e.g. a threaded bolt) for coupling to, or engaging, a second fastener member (e.g. a threaded nut). The transverse member has a bottom surface which is nonorthogonal to the shaft and contains a slot which is disposed nonparallelly to the shaft (e.g. a transverse, V-shaped notch). In one embodiment, the slot includes cavities, or dimples, extending along its length.
A fastener member for external fixation device wires in accordance with a further alternative preferred embodiment of the present invention includes a substantially planar member (e.g. a washer) with nonparallel opposing surfaces and a connecting bore therebetween. One of the nonparallel opposing surfaces contains a slot which is disposed nonparallelly to the bore (e.g. a transverse, V-shaped notch). In one embodiment, the slot includes cavities, or dimples, extending along its length. In another embodiment, the bore includes internal threads for engaging an externally threaded member (e.g. a threaded shaft or bolt).
These and other features and advantages of the present invention will be understood upon consideration of the following detailed description of the invention and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an external fixation device suitable for use with fasteners in accordance with the present invention.
FIG. 2 illustrates a wire and pin fastener in accordance with a preferred embodiment of the present invention as used on the frame members of the external fixation device of FIG. 1.
FIG. 3 illustrates a side view of the fastener of FIG. 2 while fastening a wire to one of the frame members of the external fixation device.
FIG. 4 illustrates a side view of the fastener of FIG. 2 while fastening a pin to one of the frame members of the external fixation device.
FIG. 5 illustrates a side view of a wire fastener in accordance with an alternative preferred embodiment of the present invention while fastening a wire to one of the frame members of the external fixation device of FIG. 1.
FIG. 6 illustrates a wire and pin fastener member in accordance with a further alternative preferred embodiment of the present invention for use on the frame members of the external fixation device of FIG. 1.
FIG. 7 illustrates a cross-sectional view of one embodiment of the fastener member of FIG. 6.
FIG. 8 illustrates a cross-sectional view of another embodiment of the fastener member of FIG. 6.
FIG. 9 illustrates a bottom view of the fastener member of FIG. 6.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, an external fixator assembly 100a for performing linear distraction while using fasteners in accordance with the present invention includes linear distractor mechanisms 102a, and upper 106 and lower 108 external fixator frame members, or rings. Each ring 106, 108 includes multiple, spaced holes 110, a number of which are used for mounting fastener assemblies 112 (discussed further below) for fastening transverse wires 114 and/or pins 116. These wires 114 and/or pins 116 pass through or are anchored into, respectively, the bone segments 118a, 118b which are to be externally fixated with the fixator assembly 100a.
Each distractor mechanism 102a a includes a single-threaded rod 120 which is coaxially mated with an internally like-threaded, plastic insert 128 mounted within a rotatable sleeve 122. The rod 120 is fastened to the upper ring 106 by extending it through one of the holes 110 and having two nuts 126a, 126b tightened against opposing sides of the ring 106. The sleeve 122 is rotatively connected to the lower ring 108 by way of a rotatable connector 124. At approximately the midway point of the sleeve 122, is a recessed, square portion 130 which can be used as a tool interface for mating with a tool (e.g. a wrench 134) for rotating the sleeve 122.
Further discussion of this external fixator assembly 100a and its various components can be found in the above-referenced parent U.S. Pat. application Ser. No. 08/075,179, the disclosure of which is incorporated herein by reference.
Referring to FIGS. 2, 3 and 4, a fastener assembly 112a for the wires 114 and/or pins 116 in accordance with a preferred embodiment of the present invention includes a bolt 113a and a nut 113b. The bolt 113a has a threaded shaft 113c which is inserted through one of the holes 110 of the ring 106/108, and onto which is threaded and tightened the nut 113b. The bolt 113a also has a shank 113d with a transverse bore 113e. It is into this bore 113e that the wire 114, or larger diameter pin 116, is inserted.
The transverse shank bore 113e is asymmetrical with respect to the mounting surface for the fastener assembly 113, i.e. the plane of the ring 106/108. As can be seen, the bore 113e has a minimum radius RMIN and a maximum radius RMAX, with the minimum radius RMIN directed toward the threaded shaft 113c and the maximum radius RMAX directed toward the head of the bolt 113a. Preferably, the bore 113e is a teardrop-shaped hole as shown, but other asymmetrical shapes can be used as desired.
It can seen that such an asymmetrical hole 113e advantageously provides multiple, consistent contact surfaces for contacting and securing the wire 114 or pin 116, regardless of their diameters. Accordingly, the same fastener assembly 112a can be used for wires 114 and/or pins 116 having a large variety of diameters.
Referring to FIGS. 5, a fastener assembly 112b for the wires 114 in accordance with an alternative preferred embodiment of the present invention includes a bolt 115a and a nut 115b. The bolt 115a has a threaded shaft 115c and a shank 115d which are inserted through one of the holes 110 of the ring 106/108, and onto the former of which is threaded and tightened the nut 115b. The angled, bottom surface of the head of the bolt 115a has a slot 115e (e.g. a V-shaped notch or groove). It is in this slot 115e that the wire 114 is inserted. The angled bottom surface 115f of the bolthead causes the formation of a fulcrum point, or foot, 115g at the side opposite the slot 115e. This has the effect of leveling the bolthead when a wire 114 is clamped, thereby helping to prevent bending of either the threaded shaft 115c or shank 115d.
Referring to FIG. 6, a fastener assembly 112c for wires 114 in accordance with a further alternative preferred embodiment of the present invention includes a bolt 117a, a nut 117b and a washer-like member 212 (discussed further below). The bolt 117a has a threaded shaft 117c which is inserted through the washer-like member 212 and one of the holes 110 of the ring 106/108, and onto which is threaded and tightened the nut 117b. The bottom surface of the washer-like member 212 has a slot (e.g. a V-shaped notch or groove) into which the wire 114 is inserted.
Referring to FIG. 7, a preferred embodiment 212a of the washer-like member 212 is substantially planar with opposing top 213a and bottom 213b surfaces connected by a bore, or hole, 213c. The top 213a and bottom 213b surfaces are nonparallel (with the bottom surface 213b off the horizontal by a slight angle 213d, e.g. five degrees), thereby causing the thickness dimension 213e of one side to be greater than the other 213f. In the side of lesser thickness 213f is the above-mentioned slot 213g, with a sufficiently wide angle 213h (e.g. 118 degrees) to accommodate either the wires 114 or the larger-diameter pins 116. (As is evident, the longitudinal axis, i.e. along the length, of the slot 213g is nonparallel to the axis 213i of the bore 213c.)
The slight angle 213d of the bottom surface 213b causes the formation of a fulcrum point, or foot, at the side opposite the slot 213g. This has the effect of leveling the top 213a when a wire 114 is clamped, thereby helping to prevent bending of the bolt 117a. (See FIG. 6.) Also, the clamping force causes the fulcrum point to cut, or bite, into the face of the ring 106/108, thereby helping to prevent rotation of the washer-like member 212.
Referring to FIG. 8, an alternative preferred embodiment 212b of the washer-like member 212 is similar to that embodiment 212a shown in FIG. 7 and described above, with the exception that its bore 215a has internal threads 215b. This allows this fastener member 212b to be retained on threaded shafts or bolts of varying length.
Referring to FIG. 9, embodiments of the washer-like member 212 preferably include a series of cavities 217 along the length of the slot 213g. These cavities 217 can be formed by drilling a series of overlapping dimples along the longitudinal axis of the slot 213g. A ridge, or tooth, 219 is formed where the dimples 217 intersect. This advantageously achieves a geometry which captures a wire 114 (or pin 116) and deforms its surface enough to create a sufficient amount of mechanical interference to ensure a nonslip grip when the wire 114 (or pin 116) is tensioned. (In accordance with this discussion, it should be understood that the slot 115e in the bolt 115a of the fastener assembly 112b of FIGS. 5 can also include a series of cavities 217 with similar benefits and advantages.)
The above-described fasteners 112 and fastener members 212 are preferably fabricated of 17-4 stainless steel and heat-tempered after machining.
It should be recognized that the modifiers "upper" and "lower" as used herein have been used for purposes of convenience only and are not to be construed as limitations upon the actual location or orientation of any element with respect to another.
Various other modifications and alterations in the structure and method of operation of this invention will be apparent to those skilled in the art without departing from the scope and spirit of this invention. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments.
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A fastener for wires or pins used with an external fixation device to rigidly immobilize bone fragments during linear or angular distraction thereof includes a fixation bolt with either a transverse asymmetrical shank bore, or a transversely slotted bolthead for providing multiple contact surfaces to secure the wires or pins, regardless of their diameters. Alternatively, the fastener can include a washer or a threaded washer-like member having nonparallel opposing planar surfaces with a transverse slot in one. The transverse slots in the bolthead, washer and/or threaded washer-like member preferably include multiple cavities so as to increase the number of surfaces for contacting the wires or pins.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application No. 61/295,709 filed on Jan. 16, 2010, of the same inventorship and entitled “Garbage Disposal Guard”, the contents which are incorporated herein by reference in entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains generally to the field of solid material comminution or disintegration, and more particularly to inlet provisions for under-sink garbage disposals. In a preferred embodiment, an inlet to an under-sink garbage disposal is guarded by a novel guard and splash-back baffle that permits large waste to pass through, while preventing accidental passage of utensils and other undesirable objects. Further, the combination guard and splash-back baffle co-operatively protect an operator from both harm and splash-back.
2. Description of the Related Art
Persons working in a kitchen generate large amounts of food scraps during the preparation of food. These scraps can range in size from relatively large waste, such as a rotten potato or tomato down to very small trimmings or cuttings that are stuck to a utensil or cutting board. Likewise, those persons consuming the food often leave behind more or less food as waste. Since this food waste will decompose quickly and harmlessly in waste treatment systems, including both municipal and septic systems, the food may be effortlessly disposed of by sending it directly out a sink drain. This permits a cook or cleaner to simply rinse the dishes, utensils and the like, and run the food waste down the drain. However, larger waste such as a whole potato would undesirably clog the plumbing. In fact, even mid-sized food waste can be caught in a partial clog in the plumbing with adverse consequence.
To avoid clogging the plumbing, artisans have developed garbage disposals that comminute or grind food waste into small particles that will pass safely through plumbing. A conventional garbage disposal includes an inlet connected to the sink drain, a grinder, and a motor. The inlet is generally fitted with a rubber splash baffle that has a small center opening and is generally slit radially into sections resembling pie slices. A number of United States patents illustrate these prior art splash baffles, the contents and teachings of each which are incorporated herein by reference, including 2,793,373 by Ewing, entitled “Baffle and closure assembly for food waste disposer”; 2,846,154 by Wieczorek, entitled “Sink mount for waste disposal units”; 2,875,958 by Wieczorek, entitled “Baffle and stopper for waste disposal unit”; 2,896,866 by Hyde, entitled “Baffle and stopper for waste disposal unit”; 2,925,225 by Jordan, entitled “Cushioned hanging device for garbage grinders”; 2,948,482 by Jordan, entitled “Splash guard with plug for waste disposal apparatus”; 2,980,351 by Greene, entitled “Waste disposer and splash guard therefor”; and 6,735,791 by Lordahl et al, entitled “Disposal adapter”. The splash baffle provides nominal resilience or resistance in either direction, thereby deforming to permit flow down into the garbage disposal, but when there is insufficient flow, the water will pass around and not deform the rubber. Since during low flow the rubber splash baffle is not deformed, low-mass water and food that is kicked up toward the operator will hit the rubber and not pass back up.
Unfortunately, the splash baffle must be very pliant to permit food and low volumes of water to pass through. This means that more forceful back-splashes will still deform the rubber upwardly, causing the operator to be unpleasantly splashed. Furthermore, since there is no guard or screen, utensils may pass down into the sink. When a hard object such as a spoon engages with the disposal blades, the utensil may be thrown forcefully from the sink, or the utensil may block and seize the disposal.
The splash baffle also provides no protection against a person inserting their hand into the disposal inlet, particularly when the disposal has seized from engagement with a spoon or other hard object. Yet, as may be appreciated, it is a natural first response for a person to reach in and try to remove the utensil. A typical household garbage disposal has a motor that is more powerful than most all blenders, and so, even if the person successfully dislodges the utensil, the motor may force the utensil as soon as the utensil is loosened sufficiently, which can cause great harm to the person. Further, when a person is working on food preparation, it is very easy for them to rush and push material into the disposal, or for a myriad of other reasons accidentally endanger themselves.
Typically, one thinks of garbage disposals for home use, but disposals are extensively used throughout the commercial food industry, where great quantities of food must be disposed of quickly. Examples of food industries range from school and restaurant kitchens to food preparation businesses, such as frozen or non-frozen food manufacturers, butcher shops, and even meat packers where unusable portions of the meat must be disposed. The throat of a home garbage disposal is of a size that allows the insertion of an adult hand. In retail and industrial food preparation establishments, garbage disposal capacity is even larger than those used in the home. Consequently, the garbage disposal throat is larger than that for home use, making the danger of hand insertion even greater. Garbage disposals in school and commercial kitchens are also potentially more powerful, so that they may quickly and efficiently grind up anything coming in to contact with the grinding or cutting heads. The garbage disposals represent a clear and present danger to kitchen staff. Consequently, a guard is necessary to protect kitchen staff from accidental injury or harm caused by accidental contact with the garbage disposal blades, or contact with matter expelled therefrom. As a result of the risk, in a commercial setting Occupational Safety and Health Administration (OSHA) regulations mandate that the garbage disposal entrance be protected. The regulations further require that the guard not be user-removable, so that it cannot easily be tampered with.
My prior U.S. Pat. No. 7,740,197, entitled “Garbage disposal guard”, the teachings and contents which are incorporated herein by reference, illustrates one exemplary guard which is designed to meet the OSHA regulations in combination with a garbage disposal unit. While this guard performs the intended functions in an exemplary manner, several opportunities exist for improvement. A first opportunity has to do with splash-back. The rubber splash baffle found in some disposal units is only of limited effectiveness, as has been outlined herein above. Further, since the guard in commercial units by OSHA regulations is not operator-removable, the guard acts as a limit to the ultimate size of food that may be passed therethrough. A finer grating will prevent hands and utensils from passing through, but will also prevent larger food waste from passing, including the rotten potato or tomato mentioned herein above.
A number of other artisans have designed drain guards, including features specifically for garbage disposal. The following U.S. patents, the contents and teachings which are incorporated herein by reference, are exemplary of these: 2,244,402 by Powers, entitled “Waste disposal apparatus”; 2,544,498 by Hiertz, entitled “Removable strainer-stopper assembly for sinks or the like”; 2,670,143 by Jordan, entitled “Garbage disposer with protective inlet”; 2,953,308 by Isola, entitled “Domestic appliance”; 3,161,360 by Levine, entitled “Guard for garbage disposal”; 4,519,102 by Efstratis, entitled “Garbage disposal guard”; 4,752,035 by Felder, entitled “Disposal guard”; 5,271,108 by Wicke, entitled “Sink drain guard”; 6,000,643 by Gelder, entitled “Safety entrance for garbage grinder”; 7,264,188 by Anderson et al, entitled “Noise baffle for food waste disposer”; and 7,533,836 by Pan, entitled “Splash guard for a garbage disposal unit”.
Additional patents and published applications that illustrate various sink and drain strainers, the contents and teachings which are incorporated herein by reference, include: 2,236,885 by Zinkil et al, entitled “Sink strainer and stopper and the like”; 3,449,775 by De Krauze, entitled “Kitchen sink plug”; 3,702,013 by Gebert, entitled “Hair Catching Device”; 3,742,524 by Ballentine, entitled “Hair Strainer: Drain Strainer”; 3,742,525 by Oropallo, entitled “Drain Fitting”; 3,745,594 by Cosper, entitled “Shower Floor Drain”; 3,788,485 by Bruning, entitled “Drain Guard for Contact Lens”; 3,854,151 by Boudewyn, entitled “Floor Drain”; 3,982,289 by Robbins, entitled “Disposable sink strainer”; 4,138,747 by Zijlstra, entitled “Drainage fittings and/or wash-house fittings”; 4,161,043 by Flores, entitled “Sealing mechanism for a liquid floor drain”; 4,164,796 by Sakow, entitled “Sink strainer assembly”; 4,321,713 by Thompson, entitled “Large capacity drainage receptacle”; 4,329,744 by Cuschera, entitled “Shower receptor drain”; 4,443,897 by Austin, entitled “Anti-clog sink device”; 4,883,590 by Papp, entitled “Adjustable floor drain apparatus”; 4,910,811 by Izzi, Sr., entitled “Plastic floor drain”; Des 278,459by Cook, entitled “Sink strainer”; Des 370,716by Menzies, entitled “Deck drain”; Des 461,233by Whalen, entitled “Marine deck drain strainer”; WO 03/093592 by Stephenson et al, entitled “Pipe filter and closure assembly”; EP 1,509,658 by Stephenson et al, entitled “Pipe filter and closure assembly”; and WO 2009/116736 by Lee, entitled “Foreign substance filtering film for drain and method for manufacturing same”.
Other patents and published applications of no relevance to patentability but that illustrate various concepts for which the contents and teachings which are incorporated herein by reference, include: Des 54,617by Haven, entitled “Gutter screen”; Des 92,115by Spencer, entitled “Flower holder”; Des 92,433by Spencer, entitled “Flower holder”; Des 103,769by Spencer, entitled “Flower holder”; Des 194,506by Laan, entitled “Flower pot”; and Des 290,679by Thorpe, entitled “Drain pan”.
In addition to the foregoing documents, Webster's New Universal Unabridged Dictionary, Second Edition copyright 1983, is incorporated herein by reference in entirety for the definitions of words and terms used herein.
SUMMARY OF THE INVENTION
In a first manifestation, the invention is, in combination, a garbage disposal blade guard and splash baffle for guarding a garbage disposal adjacent a plumbing inlet thereof from accidental and harmful interaction. The garbage disposal blade guard comprises an outer ring defining an exterior circumference approximately sized to coincide with an inside diameter of the plumbing inlet; an inner ring defining an open and unobstructed inner circumference; and radial bars extending between the inner and outer rings. The splash baffle comprises an elastomeric sheet affixed adjacent to the garbage disposal blade guard, and has slits radiating from a center of the elastomeric sheet that divide the elastomeric sheet into a plurality of resilient flaps. The splash baffle is operative in combination with the garbage disposal blade guard to define a flexible one-way valve permitting matter to pass into a garbage disposal while substantially blocking matter from being ejected by the garbage disposal through the garbage disposal blade guard.
In a second manifestation, the invention is, in combination, a garbage disposal blade guard and splash baffle for guarding a garbage disposal adjacent a plumbing inlet thereof from accidental and harmful interaction. The garbage disposal blade guard comprises an outer ring defining an exterior circumference approximately sized to coincide with an inside diameter of the plumbing inlet; and an inner ring coupled with the outer ring and defining an open and unobstructed inner circumference. The splash baffle comprises a resilient body affixed adjacent to the garbage disposal blade guard that extends generally across the plumbing inlet to constrict flow therethrough. The guard is divided into a plurality of resilient flaps, and is operative in combination with the garbage disposal blade guard to define a flexible one-way valve permitting matter to pass into a garbage disposal while substantially blocking matter from being ejected from the garbage disposal through the garbage disposal blade guard.
In a third manifestation, the invention is a garbage disposal blade guard, for guarding a garbage disposal adjacent a plumbing inlet thereof from accidental and harmful interaction. The blade guard comprises an outer ring defining an exterior circumference approximately sized to coincide with an inside diameter of the plumbing inlet; an inner ring defining an open and unobstructed inner circumference; and radial bars extending between the inner ring and said outer ring.
OBJECTS OF THE INVENTION
Exemplary embodiments of the present invention solve inadequacies of the prior art by providing a novel guard and splash-back baffle to an inlet of an under-sink garbage disposal, where the splash back guard is placed immediately adjacent to and cooperative with the garbage disposal blade guard.
A first object of the invention is to guard an inlet of an under-sink garbage disposal against accidental passage of utensils and other undesirable objects. A second object of the invention is to permit large waste to pass through and provide minimal obstruction to waste disposal. Another object of the present invention is to protect an operator from both harm and splash-back. A further object of the invention is to provide a guard which is readily fabricated using optimal materials and techniques. Yet another object of the present invention is to comply fully with OSHA requirements.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, advantages, and novel features of the present invention can be understood and appreciated by reference to the following detailed description of the invention, taken in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates a preferred embodiment garbage disposal blade guard designed in accord with the teachings of the present invention from a projected view.
FIG. 2 illustrates the preferred embodiment garbage disposal blade guard of FIG. 1 from a top plan view.
FIG. 3 illustrates the preferred embodiment garbage disposal blade guard from sectional view taken along line 3 ′ of FIG. 2 .
FIG. 4 illustrates the preferred embodiment garbage disposal blade guard of FIG. 1 from a bottom plan view.
FIG. 5 illustrates the preferred embodiment garbage disposal blade guard of FIG. 1 from a side elevational view.
FIG. 6 illustrates a most preferred splash baffle for use in combination with the present invention.
FIG. 7 illustrates a preferred combination of the splash baffle illustrated in FIG. 6 with garbage disposal blade guard of FIGS. 1-5 from a projected view.
FIG. 8 illustrates the preferred combination splash baffle and garbage disposal blade guard of FIG. 7 from a top plan view.
FIG. 9 illustrates the preferred combination splash baffle and garbage disposal blade guard of FIG. 7 from sectional view taken along line 9 ′ of FIG. 8 .
FIG. 10 illustrates the preferred combination splash baffle and garbage disposal blade guard of FIG. 7 from a bottom plan view.
FIG. 11 illustrates the preferred combination splash baffle and garbage disposal blade guard of FIG. 7 from a side elevational view.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Manifested in the preferred embodiment, the present invention provides a novel garbage disposal blade guard that permits large waste to pass through, while preventing accidental passage of utensils and other undesirable objects. Further, the combination of guard and splash-back baffle co-operatively protects an operator from both harm and splash-back. In a preferred embodiment of the invention illustrated in FIGS. 1-5 , a garbage disposal blade guard 1 is comprised of an outer ring 2 , an inner ring 4 , and radially extending bars 6 . Inner ring 4 is connected to and supported from outer ring 2 by radially extending bars 6 .
While garbage disposal blade guard 1 may be fabricated to meet various different sized drains, as will be understood by those reasonably skilled in the art, in one preferred embodiment outer ring 2 has sufficient diameter to fit within a school or commercial kitchen sink drain, and a sufficient depth to sit inside the throat of the drain. An exemplary garbage disposal and drain in co-operation with a similar guard is illustrated in my prior U.S. Pat. No. 7,740,197, entitled “Garbage disposal guard”, the teachings and contents which were incorporated herein above by reference.
In the preferred embodiment, outer ring 2 and inner ring 4 are tubular, which means they may be designed to have minimal wall thickness for a minimum satisfactory strength to withstand operating forces applied thereto. The minimal wall thickness ensures a maximum open diameter. As a result, the use of this radial pattern of radially extending bars 6 in combination with inner ring 4 and outer ring 2 reduces the percentage of opening that is obstructed, thereby also improving the ease of passage of both water and waste through and into the garbage disposal. Inner ring 4 is designed and shaped generally circularly, to allow passage of relatively large food objects such as potatoes or partially eaten sandwiches, while limiting the size of other objects passing through the drain, thereby helping to prevent hands, dishes, silverware and cooking utensils from contacting the garbage disposal. Furthermore, by virtue of the round geometry of inner ring 4 and the radial arrangement of radially extending bars 6 , larger sizes and quantities of food may pass through than prior art guards.
Outer ring 2 has a primary outer perimeter 5 that is designed to engage into the throat of the drain, or into the garbage disposal throat as may be appropriate. In order to assist with proper placement on installation and to prevent the preferred embodiment garbage disposal blade guard 1 from coming into contact with the garbage disposal grinding or cutting heads, outer ring 2 has a lip 3 of greater outer diameter than that of primary outer perimeter 5 , preferably of such size to allow it to brace on the base of the sink. With appropriate dimensions of lip 3 , the garbage disposal blade guard 1 can fit in drains within a range of dimensions. The smallest suitable size would be a pipe having an inside diameter approximately equal to the outer diameter of primary outer perimeter 5 . The largest suitable inside diameter would be a pipe having an inside diameter just less than the outside diameter of lip 3 .
Additional securement between guard 1 and a drain may preferably be obtained using one or more set screws 7 running radially through outer ring 2 and making contact with the throat of the drain, or may be obtained with other suitable fasteners as will be recognized and may be desired by those familiar with the art. For the purposes of the present disclosure, fasteners will be understood herein to include anything which fastens one object to another, and so is not limited to mechanical fasteners, and may, for exemplary purposes only and without limitation thereto, include adhesives or other bonding techniques. The use of set screws 7 permits the guard to be installed and removed at will, but not by someone without the proper tools to fit the set screw head geometry. As is known in the hardware art and incorporated herein, a wide variety of known head geometries are available. Consequently, an installer may determine what the preferred tool will be to fit set screw 7 , and thereby determine how readily someone may access a tool.
While garbage disposal blade guard 1 as illustrated in FIGS. 1-5 offers benefit over prior art disposal blade guards, garbage disposal blade guard 1 will permit back splash through the open regions between outer ring 2 , inner ring 4 and radially extending bars 6 . This may be preferred in some installations, particularly where a user is satisfied with the disposal, including any back splash baffles that may be provided therewith. However, to further enhance the performance of garbage disposal blade guard 1 , splash baffle 20 as illustrated in FIG. 6 may be further combined therewith. Splash baffle 20 most preferably is fabricated from generally planar and resilient sheet stock such as a semi-rigid rubber or elastomeric material. This material defines a base 22 . The sheet stock is preferably flexible enough when unsupported to allow food to readily pass through and yet resilient enough when even partially supported to prevent passage of unintended utensils or other objects, and to prevent back splash from coming up the drain throat.
In order to allow for passage of food, base 22 has flaps 23 radiating from the center of base 22 . Flaps 23 are created by slits 24 , which likewise radiate from the center of the base 22 . During operation, wear and tear through use of splash baffle 20 and the associated flexure of flaps 23 could cause slits 24 to extend and rip base 22 apart over time. To help prevent this, the ends of slits 24 closest to the perimeter of base 22 are rounded off into circles 26 . Furthermore, to ease the flow of materials through the splash baffle 20 , there is a small cut-out 28 at the center of base 22 .
Most preferably, splash baffle base 22 is of the same or similar diameter as outer ring 2 , allowing base 22 to be anchored in place on the underside of the garbage disposal blade guard 1 as illustrated in FIGS. 7-11 . Splash baffle 20 may be screwed into secure engagement with garbage disposal blade guard 1 , or may alternatively be affixed with other suitable fasteners or using other suitable coupling. A benefit of screw engagement is the ability to remove and replace splash baffle 20 , though there are many factors that will be considered in selecting the method and permanency of securement between splash baffle 20 and garbage disposal blade guard 1 .
Once splash baffle 20 is coupled with garbage disposal blade guard 1 , as illustrated in FIGS. 7-11 , waste matter and water may readily deform flaps 23 downward towards the garbage disposal, to thereby slide through the unsupported splash baffle 20 and pass into the garbage disposal grinder or cutter heads. In the case of back splash, or objects being propelled off of the grinder or cutter blades, splash baffle 20 including flaps 23 will be deflected upwards and stopped in firm support against garbage disposal blade guard 1 . In this way, flaps 23 and garbage disposal blade guard 1 act as a whole in a manner similar to a one-way valve, to permit passage of matter to the garbage disposal while preventing passage of matter from the disposal back into the sink. The proximity of inner ring 4 to the inner circumference of flaps 23 adds stiffness to flaps 23 when flaps 23 would otherwise deflect upwards. Furthermore, a designer may decide how many radially extending bars 6 and slits 24 to provide, and at what positions relative to each other, to optimize the design for a particular application. The unique combination of outer ring 2 , inner ring 4 , and radially extending bars 6 with splash baffle 20 , and the placement of splash baffle 20 immediately adjacent to inner ring 4 and radially extending bars 6 , allows a substantially larger percentage of garbage disposal blade guard 1 to be open, while still providing desired protection to an operator.
From the foregoing figures and description, several additional features and options become more apparent. First of all, garbage disposal blade guard 1 and splash baffle 20 may be manufactured from a variety of materials, including metals, resins and plastics, ceramics or cementitious materials, or even combinations, laminates or composites of the above. The specific material used may vary, though special benefits are attainable if several important factors are taken into consideration. First, splash baffle 20 will preferably act as a one-way valve for matter to pass into a garbage disposal. By using partially resilient or elastomeric materials, there is a dampening of energy in the event an object or matter is impelled out of the disposal. For splash baffle 20 , a rubber material is preferred, but preferably of a type which provides dampening in combination with resilience. Furthermore, it is preferable that all materials are sufficiently tough and durable to not fracture, even when great forces are applied thereto. In the case of garbage disposal blade guard 1 , a preferred material is Ultra-High Molecular Weight (UHMW) polyethylene, which has the advantages of being stain resistant, extremely tough and durable to withstand great force, scuff resistant, readily cleaned, and readily colored to yellow or other color signifying the safety function.
In addition, the exact geometry of inner ring 4 and radially extending bars 6 is not critical to the proper function and operation of the invention. For exemplary purposes, and not solely limiting thereto, radially extending bars 6 may be chamfered or rounded at their junctions with inner ring 4 and outer ring 2 , which provides greater strength and a rounded intersection rather than sharp corner, such that, when desired, the intersections will be much easier to clean. Likewise, the top surfaces may be rounded. The numbers of radially extending bars, and even the angular displacement between each pair of adjacent bars, may be varied to suit differing needs and desires, including but not limited to such considerations as optimization of splash baffle support, and optimization of opening geometry for particular matter being passed through garbage disposal blade guard 1 . Further, the geometry and materials of each individual component can deviate from the embodiments illustrated herein for other reasons, including artistic variations, without altering the scope of the invention. Finally, as is best visible in the sectional views of FIGS. 3 and 9 , the elevation of radially extending bars 6 is slightly less than the adjacent lip 3 . This provides a small indent into which a stop may be placed if desired, but there is no requirement that radially extending bars 6 be at any specific elevation.
While the foregoing details what is felt to be the preferred embodiment of the invention, no material limitations to the scope of the claimed invention are intended. Further, features and design alternatives that would be obvious to one of ordinary skill in the art are considered to be incorporated herein. The scope of the invention is set forth and particularly described in the claims herein below.
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An inlet to an under-sink garbage disposal is guarded by a novel guard and splash-back baffle that comprises an outer tubular ring defining an exterior circumference approximately sized to coincide with an inside diameter of the plumbing inlet; an inner tubular ring coupled through at least one radially extending bar with the outer ring and defining an open and unobstructed inner circumference. The splash baffle comprises a resilient body affixed adjacent to the garbage disposal blade guard that extends generally across the plumbing inlet to constrict flow therethrough. The guard is divided into a plurality of resilient flaps, and is operative in combination with the garbage disposal blade guard to define a flexible one-way valve permitting matter to pass into a garbage disposal while substantially blocking matter from being ejected from the garbage disposal through the garbage disposal blade guard.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based on and incorporates herein by reference Japanese Patent Application No. 2001-111054 filed on Apr. 10, 2001.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to an accessory equipment driving device for a vehicle.
[0003] As a technology to improve fuel economy, a vehicle having an idle stop function that stops an engine at idle is proposed. In this type of vehicle, the idle stop function is canceled in order to drive a compressor for an air conditioner by the engine. Therefore, the idle stop function is not fully effective.
[0004] To counter this problem, a hybrid-compressor with an integrated motor is proposed in JP-A-2000-229516. This hybrid-compressor is driven by the engine when the engine is running. When the engine is not running, the compressor is disconnected from the engine and driven by the motor. To disconnect the compressor from the engine, a clutch mechanism, such as a one-way clutch or a clutch, is required. In other word, a motor and its driving control circuit, and a clutch mechanism are required. This increases complexity of configuration and a cost. Moreover, additional electrical circuits, such as an inverter circuit, to control a driving operation of the compressor are required.
[0005] Here, a power generating system (rotary electric machine and electrical circuit) can be simplified with a configuration in which the motor is driven to generate electricity.
[0006] An ideal condition of connections among the engine, rotary electric machine, and compressor for an air conditioner will be analyzed.
[0007] When the engine is started, the engine and the rotary electric machine need to be connected, and the compressor is better not to be connected with the engine nor the rotary electric machine (motor operation).
[0008] When the engine is running with the air conditioner off, the engine and the rotary electric machine need to be connected, and the compressor is better not to be connected with the engine nor the rotary electric machine (motor operation).
[0009] When the engine is running with the air conditioner on, the engine, the rotary electric machine, and the compressor need to be connected.
[0010] When the idle stop function is performed, the engine is better not to be connected with the rotary electric machine nor the compressor, and the rotary electric machine and the compressor need to be connected so that proper operations of the air conditioner are ensured.
[0011] In the accessory equipment driving device for a vehicle having an idle stop function, these connections need to be accomplished with simple configuration.
SUMMARY OF THE INVENTION
[0012] The present invention has an objective to provide an accessory equipment driving device for a vehicle with high installability to a vehicle, simple system configuration, and good cost efficiency.
[0013] An accessory equipment driving device for a vehicle of the present invention makes connections among an engine having an idle stop function, a motor-generator for a power generating operation and a motor operation, and accessory equipment such as a compressor for an air conditioner.
[0014] This device is for driving the accessory equipment by the engine when the engine is running, and by the motor-generator when the engine is idle. The device has an engine connecting shaft, a motor-generator connecting shaft, an accessory equipment connecting shaft. The shafts are to be connected to the engine, the motor-generator, and the accessory equipment, respectively.
[0015] The device has a torque distribution mechanism. This mechanism is for distributing engine torque inputted through the engine connecting shaft to the motor-generator connecting shaft and accessory equipment connecting shaft. It is also for transferring torque inputted through the motor-generator connecting shaft to the engine connecting shaft.
[0016] The device has a locking mechanism which locks the accessory equipment connecting shaft, and a clutch which disengageably connects the motor-generator connecting shaft of the torque distribution mechanism with the accessory equipment connecting shaft.
[0017] According to the above configuration, a single motor-generator can perform four different operations: a driving operation of the compressor when the idle stop function is performed, a starting operation of the engine by the motor-generator, a driving operation of the motor-generator by the engine, and a driving operation of both motor-generator and the compressor by the engine. Therefore, the motor-generator and its driving circuit can be integrated, and the configuration can be simplified.
[0018] Moreover, a motor-generator/accessory equipment system which consists of the compressor, motor-generator, torque distribution mechanism, clutch and locking mechanism can be separately placed from the engine. Therefore, a total shaft length of the engine can be reduced. This improves arrangement flexibility in an engine compartment, resulting in improved installability of the device, especially in small vehicles.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The above and other objectives, features and advantages of the present invention will become more apparent from the following detailed description made with reference to the accompanying drawings. In the drawings:
[0020] [0020]FIG. 1 is a block diagram of an accessory equipment driving device according to the embodiment; and
[0021] [0021]FIG. 2 is an operation mode diagram showing operation modes of the accessory equipment driving device of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] The preferred embodiment of the present invention will be explained with reference to the accompanying drawings.
[0023] Referring to FIG. 1, the configuration and operation of the accessory equipment driving device for a vehicle of this embodiment is discussed.
[0024] An internal combustion engine 1 has an idle stop function. The engine 1 is stopped during idling. A crank pulley 2 has a belt 3 for transferring a driving power generated by the engine 1 to other devices. A motor-generator/accessory equipment system 4 will be explained later. An electricity storing device 5 , such as a secondary battery, stores electricity. A three-phase inverter 6 has a DC-AC bidirectional conversion function. It mediates between the electricity storing device 5 and the motor-generator/accessory equipment system 4 for power transfer.
[0025] A control device 7 sets a mode to a starter mode, an alternator mode, an electrical compressor mode, or an internal combustion engine driven compressor mode. The mode is determined based on information provided by an internal combustion engine control device or an air-conditioner control device, which are not shown in figures. The control device 7 controls the inverter 6 , clutch 430 of the motor-generator/accessory equipment system, and locking mechanism 460 . An electrical load 8 receives a power from the electricity storing device 5 .
[0026] The motor-generator/accessory equipment system 4 includes an input pulley 410 connected to the crank pulley 2 of the engine 1 by the belt 3 . A planetary gear mechanism 420 refers to the torque distribution mechanism of this embodiment. It includes the first shaft 421 , second shaft 422 , third shaft 423 and ring gear 424 . The ring gear 424 is fixed to the first shaft 421 , and the first shaft 421 is directly connected to a rotor shaft of the motor-generator 440 . A carrier 425 is fixed to the second shaft 422 , and the second shaft 422 is directly connected to the input pulley 410 . The third shaft 423 is connected to the first shaft 421 via the clutch 430 and to the compressor 450 for an air conditioner via the locking mechanism 460 .
[0027] In the planetary gear mechanism 420 , the sun gear and ring gear are engaged with the planet gears. The planet gears are supported by the carrier 425 as they rotate their own axes. The carrier 425 is rotated as the planet gears revolve around the sun gear 426 .
[0028] Since the third shaft 423 of the planetary gear mechanism is connected to one of the shafts of the locking mechanism 460 and that of the clutch 430 , the clutch 430 and locking mechanism 460 can be integrated. Likewise, the clutch 430 and planetary gear mechanism 420 , or the clutch 430 , locking mechanism and planetary gear mechanism can be integrated.
[0029] Moreover, the motor-generator 440 and clutch 430 , or the locking mechanism and compressor 450 can be integrated. A rotary electric machine which a planetary gear mechanism is integrated can be used for the planetary gear mechanism 420 and motor-generator 440 . Furthermore, the clutch 430 , locking mechanism 460 , and compressor 450 can be connected or integrated to the motor-generator.
[0030] A driveline device includes the planetary gear mechanism 420 , clutch 430 , and locking mechanism 460 . In this device, whether simultaneously rotating the second shaft 422 and the third shaft 423 of the planetary gear mechanism 430 , or independently rotating them is determined. Conventional electromagnetic or hydraulic clutch can be used for the clutch 430 .
[0031] Although a synchronous motor-generator is used for the motor-generator 440 , other types of motor-generator can be used as long as a selection between the power generating operation and motor operation is available. The compressor 450 is a conventional compressor for an automobile air conditioner. The locking mechanism 460 may be a conventional braking mechanism.
[0032] (I) Engine Starting Mode
[0033] When restarting the engine 1 after it stopped by the idle stop function, the clutch 430 is released (disconnected) and the locking mechanism 460 is locked.
[0034] This stops rotations of the third shaft 423 and the sun gear 426 of the planetary gear mechanism 420 . A rotor shaft of the motor-generator 440 is mechanically connected to the input pulley 410 via the ring gear 424 and the carrier 425 of the planetary gear mechanism 420 one after another. The control device 7 controls the inverter 6 so that the motor-generator 440 performs a motor operation to provide the engine 1 with starting torque. The number of rotations of the carrier 425 is smaller than that of the ring gear 424 ; therefore, the electrical torque of the motor-generator 440 is multiplied and large starting torque is provided to the engine 1 .
[0035] (II) Power Generating Mode During Halting of compressor
[0036] When a starting operation of the engine 1 is completed, the control device 7 controls the inverter 6 so that the motor-generator 440 performs a power generating operation. A power generated by the motor-generator 440 is rectified by the inverter 6 , and charged into the electricity storing device 5 . A power is supplied to the electrical load 8 . At this moment, the clutch 430 is released, the locking mechanism 460 is locked, and the compressor 450 is stopped.
[0037] (III) Compressor Driving Mode During Idle Stop
[0038] When driving the compressor 450 to drive an air conditioner while the engine 1 is not running, the clutch 430 and the locking mechanism 460 are released, and the motor-generator 440 performs a motor operation. This disables the second shaft 422 of the planetary gear mechanism 420 to rotate due to a friction of the engine 1 . As a result, the torque of the motor-generator 440 is transferred from the ring gear 424 to the compressor 450 via the sun gear 426 and the third shaft 423 of the planetary gear mechanism 420 . The control device 7 drives the inverter 6 and supplies an alternating current to the motor-generator 440 so that torque necessary for rotating the compressor 450 is generated.
[0039] (IV) Compressor Driving Mode During Running of Engine
[0040] When the engine 1 is running, the motor-generator 440 performs a power generating operation as described above. At this time, the clutch 430 is engaged and the locking mechanism 460 is released to drive the compressor 450 . By this operation, the first shaft 421 and third shaft 423 of the planetary gear mechanism have the same number of rotations. Therefore, the motor-generator 440 and compressor 450 are driven at the same speed as a result of the engine rotation.
[0041] “STARTER,” “ONLY ALTER.,” “ELEC. A/C” and “NORM. ALTER., A/C” in the table of FIG. 2 corresponds to the “Engine Starting Mode,” “Power Generating Mode during Halting of Compressor,” “Compressor Driving Mode During Idle Stop” and “Compressor Driving Mode During Running of Engine” which are discussed above, respectively.
[0042] The present invention should not be limited to the embodiment previously discussed and shown in the figures, but may be implemented in various ways without departing from the spirit of the invention.
[0043] For example, the planetary gear mechanism 420 is used for a torque distribution mechanism in the above embodiment. However, a differential gear mechanism can be used. Other types of planetary gear mechanism can be used for the planetary gear mechanism 420 . For the clutch mechanism, any two of the first to third shafts of the planetary gear mechanism 420 instead of the first and third shafts can be connectable.
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Three shafts of a planetary gear mechanism, which is a torque distribution mechanism, are connectable to an engine, a motor-generator and a compressor, respectively. An engine connecting shaft, a motor-generator connecting shaft and an accessory equipment connecting shaft are connected to a ring gear, a carrier and a sun gear, respectively. A single motor-generator can perform four different operations: a compressor driving operation when an idle stop function is performed, an engine starting operation by the motor-generator, a motor-generator driving operation by the engine, motor-generator driving and compressor driving operations by the engine.
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FIELD OF THE INVENTION
The present invention relates to hard disk drives used to store data, and more particularly to a head-media system having reduced stiction and low fly height capability.
BACKGROUND OF INVENTION
In the field of hard disk storage systems, continuous improvements have been made in increasing the area density, i.e., the number of stored bits per unit of surface area. As is well known, decreasing the fly height of the read/write head results in reduced pulse width (PW50) due to a number of factors which allows for greater recording density. For a discussion of the effects of lower fly height, see, for example, U.S. Pat. No. 5,673,156. In any event, bringing the head closer to the media has been a key area of effort in increasing recording densities.
The read/write head is typically a part of or affixed to a larger body that flies over the disk and is typically referred to as a “slider”. The slider has a lower surface referred to as the air bearing surface. The air bearing surface typically comprises one or more rails which generally generate a positive air pressure. In addition, there is often a cavity or similar structure that creates a sub-ambient pressure to counterbalance the positive pressure to some extent. The slider body is attached to a suspension via a head gimbal assembly which biases the slider body towards the disk. The net effect of the air bearing surface and the suspension is to cause the slider to fly at the desired height when the disk is at full speed, and to cause the slider to be in contact with the disk surface when the disk is at rest. The portion of the slider that contacts the disk is typically the aforementioned one or more rails. As the fly height of the slider is reduced, it is necessary to produce disks with increasingly smooth surfaces. As is well known, the slider undergoes sliding contact with a portion of the disk whenever the drive motor is turned on or off. This contact between the slider and the disk occurring when the drive is turned on and off is known as contact start stop (CSS) operation.
The CSS motion between the slider and the disk is of great concern in the reliability of the drive since it is generally the major initiator of failure in hard disk drives. In today's commercially available disk drives, generally 20,000 CSS cycles for desk-top computer applications and up to 100,000 CSS cycles for portable or hand-held computer applications is considered adequate. A greater number of CSS cycles is needed in portable and hand-held computer applications because the drives are frequently turned on and off to conserve battery power. Recently, there has been a trend to reduce power consumption in desktop computers. Therefore it is expected that CSS requirements will greatly increase for desktop applications as well.
In order to improve the CSS performance, it is well understood that friction must be minimized between the slider and the disk. Static friction or stiction is a term used to describe the force exerted against the motion of the slider relative to the disk surface when the slider is at rest on the disk surface. Stiction values are often given in grams to represent the force required to separate the slider from the disk. The stiction is greatly increased if the lubricant that is used on the surface of most disks wets a significant portion of the slider/disk interface.
Often, the term initial stiction refers to the stiction encountered when the slider contacts the disk for a minimal amount of time, without a significant opportunity for lubricant to migrate to the slider/disk interface. Parking stiction is a term used when the disk drive has not been in use, so that the slider has been at rest on the CSS zone for some time and may have some lubricant migration to the interface. Parking stiction is typically greater than initial stiction. Finally, the term fly stiction is used to describe the situation where the slider has flown over the disk for a considerable amount of time so as to pick up lubricant, and then after returning to the disk surface has remained on the disk surface for a sufficient time to allow the lubricant to flow to and significantly wet the interface, thereby greatly increasing stiction. Stiction can be strong enough to prevent the drive motor from turning, or worse yet, can damage the head, cause the slider to become detached from the suspension assembly, or cause the slider to ding the disk surface during separation of the slider from the disk surface. (The term “ding” is used in the art to describe an abnormal and sudden impact of the slider against the disk surface which dents the disk surface around the impact area. This can occur, for example, by accidentally dropping the disk drive on a hard surface. This can also occur when the slider is stuck on the disk surface during drive start-up due to high stiction, followed by sudden release of the slider, which causes it to bounce on and thereby dent the disk surface.)
It has been recognized that stiction can be reduced by putting a “micro-texture” on the disk surface to reduce the effective contact area between the slider and the disk. See, for example, Marchon et al., “Significance of Surface Roughness Measurements. Application to the Tribology of the Head/Disk Interface,” Tribology and Mechanics of Magnetic Storage Systems VI, ASLE SP-26, page 71 (1990), which describes the roughness needed to achieve an acceptable rate of increase in stiction under prolonged CSS for a disk comprising an aluminum/NiP substrate with a near concentric texture pattern. Also, Lee et al., describe the effect of texture crossing angle on CSS performance in “Effect of Disk Cross Hatch Texture on Tribological Performance”, published in IEEE Transaction on Magnetics, Vol. 28, No. 5, September 1992, pp. 2880-2882. In effect, a rougher texture and modification of texture morphology is needed to achieve acceptable CSS performance. The texture pattern may be put on the disk by mechanically abrading the substrate surface using well known methods.
In contrast to the requirements of CSS operation, for reading or writing data it is desirable that the surface of the disk be as smooth as possible to allow the head to fly as close as possible to the disk surface. Because of these differing requirements, it is known to use zone texturing where a portion of the disk used for CSS operation (the CSS zone) is textured more heavily than the portion of the disk used for data storage (the data zone). One problem with such zone texturing, however, is that it is difficult to create a precisely delineated CSS zone with mechanical texturing methods. Because of this, some portion of the data zone is typically lost, thus reducing the amount of data a disk can hold.
Because the data zone is smoother than the CSS zone, both the glide height (minimum distance at which a slider may fly without contacting any portion of the disk surface) and the glide avalanche height (distance above mean disk surface level at which the slider makes regular and continuous contact with the disk surface) are lower in the data zone than in the CSS zone. However, because it is necessary to move the head from over the data zone to the CSS zone, the glide avalanche height of the CSS zone limits the fly height over the data zone, as the head must be able to safely move between the two zones, without undue contact in the CSS zone which could lead to wear of the disk surface, the slider, and generation of debris. It should be noted that it is difficult to produce mechanical texturing with a high degree of uniformity. This nonuniformity in surface texture means that some portions of the CSS zone may be considerably rougher than average, which poses further limitations on the fly height.
Another known method to provide the necessary texture in the CSS zone is laser zone texturing. An example of this method is described in U.S. Pat. No. 5,108,781. In such a method, a laser beam is focused to a small spot on the disk surface, forming uniformly shaped and sized features in a controllable pattern. Because of the high degree of control possible with a laser system, the CSS zone can be precisely delineated so that loss of data zone area can be minimized. Furthermore, because the size of the features is better controlled than the surface morphology resulting from mechanical texturing, the above-described uniformity problem is greatly reduced. However, because the surface in the laser texture zone has a considerably greater roughness than the data zone, the CSS zone still provides a limitation to the fly height even in laser zone textured disks. See “The Special Needs of Server Class Drives” by Wachenschwanz et al., IDEMA Insight, Vol. XI, No. 1, January/February 1998 which illustrates that laser zone texturing achieves acceptable stiction performance for today's devices and further asserts that laser based zone textured disks should be extendible for at least two generations.
Another method to reduce stiction in CSS operation is to provide a texture on the surface of the slider rather than the disk. Such sliders are frequently referred to as “padded” sliders or “stiction-free” sliders. The texture may be provided in a variety of manners. For example, “Numerical Simulation of the Steady State Flying Characteristics of a Fifty Percent Slider with Surface Texture” by Wahl et al., IEEE Transactions on Magnetics, Vol. 30, No. 6, November 1994, discloses a slider having a plurality of hemispherical, conical, or cylindrical features arranged in a densely packed pattern thereon. U.S. Pat. No. 5,079,657 teaches several varieties of textured sliders using chemical etching in one embodiment formed by differential etching, and in another embodiment formed by the use of a masked photo resist layer. “Stiction Free Slider for Lightly Textured Disks”, by D. Yamamoto et al., IEEE Trans. Mag. Vol. 34, No. 4, 1998, shows a textured slider which has one or more “pads” along the length of each rail. Herein, a slider having texture formed by any method, including the foregoing, with any type of pattern is referred to as a textured slider.
FIGS. 1A and 1B show two examples of textured sliders. As shown in FIGS. 1A and 1B, the sliders comprise a slider body 101 a/b coupled to suspension 102 a/b . Each of the sliders comprises two rails 103 a/b (although sliders with a single rail and sliders with more than two rails may be used). Also as shown in FIGS. 1A and 1B, each of the rails has a plurality of pads 104 a/b . In the particular slider shown in FIG. 1B, each pad 104 b may have dimensions, for example, of approximately 35-50 microns wide by 50-100 microns long. Of course other dimensions may be used.
In the above described textured sliders, the intent is to provide a slider surface that has some portions at a different elevation than others to reduce the total contact area and thereby reduce stiction. One advantage to using such sliders is that a lower roughness of the disk surface is needed to meet stiction requirements. This lower roughness is comparable to the roughness of current data zone texture, so that the entire disk surface may be textured as appropriate for data storage, thus allowing for lower fly heights and increased density. Additionally, textured sliders are intended to eliminate the need for a separate zone, whether by mechanical texturing with its concomitant loss in usable area, or laser zone texturing which typically adds a step to the disk fabrication process. In the above mentioned article by Yamamoto et al., it is stated that the stiction results obtained with the stiction free slider described therein is acceptable even on relatively lightly textured surfaces which have a roughness comparable to current data zone texture. Recently, it has been reported that a textured slider may be extendible for the next several generations of disk drives. See “Fujitsu's Padded Slider Hold Stiction at Bay”, Data Storage, May 1998, page 8.
A further approach to the stiction problem is drives using a so-called “load/unload” mechanism. In these drives, when the drive is turned off, the head is parked on a ramp and not on the disk surface. Therefore, in load/unload drives, the problem of stiction is eliminated. However, the load/unload mechanism adds to the cost and complexity of the drive.
As can be seen from the foregoing, current attempts are to either improve the disk texturing, with particular current emphasis on laser zone texturing or alternatively to eliminate the need for a separate zone by providing a textured slider or by providing a load/unload mechanism.
As recording density increases, ever smoother surfaces will be required so that heads may fly lower. Current state-of-the-art systems have glide avalanche heights in the data zone of approximately 0.8 through 1.0 microinch (μ″). In the future, glide avalanche heights of approximately 0.4 μ″ or below will be needed for disks having densities in the range of approximately 3-5 gigabits per square inch (Gb/in 2 ). On a laser zone textured disk, the glide avalanche height for such CSS zone would need to be in the range of approximately 0.6-0.7 μ″. An average laser bump height in the range of approximately 50-100 angstroms (Å) will provide a glide avalanche height in this range, but is likely to have unacceptably high stiction for conventional sliders. Thus, what is needed is a method and apparatus for providing a slider-head system having very low glide height and acceptable stiction performance.
SUMMARY OF THE INVENTION
An embodiment of the present invention comprises a slider and a disk for storing magnetic data. The slider is textured to reduce stiction. The disk has a contact area for CSS operation (CSS zone) having a surface roughness greater than that of an area for data storage. The surface roughness may be created by any means such as mechanical texturing, top surface texturing, sputter texturing, or may comprise a pattern of features with relatively uniform height such as those formed by laser texturing. The CSS zone can be made with a sufficiently low average height to allow for the low fly heights of advanced disk drives. By use of a textured slider and a disk having, for example, laser features in the CSS zone, stiction is kept sufficiently low to allow for reliable operation.
Other features and advantages of the present invention will become apparent from the detailed description, figures and claims which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B show two exemplary types of textured sliders.
FIG. 2 shows glide avalanche height as a function of surface roughness.
FIGS. 3A and 3B illustrate the data zone and the CSS zone, respectively, of a laser textured disk.
FIG. 4 shows glide avalanche height as a function of average bump height for a laser textured disk.
FIG. 5 shows initial stiction results for a textured slider on a low roughness mechanically textured surface, and on a laser textured surface.
FIGS. 6A, 6 B, and 6 C show initial stiction over 10,000 cycles for a textured slider on a mechanically textured surface of a first roughness, a mechanically textured surface of a second roughness, and a laser textured surface, respectively.
FIG. 7 shows initial stiction as a function of glide avalanche height for an embodiment of the present invention.
FIG. 8 shows stiction results over 10,000 cycles for a textured slider on mechanically textured surfaces and on a laser textured surface.
FIGS. 9A and 9B show stiction as a function of glide avalanche height for a conventional slider and for an embodiment of the present invention, respectively.
FIG. 10 shows contact area of the slider surface as function of slicing depth.
DETAILED DESCRIPTION
A head-media system comprising a textured slider and a disk having a CSS zone with a greater roughness than a data zone. In the following description, numerous specific details are set forth such as specific sliders, disks, roughness values, etc. It will be appreciated, however, that these specific details need not be employed to practice the present invention. In other instances, well known methods and apparatuses are not described in detail in order not to obscure unnecessarily the present invention.
As described earlier, one important parameter is the glide avalanche height which is the height at which the lowest portion of the slider begins to make regular contact with the disk. Typically, the glide avalanche is stated as distance above the average surface height, typically expressed in microinches. Referring to FIG. 2, a graph of surface roughness (RMS Roughness) versus avalanche height for a mechanically textured disk surface is shown. As expected, as the surface gets smoother, the glide avalanche is reduced. As is well known in the industry, a lower glide avalanche point is needed for lower fly heights. It is believed that in disks having a density in the 3-5 Gb/in 2 range, the glide avalanche in the data zone will need to be approximately 0.4 μ″. Although the CSS zone need not have as low a glide avalanche as the data zone, it too must be reduced to enable lower fly heights over the data zone, because too great a disparity in glide avalanche between the two areas would cause excessively severe wear on the slider as the head is moved back and forth, as described previously. For disks having the aforementioned 3-5 Gb/in 2 density, it is believed that the glide avalanche height in the CSS zone should be in the range of approximately 0.6-0.7 μ″. Referring to FIG. 2, it can be seen that to meet the above requirements the data zone would need to have a maximum RMS roughness of approximately 10-15 Å, and the CSS zone would need to have a maximum RMS roughness of approximately 35 Å.
Also as described earlier, it is preferable not to have two mechanically textured zones because it drastically reduces the amount of space for storing data, and adds to process complexity. A disk textured in its entirety with the requisite low roughness needed for advanced densities would therefore require a surface roughness of about 15 Å RMS or lower, which corresponds to an Ra roughness of approximately 12 Å or lower.
Referring to FIG. 3A, a portion of the data surface of a disk is shown. As can be seen, the surface 300 has mechanical texturing thereon. FIG. 3B shows the CSS zone of the same disk where laser zone texturing was used. As can be seen, the surface still has mechanical texturing 300 as well as numerous laser features 301 thereon. The laser features 301 shown in FIG. 3B are generally circular, crater shaped features. It will be appreciated that other types of laser features such as the so-called “sombrero” type, or other shapes of the laser features may be used in the below described embodiments of the present invention utilizing laser texture. Typical horizontal dimensions of laser features, for example measuring from one side of the rim to the other, are in the range of about 1 micron through several microns. It will be appreciated of course that dimensions outside this range may be used in the present invention as well. The average height of the features 301 above the surface 300 is approximately 200-300 Å in most state of the art devices.
Referring now to FIG. 4, a graph of bump height as measured by an atomic force microscope (AFM) versus the glide avalanche is shown. As can be seen, a bump height in the range of approximately 200-250 Å results in a glide avalanche of approximately 0.85-1.1 μ″. While this glide avalanche is acceptable for the CSS zone of current devices, as noted above a much lower glide avalanche will be required for future devices. For example, to achieve a glide avalanche of approximately 0.6 μ″, an average bump height of approximately 100 Å is needed.
As will be seen it has been found by the present inventors that the use of a textured slider on a very lightly textured disk (e.g., avalanche height of about 0.4 μ″) may encounter stiction problems after use. Furthermore, although considerable effort is being expended to produce textured sliders for current and future requirements, considerable development work remains. Similarly, with respect to laser texture, significant effort will be required to provide features having a low enough height for glide avalanche requirements without poor stiction performance. It would be desirable to provide for good stiction performance at low glide avalanche heights utilizing currently manufacturable technology for current and future devices. Furthermore, it would be desirable that the system be robust to provide an acceptable operating window.
To overcome these problems, the present invention comprises the use of a textured slider together with a disk having a separate zone having a greater roughness than the data zone. In one embodiment, a mechanically textured zone may be used if desired. Although this embodiment would still have the above described problems of mechanically zoned disks of the prior art, i.e. loss of some of the surface area of the disk for data storage, and greater nonuniformity than laser texturing, such an embodiment achieves improved stiction results as compared with a textured slider used on a disk textured entirely as is needed for the data zone. Alternatively, other methods of texturing may be used such as texture provided by sputtering, top surface texturing wherein the carbon overcoat is in some way treated to provide a texture, by various patterning methods to provide features, or as described in detail herein, by a method such as laser texturing.
In a particularly preferred embodiment, the invention comprises a disk having a zone that is textured by forming a plurality of features of uniform height, such as features formed by use of concentrated radiation in the CSS zone. For purposes of discussion, the latter embodiment will be discussed in conjunction with laser texturing for illustration. It will be appreciated, however, that any method of forming features with this morphology i.e. texture by way of discreet and relatively uniform protrusions, as opposed to random surface texturing characteristic of mechanical texturing processes and some chemical texturing processes, will provide the benefits of this embodiment. As will be seen, by use of this method, stiction results approximately equivalent to results achieved with a stiction-free slider when used on a mechanically textured surface of high roughness are achieved. Because of the use of a textured slider, the average laser feature height can be very low, such as 100 Å for disks storing approximately 3-5 Gb/in 2 and lower heights for capacities beyond this range, without encountering the above described stiction problems of such small bumps. Because the glide avalanche height of such bumps is relatively small, the disk may be used in high density applications.
Referring to FIG. 5, a bar graph of stiction in grams is shown. The texture on the slider comprised a pattern of small protrusions or bumps over most of the surface of the rails such as is shown in the article by Wahl et al. Herein, such textured sliders will be referred to as “full texture” sliders. FIG. 5 shows the stiction for this slider on several different disk surfaces. Bar 501 shows the initial stiction on a mechanically textured portion of a disk having a glide avalanche of 0.5 μ″. As can be seen, the amount of stiction is clearly within an acceptable range. Bar 502 shows the stiction in another mechanically textured region having a glide avalanche of approximately 0.45 μ″, and again as can be seen the stiction is acceptable. Bars 503 and 504 show the stiction in two more mechanically textured locations on the disk, both with a glide avalanche height of 0.45 μ″. However, the locations represented by 503 and 504 show the stiction results after the same slider has undergone a few hundred CSS cycles. As can be seen, the stiction has now gone well above acceptable limits and is now in the range of approximately 13-20 grams. This data suggests that some type of degradation in the condition of the slider surface occurs after a significant number of CSS cycles. It appears that the condition of the disk does not cause the degradation as each bar represents a new location on the disk. This head degradation significantly degrades the stiction performance on very smooth surfaces.
Referring now to Bars 505 , 506 , 507 , and 508 stiction results using the same slider that was used to produce Bars 501 - 504 is shown. The data for Bars 505 - 508 was generated with this slider after it had generated the data for Bars 501 - 504 so that the slider at this point has had considerable degradation. Bars 505 - 508 represent stiction results from laser textured disk surfaces that have glide avalanche heights of 0.60μ″, 0.65μ″, 0.85 μ″ and 1.20 μ″ respectively. The patterns of the laser features were 25 μm×25 μm, 20 μm×20 μm, 20 μm×40 μm, and 50 μm×50 μm, respectively, where the first number represents the spacing of features along the track i.e. in the circumferential direction, and the second number represents the spacing of the features radially. As can be seen, in all cases the stiction remained at acceptable levels, even though the textured slider had degraded considerably such that the stiction rose to high levels in very smooth regions.
As noted earlier, the CSS zone needs to have a glide avalanche in the range of 0.6-0.7 μ″ or less in the next couple of generations of drives. As can be seen from Bars 505 and 506 , which represent zones with glide avalanche heights of 0.60 and 0.65 μ″, the present invention provides acceptable stiction results for future devices. Referring back to FIG. 4, as can be seen, the average bump height to achieve this glide avalanche is approximately 100 Å. Thus, the height of the laser features is much lower than currently being used in laser textured disks which use greater average heights to avoid stiction problems.
Referring again to FIG. 5, it will be noted that the glide avalanche of the slider/disk system of the present invention (Bars 505 - 508 ) is at a higher glide avalanche than the mechanically textured regions shown in Bars 501 - 504 which have a smooth surface characteristic of data zone regions. In embodiments using a mechanically textured CSS zone, the mechanically textured region should have a similar glide avalanche as the laser texturing used in FIG. 5 to achieve comparable results. However, importantly, the laser texture embodiment avoids having the need to produce a mechanically zoned disk that loses valuable data storage area. In any embodiment, the present invention avoids having to limit the data zone roughness by the higher roughness needed for acceptable stiction performance in future devices.
FIGS. 6A-6C illustrate the improvement achieved with the present invention. FIGS. 6A-6C show initial stiction in grams versus cycle number, for 10,000 cycles. The textured slider used in FIGS. 6A-6C was again a full texture slider. In the graph of FIG. 6A, the slider was used on a very smooth mechanically textured surface. The surface had a roughness Ra in the range of approximately 10 Å and a glide avalanche height of approximately 0.4-0.5 μ″. As can be seen, the stiction quickly exceeded 10 grams after several cycles, and exceeded 30 grams after a couple thousand cycles.
FIG. 6B shows initial stiction for a textured slider on a mechanically textured surface having an average roughness Ra of approximately 16 Å. As can be seen, by using a higher roughness the stiction results are greatly improved with the stiction being slightly over 10 grams after 10,000 cycles. The results can be further improved by providing an even rougher surface in the CSS zone. Note that the roughness of approximately 16 Å is much lower than the approximately 35 Å roughness upper limit needed for the CSS zone for producing systems in the 3-5 Gb/in 2 range. Thus, FIG. 6B illustrates the benefits of a mechanically textured zone having a roughness greater than the data zone.
Referring to FIG. 6C, the stiction versus cycle for 10,000 cycles for a disk having laser features thereon is shown. In the graph of FIG. 6C, the CSS zone had laser textured features with an average height of approximately 85 Å and a glide avalanche height of approximately 0.6 μ″. As can be seen, the typical stiction value is well under 5 grams (with the exception of 1 parking stiction event as shown by the spike in the graph) for the entire 10,000 cycles. The average initial stiction in FIG. 6C after 10,000 cycles was approximately 2.3 grams. The maximum stiction, other than the parking event, was 4.5 grams. This compares particularly well to the first 10,000 cycles of FIG. 6 A. In comparing the graphs, note the scale difference in the Y axis.
FIG. 7 further shows the results of the present invention. Shown in FIG. 7 is the average initial stiction in grams versus the avalanche height for a full texture head on a laser textured surface. As can be seen, by use of the present invention the stiction can be kept to acceptable levels even when the glide avalanche is below 0.5 μ″. Thus, the present invention will allow for acceptable stiction performance on disks having low glide avalanche in the CSS zone, as required by future 3-5 Gb/in 2 devices and beyond.
FIG. 8 again shows the improvement achieved with the present invention. Curves 801 , 802 , 803 , and 804 show stiction in grams as a function of CSS cycle. The slider design used in all of Curves 801 - 804 was a four pad design similar to the design illustrated in FIG. 1B, with two of the pads 104 b on each of two rails. Curves 801 and 802 show the results for the slider when used on a mechanically textured surface having an Ra roughness of approximately 10 Å. As can be seen, the initial stiction is marginal at about 5 grams and after approximately 100 cycles increases up to approximately 10 or more grams, which increase is believed to be due to head degradation as described earlier. Curve 803 was generated using the same type of slider but on a mechanically textured surface having an Ra roughness of approximately 20 Å. As can be seen, the stiction behavior is generally very good. Finally, Curve 804 was generated with the same type of slider but on a CSS zone having laser features. The laser features had an average height of approximately 85 Å and a glide avalanche height of approximately 0.6 μ″. As can be seen, even after 10,000 cycles, the stiction remained below 2 grams. It should be further noted with respect to curves 803 and 804 that not only do these embodiments of the present invention achieve low stiction, but the stiction remains low over many cycles, indicating that the present invention is relatively insensitive to degradation of the textured slider.
As shown in FIGS. 5-8, the present invention provides for reduced stiction when using a textured slider on a CSS zone in accordance with the present invention. FIGS. 9A and 9B illustrate the improvement of the present invention as compared with a non-textured slider. First referring to FIG. 9A, a graph of avalanche height versus stiction in grams is shown. In FIG. 9A, curve 901 shows the results for the conventional slider on a laser textured surface and the Curve 902 shows the conventional slider on a mechanically textured surface. As can be seen, the stiction with a conventional head on a laser textured surface typically reaches unacceptable values at a glide avalanche height of around 0.8 μ″. The stiction on the mechanically textured surface reaches unacceptable levels at approximately 0.7 μ″. The stiction response is generally more gradual on the mechanically textured surface as compared with the laser textured surface because the laser textured surface generally has peaks with relatively uniform heights, so that the surface area contacted increases much more rapidly on a laser textured surface as the slider is moved closer to the disk.
Referring now to FIG. 9B, a graph of avalanche height versus initial stiction for a full texture slider is shown. Curve 905 shows the results for the textured slider on a mechanically textured surface. As can be seen, the stiction results are improved over FIG. 9A by virtue of the use of the textured slider. Curve 906 shows the stiction results for the textured slider on a surface having laser texturing. As shown by curve 906 , the use of a textured slider on a CSS zone having laser features dramatically improves the initial stiction. As can be seen, in contrast to FIG. 9A the stiction remains under 5 grams at 0.8 μ″ glide avalanche height and on average remains below this value to about 0.4 μ″ glide avalanche height.
FIG. 10 shows a bearing ratio curve for several types of sliders. The curves show the percent of the slider area in contact with the surface as a function of distance from the disk surface. The chart shows the contact area in mm 2 of the slider as a function of slicing depth into the surface of the slider—i.e. a depth of zero indicates the first point of contact with greater contact at greater slicing depths. Curves 1001 , 1002 , and 1003 show current designs having a contact area of approximately 1.4 mm 2 . Curves 1005 - 1010 show so called “pico” sliders which have a reduced form factor and have a lower total contact area of approximately 0.6 mm 2 used in advanced designs. The curves 1009 and 1010 represent curves for textured sliders. Because the sliders have some type of texture, the area increases very slowly with slicing depth as compared with non-textured sliders. It has been found that the present invention works well with all types of textured sliders. In particular however, the best results appear to be obtained with sliders that have numerous point contact areas such as that shown in the article by Wahl et al., or other sliders with multiple points of low surface area contact such as some of the sliders shown in U.S. Pat. No. 5,079,657, or sliders according to the teachings of U.S. Pat. No. 5,673,156. It will be appreciated that any textured sliders including the foregoing, or sliders having a combination of the various types of textures, such as a pattern of small protrusions in one portion, and a single large area pad in another, may be used in the present invention.
The laser features on the disk in laser texture embodiments were made and formed using conventional patterns. As described herein, the typical average height of the laser texture features may be much less than is used with a non-textured slider. For example, laser features in the range of approximately 50Å-150 Å provide for lower glide avalanche, needed to improve fly height in the data zone. Further, reduced laser feature height may be used in future devices requiring even lower glide avalanche height. However, by use of a textured slider, the stiction is considerably reduced compared with that which would be obtained by use of a conventional slider on such small laser features.
In designing the laser texture pattern one consideration is that the pattern should be such to ensure that the textured surface contacts the laser features. For example, in the padded slider shown in FIGS. 1A and 1B, the radial spacing between the laser features should be less than the width of the narrowest pad, (e.g., less than approximately 35-50 μm radial spacing for the exemplary dimensions given in conjunction with FIG. 1B) so that it is ensured that each pad lands on a laser feature. Similarly, the distance between each laser feature in the circumferential direction should be no more than the length of the shortest pad (e.g. less than approximately 50-100 μm circumferential spacing for the exemplary dimensions given in conjunction with FIG. 1 B). In this way, the elevated portions on the slider are ensured to contact the texture features on the disk to minimize surface area contact and therefore stiction. As used herein, the higher or greater elevation on a slider is considered to be a portion closer to the disk surface than other portions. For sliders that comprise texturing over a greater area, such as sliders having a plurality of protrusions over the entire surface and sliders with stripes and bars, the laser feature pattern can be less dense than for the sliders having a limited number of pads.
While the invention has been described with respect to specific embodiments thereof, those skilled in the art will recognize that changes can be made in form and detail without departing from the spirit and scope of the invention. The use of a textured slider and a disk having a CSS zone with a rougher texture provides the ability to achieve low fly heights, while achieving acceptable stiction in the CSS zone. In one embodiment, a texture comprising precisely placed features of uniform height, such as those formed by radiant energy focused to a spot on the disk, is used. The precise placement allows for a precisely delineated CSS zone maximizing area usable for data storage. The good uniformity reduces the margin that must be added to the fly height to account for the highest peaks in the CSS zone. Preferably, the ±3 sigma uniformity is approximately ±20%, more preferably ±15% and most preferably ±10% or better. Although the latter embodiment has been described using laser texture features, any type of method that produces a similar morphology, such as use of concentrated radiant energy, or other methods, such as by performing a patterning and etch step on the disk surface, achieves these advantages. However, any type of texture may be used in the CSS zone provided it is sufficiently rough to achieve the stiction performance described herein. Furthermore, as mentioned earlier, numerous types of textured sliders may be used. The embodiments described herein, as well as embodiments having such changes in form and detail come within the scope of the present invention.
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A head and disk system for use in a disk drive includes a slider having a surface that contacts the disk. This disk contacting surface of the slider is textured with pads, bumps, an etched surface or an otherwise roughened surface. The contact area of the disk has a greater roughness than a data zone. The head disk system exhibits acceptable stiction. Additionally, low glide avalanche over the CSS zone, thus enabling low fly height, is achieved.
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This is a divisional of application Ser. No. 361,473, filed June 5, 1989, issued 1/29/91 now U.S. Pat. No. 4,988,341.
FIELD OF THE INVENTION
This invention relates to dressing device and a method used to prevent infection of a live host body during injection to remove blood or inject a medicament.
BACKGROUND OF THE INVENTION
The conventional procedure by medical practitioners for drawing blood from, or injecting a substance into, a live host body, has been for years to do the following steps:
1. Sterilizing the skin to be punctured by vigorous abrasive rubbing with an alcohol swab,
2. removing a needle or cannula from a needle case and inserting it into a syringe holder fitted with a vacutainer or a drug-containing syringe,
3. injecting through the skin in the swabbed area and drawing blood or injecting a drug,
4. destroying the needle,
5. removing and labeling of the vacutainer containing the sample (if blood has been taken),
6. swabbing the wound to disinfect and remove blood leaking from the wound, and
7. covering the wound with a covering.
This practice continues, even though it is now well recognized that alcohol swabbing of the skin is inadequate protection from infection. Not only is the alcohol swab deficient in skin cleansing, but also the cannula can be contaminated and require cleansing. Alcohol is bactericidal against vegetative forms of bacteria through the denaturation of cellular proteins; however, it is far from ideal as a skin or surface disinfectant. Alcohol is flammable, it evaporates too fast to be very effective (it should remain on the skin surface for about 10 minutes), and it dries and irritates the skin.
It would thus be highly desirable to provide a means for sterilizing human skin prior to venipuncture, without abrasion, and in the same step provide protection from infection of the patient by the needle and continued protection of the patient after injection while minimizing the potential of infection of others by the patient's blood as a result of aerosols, leakage from the wound, handling of a swab before dressing the wound, or leakage from the cannula.
Some early attempts have been made to provide alternate procedures. For example, U.S. Pat. No. 3,367,332 (1968) teaches the use of a resealable patch and membrane bandage through which the needle is inserted (FIG. 3), at least the bandage having been sterilized with an antiseptic prior to injection of the host. However, the patch does not contain a sterilizing agent, so that the needle encounters only a thin layer of the sterilizing agent presented by the membrane. Furthermore, although the membrane may be thin and transparent, the patch is not and has substantial thickness, so that the phlebotomist is unable to correctly identify the injection site by sight or by feel, through the patch. In the case of a blood draw, stabbing "in the dark" is unacceptable. For these and other reasons, the technology of this patent has failed to replace the traditional use of alcohol swabs, deficient though the latter might be.
Thus, prior to this invention there has been a need for a sterilizing medium to be used with a needle, and a method of phlebotomy or drug injection, that more adequately sterilizes the needle while permitting precise location of the injection site.
SUMMARY OF THE INVENTION
We have devised a sterilizing device and method that overcome the above-noted disadvantages.
More specifically, in accord with one aspect of the invention there is provided a sterilizing device for use with a needle to inject into or remove a liquid from a site on a live host body, the device comprising: a transparent, puncturable, resealable gel medium containing a sterilizing agent preincorporated therein, the medium being constructed to cover the site; a non-absorbent protective cover on one side of the medium having margin portions extending beyond the outside margin of the medium; means for retaining the medium to the cover; and adhesive disposed on surface portions of the extending portions of the cover, the adhesive being disposed for exposure and contact of the host body when the medium is exposed and in contact with the host body.
In accord with another aspect of the invention, there is provided a method of injecting liquid into, or removing liquid from, a site on a live host body. The method comprises (a) positioning a transparent, puncturable, resealable gel medium containing a sterilizing agent preincorporated therein, to cover the site, said medium having adhesive at least partially surrounding it and positioned to temporarily hold the medium on the host body; (b) contacting the body site with the medium and adhesive; and (c) inserting a needle into the host body by injecting the needle first through the medium so as to contact the sterilizing agent; whereby sterility of the needle is insured.
The gel medium of this invention is considered superior because it is transparent, admixes well with the sterilizing agent, provides no objectionable contaminant of the host, and is manipulatable enough to allow the site, at least in the case of a vein, to be identified by feel. This is in contrast to alternative media such as fibers, which tend to interfere both with seeing the site and feeling the site, for the injection. Furthermore, fibers can be objectionable if the needle inadvertently injects one of them into the host.
Accordingly, it is an advantageous feature of this invention that a medium properly sterilizes both the skin of the host to be penetrated and the penetrating instrument, without interfering with the proper detection of the injection site.
It is another advantageous feature of the invention that a sterilizing medium and method are provided that are free of the use of alcohol and its attendant disadvantages.
Other advantageous features will become apparent upon reference to the Detailed Description of the Preferred Embodiment, when read in light of the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view in section of a sterilizing dressing medium constructed in accord with the invention; and
FIG. 2 is a view similar to that of FIG. 1, illustrating the use of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is hereinafter described with respect to a dressing used with a needle to draw blood from a site, a preferred embodiment. In addition, it is useful with a syringe needle used to inject medicaments into a site. As is customary with skin dressings, the device 10 of the invention comprises a first non-absorptive cover or base portion 12, a second non-absorptive cover or top portion 16 only, to the first affixed along margin portion 16 only, to the first cover by means such as an adhesive layer 18, and a medium 20 sandwiched between the two covers. All three are most preferably symmetric about the center axis 22, that is, are generally disc-shaped. Both covers 12 and 14 are preferably apertured at 24 and 26, respectively, for reasons which will become apparent. It is the non-attached inside margin portions 28 of covers 12 and 14 that hold medium 20 in place.
The outer surface 30 of cover 12 has at least a portion thereof coated with a conventional releasable adhesive 32 suitable for contact with skin. As sold, device 10 includes a plastic, paper, metal foil or a laminate release sheet 34 adhered to adhesive 32, until that sheet is peeled away by the user to allow the device to be stuck to the skin. Sheet 34 is preferably a solid disk having a shape and size effective to cover adhesive 32.
Conventional plastics or plastic-covered paper, metal foil or laminates can be used for covers 12 and 14.
In accordance with one aspect of the invention, medium 20 comprises a transparent, resealable, puncturable gel that contains throughout its volume, a sterilizing agent preincorporated therein. As used herein, "sterilizing agent" is any anti-bacterial agent, fungicide, anti-yeast agent or anti-viral agent or combination thereof. The selection, of course, is dependent upon the end use, a combination of an anti-viral agent and a anti-bacterial agent being preferred. Useful examples include parachlorometaxylenol (PCMX), chlorhexidine gluconate (CHG), triclosan, alcohol, iodophores and povidone-iodine, Nonoxynol-9™, phenolic compounds, quaternary ammonium compounds, chlorine solutions (sodium hypochlorite or chlorine dioxide), and glutaraldehyde. In addition, a topical anesthetic is optionally included, for example, benzocaine, xylocaine, menthol, pramoxine or dimethisoquin, which is effective upon contact with the skin.
Any gel material is useful for medium 20 if it provides the above functions. Most preferred is a hydrogel that is an interlaced network of agar and a copolymer of acrylamide crosslinked with the monomer N, N'-methylenebisacrylamide, and 96 by weight %, bound water. A preferred example is the gel sold by Geistlich Pharma of Switzerland under the trademark "Geliperm"™. Other useful examples include gels that are copolymers of 2-hydroxyethyl methacrylate. The water is essential to keep the polymer network expanded, and to disperse the sterilizing agent. The polymer network serves to hold the liquid in place. The net result is a medium that is transparent, has no fibers to be injected into the skin, and distributes the sterilizing agent throughout. Thus, no matter which portion of medium 20 is penetrated by the needle, the agent will be effective to sterilize the needle.
Although for ease in manufacturing, the sterilizing agent is preferably dispersed throughout the medium, the sterilizing agent will also function if it is located primarily at the upper and lower surfaces of the medium, that is, where the needle and the skin encounter the gel medium.
The gel is also effective to reseal when the needle is withdrawn, and to wipe the needle of any blood on its exterior. The sterilizing agent is preferably effective to sterilize any harmful virus or bacteria that might remain on the removed needle, for example, the HIV-1 virus or hepatitis-B virus that can be present in the blood withdrawn by the needle.
The thickness of medium 20 is not critical, other than it must be sufficiently thick as to hold together, and thin enough to permit the user to feel the skin underneath. For example, 100 microns is useful.
The purpose of aperture 26 will become more apparent in the description of the use of the device 10, FIG. 2. That is, release sheet 34 is stripped off and discarded, thus exposing both adhesive 32 and gel medium 20 to the skin S to which device 10 is to attach. Device 10 is maneuvered to cover the site of the needle puncture, and to this end, aperture 26 or its equivalent is used to aid in finding the proper site. For example, vein V can be seen through aperture 26 and the transparent medium 20, and properly located vis-a-vis medium 20. In addition, the vein V can be felt through medium 20, since it is devoid of fibers that could camouflage the feel of the vein's location.
After medium 20 is properly located on the site, medium 20 is preferably massaged onto the site to disperse the sterilizing agent over the site. Such massaging further confirms the proper location by the sense of touch.
After device 10 is in contact with skin S at the site, a needle 50 is positioned at aperture 26, and then inserted via arrow 52 first (not shown) through medium 20 and then into the skin S.
Thus, an equivalent to aperture 26 in cover 14 is a transparent portion (not shown) of the cover that physically covers medium 20 in its entirety, while still making it possible to see and feel through device 10 to the site. In such a case, device 20 is fully covered and protected against premature exposure of medium 20. Alternatively, if aperture 26 is present as such, the entire device is wrapped and stored in protective plastic.
Preferably, device 10 is thrown away after a single use. However, and particularly if used with a syringe to deliver a medicament, because of the gel nature of medium 20, device 10 can be reused if a second injection is to occur elsewhere on the patient. That is, when the needle is withdrawn the gel completely reseals, and becomes an integral member in which the sterilizing agent is still uniformly dispersed. Thus, additional needles can penetrate the same medium, without fear of the sterilizing agent no longer being effective.
Other agents can be optionally added to medium 20 as desired, for particular applications. For example, perfumes, silicones, antioxidants, and even coagulating agents can be added.
The invention has been described in detail with particular reference to preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
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A dressing device and method are described, for use with a needle that is injected into the skin. The dressing device comprises a cover sheet and a gel medium attached to the cover sheet, the gel medium being transparent and effective to reseal after being punctured by the needle. Most importantly, the gel medium includes a sterilizing agent.
Injection of the needle into the skin occurs only after the needle penetrates the gel medium, so that the needle is disinfected or sterilized.
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OBJECT OF THE INVENTION
[0001] The object of the present invention is to provide for a multiunit washstand, which is capable to render services to several people simultaneously, which can be installed quickly and easily, which can be foldable and stackable and can be aligned with other multiunit washstands of the invention and furthermore shows a good appearance which does not wear out as time passes.
[0002] As a consequence of the objectives listed above a time-winning situation is created with respect to the mounting/dismounting of the washstands and the storage and transport of reduced volume, and the possibility to render the service to a number of users which is as big as needed, as this number will depend on the quantity of the aligned units.
BACKGROUND OF THE INVENTION
[0003] In general, in all those places being selected for events wherein there are massive gatherings of persons like military maneuvers, camp-outs, outdoor concerts, and patronal feasts of towns or of capital city suburbs, there are no sanitary installations enough to give the services to the attending public. A fundamental part of the mentioned services is that related to personal hygiene, dishes washing or kitchen belongings rinsing/washing, that for it to be provided, equipment is needed to be installed in the place of the event, as well as a water supply and the collection of the residual water. The objective to provide a multiple washstand that is installable in points such as the aforementioned ones have been stated in different patents.
[0004] The spanish application UO262513(Avelino Martinez) titled “Mountable multiple autonomous washstand” claims of an autonomous multiple washstand characterized by a water deposit situated on a tripod, whose fastening device is a frame which at the same time is the support of the equipped washbasins. The water falls from said container by means of hoses and taps(faucets), whereby the set-up/dismantling is carried out through a mechano-type assemblage by means of drive-pins, pattern screws, eyelets, southern cones, magnets and L shaped supports.
[0005] The U.S. Pat. No. 3,069,694 of M. E. McCormack titled “Portable dismountable multiple washstand” claims of a portable foldable dismountable washstand that is basically composed of a rectangular shaped horizontal structure, which forms every two by two a series of squares in which several semi-spherically shaped independent washstands are supported. The washstands are mounted incorporated on said squares and a piping is mounted on the longitudinal axis of the frame, which serves the taps that are installed in each washstand. The equipment is also composed of several legs over which the frame is mounted.
[0006] In the aforementioned patents, there exists a problem of slow mounting procedure, that requires specific manuals both for its correct start as much as for its dismantling and storage. Although some of its parts are stackable, like the deposit and the washstands, in pyramidal form in the spanish patent, and the washstands in a semi-spherical form in the USA patent, not the whole equipment is. Therefore, it is desirable to have an equipment that provides for an easier setting up and dismantling and a more efficient storage and transportation.
[0007] What is aspired for is a structure that avoids the aforementioned problems, integrating all the necessary devices into one unit, that way avoiding manuals for set-ups/dismantling and providing a quick installation and a piling up and complete transporting of all the devices that it is composed of.
[0008] The basic idea of the actual invention is to obtain an equipment that is unfolded instead of being assembled by mounting, being its handling so elementary that instructions are not needed. The deployment of the equipment is executed in just a few seconds, since the placing of screws or nuts/bolts is not necessary, which is obtained because there is no part that is not integrated in the equipment, which moreover provides the advantage of not having to lose parts or elements of the ensemble.
[0009] To get the service functioning all that is needed is to connect the water supply and the drainage to the multiple washstand of the actual invention. Depending on where the event is taking place, the water supply can be taken from the local water network itself or from a water-tank truck, and the means of drainage can be as simple as gutters or hoses that take the water to a drain or, better yet, to tank trucks that suction the residual water to leave the environment totally clean.
[0010] Mass events wherein the invention has an application are of limited duration and with a floor use not exclusive for such an event, therefore, a very important objective of the invention is the rapid and easiness to maneuver in the installation/dismounting of mentioned washstands. On the other hand, said washstands must be stored when not in use, or transported aptly from its storage place to the place where it will be used, and so another important objective of the invention is for it to occupy a reduced space during the storage and transport phases.
[0011] The aforementioned characteristics of speed and easiness to maneuver in the installation/dismantling of the washstand, as of the space used during the storage and transport phases, is obtained with the stackable storable multiunit washstand of the invention.
DESCRIPTION OF THE INVENTION
[0012] The invented fold-out storable multiple washstand is composed of, as principal elements, a basin or bucket, a water supplier, four foldable legs for the sustaining of the basin and four foldable legs for the sustaining of the water supplier.
[0013] The basin or bucket is provided with the necessary means for the union of said basin with the four foldable legs in it's sides for the sustaining of the basin, which stay stuck when they have been totally unfolded. Also, the basin is provided in its top surface with four handrails with guides over which each one of the inferior ends of every one of the foldable legs for sustenance of the water supplier can slide, which besides joining said basin with said supplier, allows the setting of the said water supplier open for service or in the piling position. In the vicinity of the lateral ends, the bucket or basin is provided with two holes, provided with vertical cylinders, which are located in the central and lowest area of the basin, which serve as a drainage. Lastly, the basin is also provided with a central hole which serves as a pathway for the hose that supplies water and has to be joined to the water supplier.
[0014] The water supplier is provided at its sides with the necessary means for the union of said water supplier with the top ends of the four foldable legs of the sustenance of the water supplier, and also with an access with a threaded sleeve joint that serves as a union with the water supply hose, from this part on providing for a set of pipes for which the water connects with several lateral holes in which the faucets that are managed by the users are installed.
[0015] In the case that a multiple of washstands as described is needed, some could be added on through contact between the extreme faces of the basins that way forming a continuous longitudinal installation of the length necessary.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] For a better understanding of the actual invention, a practical embodiment thereof is described on the basics of the attached Figures, wherein:
[0017] FIG. 1 —Shows an elevation schematic view and profile of the invented multiple washstand with the water supplier and the unfolded sustaining legs of the basin.
[0018] FIG. 2 —Shows a top schematic view of the multiple washstand of FIG. 1 with the folded water supplier.
[0019] FIG. 3 —Shows a top schematic view and profile of the multiple washstand of FIG. 1 with the folded sustaining legs of the basin.
[0020] FIG. 4 —Shows a top view of the basin or bucket
[0021] FIG. 5 —Shows a section in accordance with Plan A-A of FIG. 4 .
[0022] FIG. 6 —Shows a partial top view of the water supplier and its' union with the basin or bucket.
[0023] FIG. 7 —Shows a partial top view of one of the sustaining legs of the basin or bucket and the union with the same.
[0024] FIG. 8 —Shows a profile view of the piling of the four multiple washstands of the preferred embodiment of the invention.
[0025] FIG. 9 —Shows a schematic top view of the multiple washstand of FIG. 1 in which a platform of mirrors is added as a complement.
[0026] FIG. 10 —Shows the steps to be taken to assemble the parts of the sustenance of the platform of mirrors with the water supplier.
[0027] FIG. 11 —Shows a section view in accordance with plan B-B of FIG. 9 , of the sustaining parts over which the platform of mirrors that complement the multiple washstand is set on.
PREFERRED EMBODIMENT OF THE INVENTION
[0028] FIGS. 1-3 shows a preferred embodiment of the invented foldable stackable multiple washstand that is composed of a basin or bucket ( 1 ), a water supplier ( 2 ), four foldable legs ( 3 ) of the basin sustenance ( 1 ) and four foldable legs ( 4 ) for the sustenance of the water supplier ( 2 ).
[0029] The basin or bucket ( 1 ), as can be noted in FIGS. 4-5 is formed by the union of two longitudinal profiles ( 11 ), two transversal profiles ( 12 ) and a plate body ( 13 ) of boat keel shape welded on to them. In the longitudinal profiles ( 11 ) several primary joining means in joint shape ( 14 , 14 ′) is provided with the sustaining legs ( 3 ) of the basin ( 1 ), and in the top surface of the body ( 13 ), (see FIG. 5 ) the joining and screwing means with the water supplier ( 2 ) is provided, with mentioned means constituted by a first hand railing ( 17 ), a sliding guide ( 15 ) and a prime bar ( 16 ). In the basin or bucket ( 1 ) the drainage ( 18 ) is supplied, through which the residual water goes out, and the hole of the hose path ( 19 ) through which a hose that supplies the water to the water supplier ( 2 ) passes.
[0030] The water supplier ( 2 ) has a straight parallelopipedic rectangular shape in whose base a water access ( 21 ) in provided by means of a threaded female socket. From this water access ( 21 ), through a conventional plumbing system that is located in the inner hollow of the rectangle, water is distributed until each one of the eight faucets/taps ( 22 ) that are distributed by four and four in the longitudinal faces of the mentioned supplier ( 2 ). Also provided in the longitudinal sides is a secondary joint means connected ( 23 ) with the sustaining legs ( 4 ) of the water supplier ( 2 ).
[0031] The fold-out legs ( 3 ) of the sustenance of the basin ( 1 ) are comprised of the retention crossbar ( 31 ) and positioning crossbar ( 32 ). The retention crossbar ( 31 ) turns over the joint ( 14 ) of the first joining means and has incorporated a second handrail ( 33 ) and a second bar ( 34 ). The positioning crossbar ( 32 ) turns on the joint ( 14 ′) of the first joining means and has incorporated in the opposite end of the turning axis of the mentioned joint a drive pin ( 35 ), which slides on the slots ( 36 ) that are formed between the second handrail ( 33 ) and the second bar ( 34 ). The spreading out of the foldable legs ( 3 ) of the basin sustenance ( 1 ) is executed by letting them drop; contrary to this, two combined movements are needed for the mentioned legs to be folded which are done in the following order: first, one has to slightly lift the lateral formed by the transversal profile ( 12 ) and second, by unhooking the drive pin ( 35 ) that will then run through the slots ( 36 ) allowing the retention crossbar ( 31 ) and the positioning crossbar ( 32 ) to turn until reaching a horizontal position. This way of folding is useful so that unwanted folding/bending is avoided, for example due to hits/bumps.
[0032] The sustaining legs ( 4 ) of the water supplier ( 2 ) turn on the second means of jointed unions ( 23 ) located in the water supplier ( 2 ) and incorporates a driving pin ( 41 ) in the opposite end of the joint that slides through by the slots that make up the first handrail ( 17 ) and the first bar ( 16 ) with the help of the sliding guides ( 15 ), which is made of plastic and avoids the grazing between metal parts.
[0033] As can be seen in FIG. 8 , in a column of piled-up washstands, with exception of the washstand located in the top, the occupied space at height level of each washstand is the same for all of them and inferior for the one occupying an already folded washstand. In the preferred embodiment of the invention this length is practically of 95 mm for each unit so, connecting two european pallets ( 50 ) in a way that form a rectangle between the two, over which supporting the washstands and fitting in the washstand located in the lower part with several cubes ( 51 ) will enable the transport of up to 25 units, therefore provided with 200 faucets would occupy a height of approximately 2,5 m in its transport or storage.
[0034] The material used in all the components, excluding the plumbing pipes, is of high quality stainless steel, which gives the equipment a good appearance that does not deteriorate as time passes.
[0035] Additionally, by means of a simple set-up, the washstand may be equipped with other useful devices like mirrors, towel-rails, soap dishes, etc. To do this, two support devices ( 60 ) are fastened onto the water supplier ( 2 ) over which a longitudinal platform for mirrors ( 61 ) preferably made of plastic is fitted into, which in a transversal section has a general “A” shape and that extends on each longitudinal side presenting two sides that have four mirrors ( 62 ) integrated on each side.
[0036] Each supporting device ( 60 ) has an open polygonal shape on the lower part, on which several claws ( 63 ) are provided that are set into the water supplier ( 2 ) and are secured by the lock ( 64 ) that pivots on an axis ( 65 ) and remains hooked by means of a latch ( 66 ). Once both supporting devices ( 60 ) are set in, only the mirror platform ( 61 ) is left to adjust, which is fitted in by pressing on the two supports ( 60 ).
[0037] In alternative embodiments of the actual invention, the dimensions and shapes can be changed, just as the manufacturing process and of course, the material used also can. And so, in these alternative embodiments, the fold-out stackable multiple washstand can be totally or partially made with materials that have sufficient toughness to be able to comply with all the characteristics of the preferred aforementioned embodiment. Taking into account economic objectives of cost reduction, said materials could be of: mid-quality stainless steel, mixes of plastic and resins, high-density polyethylene HDPE or low density LDPE, polypropylenes, polyamides, ABS acrylics or PMMA, PCE polycarbonates, HIPS styrenes, and polyesters. Mentioned materials can be appropriately made by manufacturing processes based on: thermo-shaping, rotational moulding, manual laminating of open-moulding and injection.
[0038] It is evident that the invention herein described and accompanied by a preferred embodiment can be object to variations obvious to experts in the art as far as forms, dimensions and materials are concerned, which, must not be seen as a modification of the field of invention and of the claims that are listed as follows;
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The invention relates to a stackable, folding, multi-unit washstand which can be used simultaneously by several people. The inventive washstand can be installed quickly and easily by means of unfolding. Once folded, the washstands can be stacked, thereby facilitating the transport and storage thereof.
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FIELD OF THE INVENTION
[0001] The present invention relates to a tufting machine with replaceable self-aligning gauge modules and is more particularly concerned with a gauge module with individually replaceable gauge elements which can be readily installed and removed.
BACKGROUND OF THE INVENTION
[0002] Tufting machines are built with precision so that the needles and loopers of the machine are accurately spaced from each other along the needle bar or looper bars. The loopers and needles must be spaced from each other so that the looper bills pass closely adjacent to the needles to engage and hold loops of yarns carried by the needles. When assembling a tufting apparatus, errors in positioning these gauge elements may accumulate as the work progresses. The present invention seeks to establish consistency with these parts across the width of the apparatus, to provide a tufting environment, suitable even for narrow gauge configurations. The present invention also addresses the problem of replacing individual gauge elements that become broken or damaged during tufting. In most modular designs, a broken gauge element requires discarding the entire modular block containing a set of about one to two dozen gauge elements. The present invention allows for quick and efficient replacement of individually damaged gauge elements.
[0003] The idea of replacing individual components of assemblies in tufting machines is not new. In the past, knife holder assemblies have been devised that allow for the replacement of individual knives. The knives were arranged in pre-assembled or modular fashion in a knife holder, each knife holder having a guide mechanism which enables the knives, as a group, to be positioned on a carrying member of a tufting machine and maintained in appropriate alignment. U.S. Pat. Nos. 4,608,934; 4,669,171; 4,691,646; and 4,693,191 illustrate such prior art knife holder assemblies in which parallel knives are disposed in juxtaposition in guide bars which are provided with guides for guiding and then clamping them in appropriate positions on a tufting machine.
[0004] Needles have previously been individually secured in modular gauge blocks as shown in U.S. Pat. No. 4,170,949, and hooks and knives have also been individually secured in gauge parts mounting blocks as shown in U.S. Pat. No. 4,491,078. These designs have used individual clamping screws to hold each gauge element in place. These blocks were not mated with slots on the carrying members and were heavily machined.
[0005] More recently attempts have been made to incorporate needles and loopers into replaceable modular assemblies. U.S. Pat. Nos. RE37,108, 5,896,821, 5,295,450 illustrate such modular gauge assemblies in which the gauge elements are permanently embedded into the modular block. The block is attached to the guide bar with a single screw allowing for removal and replacement of the block. One shortcoming of these modular assemblies is that when a single gauge element breaks the entire modular assembly must be discarded.
SUMMARY OF THE INVENTION
[0006] The present invention includes a modular gauge assembly that attaches to a gauge bar. The gauge bar has a plurality of positioning recesses that allows a detent on an individual modular block to be accurately positioned along the gauge bar. Each modular block typically includes a front surface, a pair of side surfaces opposed to each other, a rear surface opposite to the front surface, and a bottom surface. A tongue, which may or may not be a part of the cast block extends from a bottom or bottom surface of the modular block. The tongue includes a threaded hole which along with a securing screw serves to mount the block to a gauge bar. The threaded hole aligns with the gauge bar receiving hole when the tongue of the modular block is positioned properly with a recess on the gauge bar. When sufficiently tightened, the securing screw holds the modular block to the gauge bar. At least the front surface contains a plurality of spaced parallel slots so that gauge elements may be positioned in the slots with proper spacing in the block. The proximal ends of the gauge elements have apertures recessed therein. The proximal ends of the gauge elements are inserted into the block and secured there by a securing pin that enters the block on one of the opposing side surfaces and passes through the apertures on the proximal ends of the gauge elements. Individual gauge elements can be replaced by demounting the affected block, removing the securing pin and removing the selected gauge element. After the selected gauge element is removed a new gauge element may be re-inserted into the proper vertical slot and secured by the securing pin.
[0007] A plurality of modular blocks are arranged along the surface of the gauge bar and are vertically positioned on the gauge bar by a horizontal surface on the gauge bar or on a guide bar that passes through a guide bar channel on the gauge bar. The width of each block is equal to the distance between the positioning recesses of the gauge bar so that the edges of the blocks abut one another and the blocks are laterally positioned.
[0008] In an alternative embodiment of the present invention the modular gauge assembly attaches to a gauge bar having a plurality of positioning recesses that allows the detent on an individual modular block to laterally position the block on the gauge bar. Each modular block typically includes a front surface, a pair of side surfaces opposed to each other, a rear surface opposite to the front surface, and opposing bottom and top surfaces. The rear surface contains a rectangular tab or detent that includes a threaded hole to receive a securing screw. The threaded hole aligns with the gauge bar receiving hole when the modular block is positioned properly on the gauge bar. When tightened, the securing screw holds the modular block securely to the gauge bar. A plurality of gauge holes extend from the bottom toward the top surface, in some cases passing through the modular block. Gauge elements with proximal ends adopted to be received within the gauge holes may be positioned with proper spacing in the block. Gauge elements that have the proximal end inserted into the block are securely positioned pin-screws that enter the block below the tab on the rear surface. The pin-screws are positioned beneath the tab. In this fashion, the pin-screws can be accessed without removing the modular block from the gauge bar.
[0009] Accordingly, it is an object of the present invention to provide a tufting machine where the gauge elements of the tufting machine are accurately positioned within a modular block assembly.
[0010] Another object of the present invention is to provide in a tufting machine, a system which can facilitate the rapid change over of one or more damaged gauge elements, reducing to a minimum the downtime of the tufting machine.
[0011] Another object of the present invention is to provide in a modular block assembly, a system which can facilitate the rapid change over of individual damaged gauge elements, reducing the cost of repairing broken gauge elements and removing the need to replace entire modular blocks when a single gauge element becomes damaged.
[0012] Other objects, features, and advantages of the present invention will become apparent from the following description when considered in conjunction with the accompanying drawing wherein like characters of reference designate corresponding parts throughout several views.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a fragmentary perspective view of a modular block assembly with single looper modular blocks in place on a gauge bar.
[0014] [0014]FIG. 2 is an exploded perspective view of modular block assembly of FIG. 1 with modular blocks removed from the gauge bar, and one single looper modular block disassembled.
[0015] [0015]FIG. 3 is a perspective view of the rear surface of a modular block of FIG. 1.
[0016] [0016]FIG. 4 is a fragmentary perspective view of a double looper modular block assembly with the modular blocks in place or the gauge bar.
[0017] [0017]FIG. 5 is an exploded perspective view of the modular block assembly of FIG. 4, with modular blocks removed from the gauge bar and one block disassembled.
[0018] [0018]FIG. 6 is a fragmentary perspective view of a modular needle block assembly with the modular blocks in place on a gauge bar.
[0019] [0019]FIG. 7 is an exploded fragmentary perspective view of the modular needle block assembly of FIG. 6 with the modular blocks removed from the gauge bar and one block disassembled.
[0020] [0020]FIG. 8 is a rear perspective view of a modular block of FIG. 6.
DETAILED DESCRIPTION
[0021] The present invention is utilized in a tufting machine of the type generally including a needle bar carrying one or more rows of longitudinally spaced needles and which is supported and reciprocally driven by a plurality of push rods. In the tufting zone, the needles carry yarns which are driven through a backing fabric by the reciprocation of the needles. While penetrating the backing fabric, a plurality of longitudinally spaced hooks cooperate with the needles to seize loops of yarns and thereby form the face of a resulting fabric. In some cases the hooks will cooperate with knives to cut the loops of yarn seized on the hooks and thereby form a cut pile face for the fabric. The present invention is directed to modular units for holding loopers or hooks and for holding needles to facilitate their cooperation during the tufting process.
[0022] Referring in detail to FIG. 1, a modular block assembly 5 is illustrated having a single row of gauge elements 10 , in this case loopers, housed in the modular blocks 15 . The individual gauge elements 10 are fastened to the block 15 by securing pin 20 . As better illustrated in FIG. 2, the securing pin 20 enters the modular block 15 at one of the opposing side surfaces 22 a, 22 b. The gauge bar 25 and guide bar 30 are used in concert to position the individual modular blocks 15 relative to one another. The guide bar 30 slides laterally through channel 35 substantially the entire length of the gauge bar 25 , and engages tab breaks 115 of the modular blocks 15 , as shown in FIG. 3, to vertically align the individual blocks 15 .
[0023] [0023]FIG. 2 illustrates a portion of the modular block assembly 5 with the blocks 15 detached from the gauge bar 25 . The gauge bar 25 has a plurality of vertical recesses 40 . The recesses 40 are crossed by lateral channel 35 so that guide bar 30 fits between the gauge bar 25 and the rear surfaces 45 of the modular blocks 15 . Guide bar 30 creates upper face 31 and lower face 32 which are normal to the side walls of recesses 40 . Theses faces 31 , 32 serve as restraining surfaces. One modular block 15 in FIG. 2 is disassembled and removed from the gauge bar 25 to reveal the spaced parallel slots 50 divided by vertical walls 51 located on the front surface 55 of the block for receiving the proximal ends 75 of the gauge element 10 . The proximal ends 75 of the gauge elements 10 contain apertures such as pin holes 70 . When the gauge elements 10 are positioned in the modular block 15 , the pinholes 70 align with apertures formed in side surfaces of the block such as pin opening 85 . Securing pin 20 is then inserted through the pin opening 85 in one of the opposing side surfaces 22 a, 22 b, and the pin opening 85 for each gauge element 10 to fasten the gauge elements 10 to the block 15 . In modular blocks 15 containing only a single row of gauge elements 10 , a tongue portion 60 extends from the rear surface 45 of the modular block 15 . The tongue 60 forms the detent. The tongue 60 has an opening 90 , as shown in FIG. 3, preferably in the form of a threaded hole which aligns with another hole 100 , located in a gauge bar recess 40 , when the modular block 15 is positioned on the gauge bar 25 . Once a modular block 15 is positioned a securing screw 65 can be inserted through the opening 90 and tightened into the hole 100 on the gauge bar. A modular block 15 , once fixed in place by the securing screw 65 , is prevented from lateral and vertical movement. The screw 65 and vertical recesses 40 resist against horizontal movement while the screw and faces 31 , 32 of the guide bar 25 resist against vertical movement. The fixed position of the blocks 15 insures that the gauge elements 10 remain properly aligned during the tufting process.
[0024] [0024]FIG. 3 shows the rear surface 45 of a modular block 15 having a single row of gauge elements 10 . On the rear surface 45 is an elongated tab 110 that extends vertically from the top 165 of the block to the bottom of the tongue portion 60 of the block. The tab 110 has a horizontal break 115 which as previously described engages with guide bar 30 to vertically position block 15 on the gauge bar 25 . The walls of break 115 are preferably substantially planar and parallel so that a part of the rectangular cross section of guide bar 30 closely fits within the break. The lower segment of the tab 120 contains the opening 90 where the securing screw 65 enters and attaches to a receiving hole 100 in the gauge bar.
[0025] [0025]FIG. 4 illustrates a modular block assembly 5 having three double gauge element modular blocks 130 mounted on the gauge bar 26 . Each modular block 130 contains two gauge element rows 125 . Modular blocks 130 have two apertures such as pin openings 85 a, 85 b that are spaced apart on the side surfaces 22 a, 22 b of the block 130 . Unlike single gauge element blocks 15 , a portion of the double gauge modular blocks 130 rests on top of the gauge bar 26 to vertically position blocks 130 . This is accomplished by pushing the tongue 60 forward to the center of the bottom of the block 135 .
[0026] [0026]FIG. 5 shows an exploded view of modular block 130 containing two rows 125 of gauge elements 11 , 12 . The gauge bar 26 in FIG. 5 has a plurality of vertical recesses 40 . Vertical recesses 40 receive tongues 60 to horizontally position blocks 130 along the gauge bar 25 . Vertical positioning is accomplished by resting part of the bottom surface of gauge blocks 130 on the top surface of gauge bar 25 . The modular block 130 in FIG. 5 is disassembled and removed from the gauge bar 26 to reveal the spaced parallel slots 50 a, 50 b located on the front 55 and rear surface 45 of the block 130 for receiving the proximal ends 75 , 78 of the gauge elements 11 , 12 . The proximal ends 77 , 78 of the gauge elements 11 , 12 contain openings such as pin holes 71 , 72 which when positioned in slots 50 a, 50 b of modular block 130 align with pin openings 85 a or 85 b, respectively. The securing pins 20 a, 20 b are inserted through the pin openings 85 a or 85 b on one of the opposing side surfaces 22 a, 22 b and through pin holes 71 , 72 for each gauge element 11 , 12 to fasten the gauge elements 11 , 12 to the modular block 130 . In the illustrated modular blocks 130 containing two rows 125 of gauge elements 11 , 12 the tongue portion 60 of the modular block 130 extends from the center of the bottom surface 135 . The tongue 60 defines an opening 90 (not shown) which aligns with receiving holes 100 , located in the vertical recesses 40 , when the modular block 130 is positioned on the gauge bar 26 . Once the modular block 130 is positioned a securing screw 65 can be inserted through opening 90 and tightened into a threaded receiving hole 100 . The modular block 130 , once fixed in place by the securing screw 65 , is prevented from lateral and vertical movement. The fixed position of the block 130 insures that the gauge elements 10 remain properly aligned during the tufting process.
[0027] Referring now to FIG. 6, another aspect of the present invention depicts a modular block assembly 5 having a single row of gauge elements, in this case needles 13 , housed in a clamping modular block 140 . FIG. 6 shows four clamping modular blocks 140 attached to the gauge bar 27 . The clamping modular blocks 140 are positioned such that the lower portion 150 of the block 140 extends beneath the gauge bar 27 . This exposed lower portion 150 contains the individual clamping elements, such as screw-pins 145 , shown in FIG. 7, that hold the gauge elements 13 in place in the block 140 . The gauge bar 127 has a horizontal shelf portion 27 a and a vertical portion 27 b which join to form an interior right angle.
[0028] [0028]FIG. 7 illustrates a portion of a modular block assembly 5 with screw-pin modular blocks 140 detached from the gauge bar 25 and one block 140 disassembled. The gauge bar 27 has a plurality of vertical recesses 40 imposed on the front of the gauge bar 27 . As illustrated, the recesses 40 do not extend the entire height of the wall portion 27 b of the gauge bar 27 . Each recess contains a preferably threaded hole 100 which receives a securing screw 65 to attach the block 140 to the gauge bar 27 . The rear surface of the modular block 45 contains a rectangular tab 160 having an opening 90 , shown in FIG. 8, which aligns with the hole 100 , located in the gauge bar vertical recesses 40 . Once the modular block 140 is positioned in the right angle between the shelf portion 27 a and wall portion 27 b , with tab 160 received in a vertical recess 40 , the securing screw 65 can be inserted through the corresponding hole 100 in the wall portion 27 b into the opening 90 in the rectangular tab 160 and tightened to hold the modular block 140 in place. Once fixed in place by securing screw 65 , the modular block 140 is prevented from lateral movement by the action of the tab 160 fitting with the walls of the vertical recess 40 , the screw 65 , and adjacent blocks 140 . Horizontal movement is restored by action of the screw 65 at the bottom of shelf portion 27 a of the gauge bar 27 . The fixed position of the block 140 insures that the gauge elements 10 remain properly aligned during the tufting process.
[0029] [0029]FIG. 7 also depicts a disassembled clamping modular block 140 thereby revealing the spaced parallel gauge element openings 155 which extend from the top surface 165 to the bottom surface 135 of the block 140 . Openings 155 need not extend completely to the top surface 165 for satisfactory operation, however, it is convenient for manufacture. The individual needles 13 are fastened to the block 140 by dedicated clamps such as screw-pins 145 that fix individual gauge elements 10 within the block 140 . Screw pins 145 enter the block 140 at the rear surface 45 of the block 45 on its lower portion 150 . When the block is attached to the gauge bar 25 the screw-pins 145 remain accessible so that individual gauge elements 10 can be removed and replaced.
[0030] [0030]FIG. 8 illustrates the top 165 and rear surface 45 of the block 140 . Gauge element openings 155 can be seen on the top surface 165 of the block 140 . The rectangular tab 160 for positioning the block 140 on the gauge bar 25 is located centrally on the rear surface 45 of the block 140 . The rectangular tab 160 defines the opening 90 which aligns with the holes 100 in vertical recesses 40 and with securing screw 65 fixes the block 140 to the gauge bar 27 . Openings 170 for screw pins 145 are located horizontally along the lower portion 150 of block 140 .
[0031] Although a preferred embodiment of the present invention has been disclosed in detail herein, it will be understood that various substitutions and modifications may be made to the disclosed embodiment described herein without departing from the scope and spirit of the present invention as recited in the appended claims.
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A tufting machine modular gauge assembly that allows damaged or broken gauge elements to be replaced individually. The modular gauge assembly consists of a gauge bar with a plurality of modular blocks removably attached to the bar. The modular blocks are six sided with a detent and fastener mechanism for attaching the block to the gauge bar. The gauge elements may be attached to the block by dedicated screw-pins or by a securing pin that passes through all the gauge elements within a block.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 10/674,862, filed Sep. 30, 2003 now abandoned, which is a continuation-in-part of U.S. patent application Ser. No. 10/222,062, filed Aug. 16, 2002, now U.S. Pat. No. 6,637,050, and a continuation-in-part of U.S. patent application Ser. No. 10/229,533, filed Aug. 28, 2002, now U.S. Pat. No. 6,675,406, which is a continuation of abandoned U.S. patent application Ser. No. 09/593,724, filed Jun 13, 2000. This application is also a continuation-in-part of pending U.S. patent application Ser. No. 10/732,726, filed Dec. 10, 2003, which is a continuation-in-part of U.S. patent application Ser. No. 10/229,533, filed Aug. 28, 2002, now U.S. Pat. No. 6,675,406, which is a continuation of abandoned U.S. patent application Ser. No. 09/593,724, filed Jun. 13, 2000, U.S. patent application Ser. No. 10/732,726 also being a continuation-in-part of U.S. patent application Ser. No. 09/954,420, filed Sep. 17, 2001, now U.S. Pat. No. 6,691,411. The entire disclosures of the above-referenced patents and applications are incorporated by reference herein.
BACKGROUND OF THE INVENTION
In new building construction, plumbers prefer not to install finished closure valves in the bottom of bathtubs, or install finished decorative plate over an overflow outlet of the bathtub until the project is finished because these elements will be often damaged during construction. Further, the plumbing for all outlets needs to be checked for leaks which involves filling a vent for the drain until the water level in the plumbing rises above the bathtub so that the inspector can determine whether any of the plumbing leaks. The bottom drain of the bathtub is plugged and some sort of seal plate is used to block the outlet port during testing.
Existing overflow plates have a center opening. There are either two or four small screw holes in the plate adjacent the center opening wherein two of the holes are used to secure the plate to the plumbing fixture. In some cases, a fitting is used so that the screw hole is located directly in the middle of the access hole that becomes an obstacle during testing. The testing procedure usually involves placing a balloon through the large center opening into a drain pipe located in the wall. The pipe is sealed when the balloon is inflated.
A more recent version of an overflow assembly is shown in the U.S. Pat. No. 5,890,241 to Ball (“Ball”), which is incorporated by reference herein. Ball discloses a flexible diaphragm that is imposed over an overflow drain pipe. A cap is also provided that allows fluid to flow into the overflow pipe. The diaphragm seals the overflow pipe when the system is being tested for leaks. Following the test, the diaphragm is cut or slashed to open the overflow port to allow fluid flow. While this device serves the intended function, it is expensive to make and cumbersome to assemble.
It is, therefore, a principal object of the invention to provide a method and a means for an overflow assembly for bathtubs and the like that will safeguard the overflow system during construction, prepare the overflow system for testing, and facilitate the final installation of bathtub hardware.
A further object of the invention is to facilitate the testing procedure of the overflow system before final installation has taken place, and to permit the assembly of parts without the use of screws, screw holes, and the like.
A still further object of the invention is to provide an overflow fitting that allows a user to install the overflow fitting without using solvent cement.
These and other objects will be apparent to those skilled in the art.
SUMMARY OF THE INVENTION
An overflow system of a bathtub generally includes an overflow port that is associated with a drain pipe. The overflow port includes a threaded flange with a stub shoulder on one end that is fitted onto a circular sleeve. The threaded flange has threads on its outer surface and a thin diaphragm secured to the end thereof opposite the stub shoulder. A large sealing washer cooperates with the outside of the circular flange on the overflow port and extends partially over the threads of the flange. A large internally threaded nut is threadably mounted on the outer end of the threaded flange and compresses the sealing washer against a vertical flange on the overflow port to seal the connection between the threaded flange and the overflow port. A decorative cap is frictionally engaged onto protrusions located on the outer surfaces of the nut. The cap can be removed if needed to permit a plumber to gain access to the diaphragm to cut it open for fluid flow after the plumbing system has been tested for leaks, or put in place after the cut takes place.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial perspective view of a conventional bathtub environment utilizing the invention of this application;
FIG. 2 is a section view taken on line 2 - 2 of FIG. 1 ;
FIG. 3 is a perspective exploded view of an overflow assembly of one embodiment of the present invention;
FIG. 4 is a cross sectional view of the assembled components of FIG. 3 ;
FIG. 5 is a perspective view showing a pierced diaphragm;
FIG. 6 is a sectional view of a conventional bathtub environment utilizing the device of another embodiment of the invention;
FIG. 7 is a side view of the device of the embodiment of the invention shown in FIG. 6 ;
FIG. 8 is a front view of the device of the embodiment of the invention shown in FIG. 6 ;
FIG. 9 is an exploded perspective view of the device of the embodiment of the invention shown in FIG. 6 ;
FIG. 10 is a perspective view of the installation of the embodiment of the invention shown in FIG. 6 ;
FIG. 11 is a perspective view of an overflow plate according to one embodiment of the present invention;
FIG. 12 is a sectional top view of the assembly according to one embodiment of the present invention;
FIG. 13 is a sectional top view of the assembly according to another embodiment of the present invention;
FIG. 14 a is a sectional side view of the assembly according to yet another embodiment of the present invention;
FIG. 14 b is a partial front view of the assembly of FIG. 14 a ; and
FIG. 15 is a sectional side view of the assembly according to yet another embodiment of the present invention.
DETAILED DESCRIPTION
With reference to FIGS. 1 and 2 , a conventional bathroom structure 10 has a floor 12 and a hollow wall 14 with a wall opening 16 therein. A conventional bathtub (“tub”) 18 has sidewalls that 22 extend upwardly from a base 20 as does an end wall 24 . The end wall 24 extends upwardly from a bottom surface 26 , perpendicular to the side walls 22 .
A conventional drain port 28 is located in the bottom surface 26 . A conventional overflow port 30 is located in the end wall 24 ( FIG. 2 ). A vertical drain pipe 34 extends downwardly from drain port 28 and an overflow drain pipe 34 extends downwardly from overflow port 30 . A horizontal pipe 36 connects pipes 32 and 34 . A drain pipe 38 extends downwardly from the junction between pipes 34 and 36 .
A conventional vent pipe 40 is located within the hollow wall 14 . Pipe 42 interconnects the vent pipe 40 and the upper end of overflow drain pipe 34 ( FIG. 2 ). Conventional water supply pipes 44 extend through hollow wall 14 and are connected to valve 46 which is interconnected to conventional control member 48 and faucet 50 .
FIGS. 3 and 4 show a radial flange 52 formed on the upper end of overflow drain pipe 34 and has a center opening or port 54 . Water can flow through center opening 54 into overflow drain pipe 34 . A sleeve 56 extends longitudinally outwardly from the perimeter of opening 54 forming a surface on its inner diameter.
A hollow cylindrical fitting 58 has a hollow cylindrical shoulder 60 on its inner end, a threaded outer surface 62 , and a thin plastic diaphragm 64 sealed across its outer end. The shoulder 60 has an outer diameter that can be manually frictionally inserted within the surface of the inner diameter of sleeve 56 to create sufficient frictional force to resist opposing force applied by fluid pressure.
A pliable sealing ring or washer 66 has a center bore 67 which frictionally receives the exterior surface of fitting 58 to engage the radial flange 52 of port 54 to seal the connection between sleeve 56 and shoulder 60 . The longitudinal thickness of washer 66 is less than the longitudinal thickness of fitting 58 so that some of the threaded surface 62 adjacent the diaphragm 64 is exposed when the washer 66 is mounted on fitting 58 in the position described above. A nut element 68 has a threaded center bore 70 which is compatible with the threaded outer surface 62 of fitting 58 . When the nut element 68 is tightened on threaded portion 62 , the washer 66 is in tight engagement with flange 52 of port 54 . The outer periphery 72 of nut element 68 has a series of radially extending lugs 74 which frictionally detachably engage the inner surface of flange 76 of cap 78 . The nut element 68 can be tightened on washer 66 either as positioned within cap 78 , or before cap 78 and the nut element 68 are engaged. A notch 80 is located in flange 76 and is adapted to receive overflow water from tub 18 when required to do so. Notch 80 is normally in a 6 o'clock position on flange 76 . FIG. 4 depicts the apparatus described above in an assembled state.
It is important to note that diaphragm 64 is of plastic material, as is fitting 58 , and is preferably integrally formed with fitting 58 wherein diaphragm 64 and fitting 58 are one unitary component. The diaphragm 64 is a thin circular plate disk that is joined to fitting 58 by its outer peripheral edge engaging the outer peripheral edge of the fitting 58 . If the two components are not molded as one unitary structure, the diaphragm 64 could be connected by fusing, hermetically sealing, or by otherwise rigidly attaching by its outer peripheral edge to the rearward outer peripheral edges of the fitting 58 by a suitable adhesive. No screws or the like are either required or desired.
A second embodiment of the invention can be seen in FIG. 6 . A one-piece overflow fitting 60 A is shown attached to second vertical drain pipe 34 A. A portion of the overflow fitting 60 A passes through overflow port 30 .
With reference to FIGS. 7-9 , the overflow fitting 60 A is shown that has an overflow pipe 62 A with an inverted L-shape. The overflow pipe 62 A has an elbow portion 65 A which defines an upper end portion 66 A and a lower end portion 67 A. It will be understood that the overflow pipe 62 A may be made of copper, plastic, or any other suitable material.
The upper end portion 66 A has threads 68 A on its outer surface and also has an outer end 70 A. The outer end 70 A defines an inlet 71 A to the upper end portion 66 A of the overflow pipe 62 A. The inlet 71 A is adapted to fit through the bathtub overflow port.
The overflow fitting 60 A also has a lip 74 A extending radially outwardly from an outer surface of the overflow pipe 62 A between the elbow portion 65 A and the upper end portion 66 A. The lip 74 A is spaced from the inlet 71 A to engage an outer surface of the bathtub end wall 24 around the bathtub overflow port 30 , thereby allowing only the upper end portion 66 A to pass through the overflow port 30 .
A thin diaphragm 80 A is sealed to the outer end 70 A of the end portion 66 A. The diaphragm 80 A is a circular membrane and has a diameter that is not less than the diameter of the outer end 70 A of the overflow pipe 62 A. In one embodiment, the diaphragm 80 A is integral with the outer end 70 A and is held to the outer end 70 A only through having been integrally formed therewith. The diaphragm 80 A may be hermetically sealed to the outer end 70 A. The diaphragm 80 A may be composed of plastic material, flexible rubber, or the like. The diaphragm 80 A is composed of a material that is easily punctured or easily removable.
The overflow fitting 60 A further includes a nut element 90 A having threads compatible with the threads 68 A on the upper end portion 66 A of the overflow pipe 62 A. The nut element 90 A removably secures the overflow pipe 62 A to the bathtub 20 by compressing the end wall 24 between the nut element 90 A and the lip 74 A. The nut element 90 A may be a slip nut.
As shown in FIG. 9 , the nut element 90 A has a series of radially extending lugs 92 A along the nut element 90 A outer periphery. These lugs 92 A detachably engage the inner surface of a cap 96 A. The cap 96 A serves to cover the overflow fitting 60 A hardware.
During installation of the overflow fitting 60 A, a washer 94 A may be placed between the upper end portion 66 A of the overflow pipe 62 A and the nut element 90 A. The washer 94 A seals the overflow fitting 60 A to the tub 18 .
In operation, the drainage system comprising the ports 28 and 30 , and pipes 34 , 36 , and 38 are installed as shown in FIG. 2 . The vent pipe 40 and connecting pipe 42 are also installed.
In the conventional testing procedure, the port 28 is plugged in any convenient manner. The fitting 58 with diaphragm 64 is installed into drain pipe 34 as described above so there is no fluid access to the upper end of pipe 34 either inwardly or outwardly through overflow port 30 . The vent pipe 40 is charged with water at some elevation above connecting pipe 42 so that the building inspectors can check to see if there are any leaks in the system. Having determined that there are no leaks, the water is purged from the system. The plumber can then approach overflow port 30 , (because cap 78 is not yet installed) and by using knife 82 or the like, cuts can be made in diaphragm 64 leaving a cutout portion 84 as shown in FIG. 5 .
Similarly, in operation the overflow fitting 60 A is attached to the second vertical drain pipe 34 A already plugged by the diaphragm 80 A as described above, so there is no fluid access to the upper end of second vertical drain pipe 34 A either inwardly or outwardly out of the overflow port 30 . The vertical vent pipe 40 is charged with water at some elevation above connecting pipe 42 so that it can be determined if there are any leaks in the system.
With reference to FIG. 10 , having determined that there are no leaks, the water is purged from the system. The plumber can then approach overflow port 30 , and by using a cutting device 100 A, such as a knife of any other sharp object, cuts 82 A can be made in the diaphragm 80 A. This can be quickly and easily done without disassembling any of the structure of overflow fitting 60 A. Any valve linkage elements required may be installed through cuts 82 A, and any cap (such as cap 96 A shown in FIG. 9 ) or cover for the overflow port 30 may be placed over the overflow pipe 62 A upper end portion 66 A.
Referring now to FIGS. 11 and 12 , an alternate embodiment of the invention is shown wherein an overflow plate 110 is modified to slide vertically into position between the surface of the tub 112 and the retainer nut 114 . The overflow plate 110 has a first section, which comprises a rim 118 and a lip 120 extending inwardly therefrom, and a second section, which does not comprise a rim or a lip, thereby forming a recessed portion. The modified overflow plate 110 engages a notched surface 124 on at least a portion of the retainer nut 114 as shown in FIG. 12 . The notch 124 may be incorporated along the entire circumference of the nut 114 as well. The overflow plate 110 according to this embodiment slides along an outward facing surface of the overflow plate 130 and engages the retainer nut 114 along the notched surface 124 . The notched surface 124 is located along a lateral face of the retainer nut 114 . The thickness of the lip 120 and the width of the notched surface 124 are such that the overflow plate 110 forms a near perfect fit once it engages the notched surface 124 , thereby firmly holding the overflow plate 110 in place between the retainer nut 114 and the surface of the tub 112 .
As shown in FIG. 13 , the notched surface 124 of the retainer nut 114 may be located nearly concentrically about the thickness of the retainer nut 114 . According to this embodiment, the overflow plate 110 may be engaged with the centrally located notched surface 124 of the retainer nut 114 , by sliding the overflow plate 110 in a downward direction to engage the lip 120 of the overflow plate 110 . According to this embodiment, the overflow plate 110 is held in place by engaging both sides of the retainer nut 114 surrounding the notched surface 124 , thereby holding the overflow plate 110 firmly in place over the overflow port 130 .
Further alternative embodiments are shown in FIGS. 14 a , 14 b and 15 , that show a removable seal 142 that may be selectively inserted or removed from the overflow assembly to prevent or permit water to flow through the overflow assembly 130 . The removable seal 142 , according to this embodiment, is such that it may be inserted into a slot 144 formed in the threaded portion 134 of the overflow assembly 130 , thereby sealing the overflow valve 130 , or removed from the slot 144 , thereby exposing the overflow port 130 without requiring a knife or other tool to cut out the seal 142 and potentially requiring the plumber to replace the seal 142 at a later time.
Referring now in detail to FIGS. 14 a and 14 b , according to one embodiment the seal 142 is inserted into a slot 144 formed within the threaded portion 134 of the overflow valve 130 , such that the seal 142 resides in a vertical plane within the threaded portion 134 of the overflow assembly 130 . The diameter seal 142 is substantially congruent with the diameter of the threaded portion 134 of the threaded portion 134 overflow valve 130 , as best shown in FIG. 14 b . The seal 142 may have a pull ring 148 , which extends outside the slot 144 formed in the threaded portion 134 of the overflow assembly 130 so that the plumber may readily grasp the pull ring 148 and remove the seal 142 from the slot 144 in the threaded portion 134 of the overflow valve.
In yet another embodiment, the seal 142 b is formed in a slot 144 b that is formed in the retainer nut 150 , which may be modified to extend outwardly from the outer most surface of the threaded portion 134 overflow assembly 130 , as shown in FIG. 15 . The seal 142 b according to this embodiment operates in the same fashion is that described in relation between FIGS. 14 a and 14 b , in that the seal 142 b may be removed or inserted at the discretion of the user.
It is therefore seen from the description above and accompanying drawing figures that this invention eliminates any need to seal the overflow pipe 34 , 60 A even after the overflow pipe 60 A has been attached to the second vertical drain pipe 34 A. The invention also eliminates any need to remove sealing components from the overflow port 30 after the testing procedure has taken place. In addition, the invention allows a user to install an overflow fitting 58 , 62 A without using solvent cement. This invention also facilitates the testing procedure and reduces the time needed to seal the overflow port 30 , and then to open the diaphragm 64 , 80 A for possible fluid flow.
It is therefore seen this invention will achieve at least all of its stated objectives.
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An overflow system in the bathtub has an overflow port and has a drain pipe in connection with the overflow port. A threaded flange has a stub shoulder on one end which is fitted into a circular sleeve on the overflow port. The threaded flange has exterior threads on its outer surface and a thin diaphragm secured to the end thereof opposite to the stub shoulder. A large sealing washer embraces the outside of the circular flange on the overflow port and extends partially over the threads of the threaded flange. A large internally threaded nut is threadably mounted on the outer end of the threaded flange and compresses the sealing washer against a vertical flange on the port to seal the connection between the threaded flange and the port. A decorative cap is frictionally snapped into engagement with protrusions on the outer surface of the nut. The cap can be removed when needed to permit the plumber to gain access to the diaphragm to cut it open for fluid flow after the system has been tested for leaks, or put in place after the cut takes place.
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RELATED U.S. APPLICATION DATA
This application claims the benefit of Provisional Application 60/561,104, filed on Apr. 8, 2004.
BACKGROUND OF THE INVENTION
This invention relates to boat attachments, and in particular, to boat-mounted, collapsible tray useful as a work station for chumming, bait rigging and filleting during fishing operations.
Most boats used by sports fishermen have no facilities for cleaning fish. The after decks and gunwales of sportfishing boats are often not flat, and therefore cannot properly accommodate an ordinary tray set thereon. Even when said surfaces are flat they are seldom of the proper working height.
Heretofore, typical fish cleaning devices have several drawbacks. Most devices use rigid, deep trough structures to hold the fish which are large and bulky and take up valuable storage area when not in use. In addition, such devices cannot be used on all gunwales and hull designs. Hand rails, molding and ornament designs along the top surface of the gunwale often prevent these devices from being properly attached to the gunwale.
It is known in the prior art for fisherman to use a flat bait cutting board to support bait while it is being cut. It is preferred that the bait cutting board be placed at a convenient height to that the fisherman does not have to bend over to use it. However, as stated above, it is not always easy to find an ideal location to use a conventional bait cutting board. Also, when a conventional bait cutting board is placed in a location where unwanted parts of the bait can be conveniently swept from the bait cutting board, there is usually no way to secure the bait cutting board and it is subject to loss overboard.
SUMMARY OF THE INVENTION
It is a primary object of this invention to provide for commercial and non-commercial anglers alike a suitable work station for chumming, bait rigging and filleting during day to day fishing excursions or weekend outings. The present invention provides a collapsible work station. Functionally designed to be ergonomically correct, the present invention work station stance is at proper height when in use and easily folded away when not in use.
Three locking hinges are used to ensure the work station is secure, taking the weight of the fisherman's work and keeping the station down in the wind. The hinges rotate and lock in place. The work station is supported on a telescoping leg, capped with a thick rubber boot to protect the boat deck. A quick release clamp snaps open and shut with the flick of a thumb, firmly locking the leg in place.
The work station fits most leaning posts with fiberglass backs and whale tails, and accommodates a wide range of whale tail tube sizes. In larger applications such as charter boats, the work station may be mounted directly to a gunnel wall or any flat or tubular surface.
These together with other objects of the invention, along with various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed hereto and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a work station constructed according to the invention.
FIG. 2 is an invention mount assembly.
FIG. 3 is an exploded view of a mount assembly.
FIG. 4 is a side view of the support plate subassembly.
FIG. 5 is a view of a conical spring.
FIG. 6 is a side view of a leg hinge subassembly.
FIG. 7 is an invention leg assembly.
FIG. 8 is an exploded view of a leg assembly.
FIG. 9A is a perspective view of a clamp assembly.
FIG. 9B is an exploded view of the clamp assembly of FIG. 9A .
FIG. 9C is another perspective view of a clamp assembly.
FIG. 9D is an exploded view of the clamp assembly of FIG. 9C .
FIG. 10 is a front view of the leg assembly with leg tubes.
FIG. 11 is a perspective view of a clip element.
FIG. 12 is a top view of a locking clamp.
DETAILED DESCRIPTION OF INVENTION
Referring to the drawings in detail wherein like elements are indicated by like numerals, there is shown a work station 1 constructed according to the principles of the invention. The work station 1 is comprised of workboard 10 supported by two mount assemblies 20 and a leg assembly 80 . The workboard 10 is planer, and preferably has a generally rectangular shape. The workboard 10 has an upper work surface 11 , an opposite lower support surface 12 , and a perimeter edge 13 . An upwardly extending flange 14 may be formed or attached to all or a portion of the perimeter edge 13 . The workboard 10 is preferably made from an ultraviolet-stabilized, high density polyethylene and is preferably ½ inch thick. The workboard 10 resists deterioration from damaging ultraviolet radiation; is easy to clean; and is stain resistant.
Each mount assembly 20 is comprised of a backing plate 21 , a hinge subassembly 30 and a support plate subassembly 50 . The backing plate 21 has a generally rectangular shape and lies in a general vertical plane. The backing plate 21 has a flat mounting surface 22 , an opposite holding surface 23 , a top edge 24 , an opposite bottom edge 25 , and two opposite side edges 26 . Four apertures 27 are formed in the backing plate, said apertures extending from the holding surface 23 through the mounting surface 22 . The apertures 27 are located near to a junction of the top edge and a side edge, and to a junction of the bottom edge and a side edge. The holding surface 23 has a central groove 28 formed horizontally across its face, said groove extending from side edge 26 to side edge 26 .
The hinge subassembly 30 is comprised of a generally rectangular hinge plate 31 lying in a general vertical plane. The hinge plate 31 has a hinge surface 32 , an opposite gripping surface 33 , a top edge 34 , an opposite bottom edge 35 , and two opposite side edges 36 . Four apertures 37 are formed in the hinge plate, said apertures extending from the gripping surface 33 through the hinge surface 32 . The apertures 37 are located near to a junction of the top edge and a side edge, and to a junction of the bottom edge and a side edge. The gripping surface 33 has a central groove 38 formed horizontally across its face, said groove extending from side edge 36 to side edge 36 .
Extending horizontally and centrally from the hinge plate hinge surface 32 is a hinge holding element 40 comprised of a generally rectangular portion 41 terminating in a cylindrical element 42 , said rectangular portion 41 having a longitudinal axis defined by said cylindrical element 42 and said hinge plate hinge surface 32 , said rectangular portion longitudinal axis being perpendicular to said hinge plate 31 . The rectangular portion 41 has a rectangular cross section. The cylindrical element 42 has a flat side 43 from which a cylindrical side wall 44 extends horizontally toward a toothed side 45 . The cylindrical element sides 43 , 45 have vertical, radial planes parallel to each other and perpendicular to the plane of the hinge plate hinge surface 32 . The cylindrical element 42 has a central aperture 46 extending from the flat side 43 through the toothed side 45 . Surrounding the central aperture 46 is a circular channel 49 extending from the toothed side 45 toward but not reaching the flat side 43 . The toothed side 45 has a plurality of radial teeth 47 extending from said circular channel 49 to a side perimeter 48 defined by said side wall 44 . The cylindrical element 42 has a thickness defined as the distance between the cylindrical element flat side 43 and toothed side 45 , said cylindrical element thickness being approximately one-half the cross sectional width of the rectangular portion 41 , said rectangular portion cross sectional width being defined as the distance between opposite rectangular portion sides.
The support plate subassembly 50 is comprised of a generally flat, rectangular holding plate 51 lying in a general horizontal plane. The holding plate 51 has a flat upper surface 52 , an opposite flat bottom surface 53 , two opposite long side edges 54 , and two opposite short side edges 55 . Four apertures 56 are formed in the holding plate, said apertures extending from the upper surface 52 through the bottom surface 53 . The apertures 56 are located near to a junction of a long edge and a side edge.
Extending horizontally and centrally from one of the holding plate short edges 55 ′ is a support plate holding element 60 comprised of a generally rectangular portion 61 terminating in a cylindrical element 62 , said rectangular portion 61 having a longitudinal axis defined by said cylindrical element 62 and said holding plate short edge 55 ′, said rectangular portion longitudinal axis being perpendicular to said holding plate short edge 55 ′. The rectangular portion 61 has a rectangular cross section. The cylindrical element 62 has a flat side 63 from which a cylindrical side wall 64 extends horizontally toward a toothed side 65 . The cylindrical element sides 63 , 65 have vertical, radial planes parallel to each other and perpendicular to the plane of the holding plate 51 . The cylindrical element 62 has a threaded central aperture 66 extending from the flat side 63 through the toothed side 65 . Surrounding the central aperture 66 is a circular channel 69 extending from the toothed side 65 toward but not reaching the flat side 63 . The toothed side 65 has a plurality of radial teeth 67 extending from said circular channel 69 to a side perimeter 68 defined by said side wall 64 . The cylindrical element 62 has a thickness defined as the distance between the cylindrical element flat side 63 and toothed side 65 , said cylindrical element thickness being approximately one-half the cross sectional width of the rectangular portion 61 , said rectangular portion cross sectional width being defined as the distance between opposite rectangular portion sides.
Each mount assembly 20 is attached to the workboard 10 by attaching each support plate subassembly holding plate 51 to the workboard 10 , wherein a holding plate upper surface 52 is positioned against the workboard lower support surface 12 adjacent a workboard perimeter edge 13 . Four fasteners 57 are inserted into the holding plate apertures 56 extending into and fixedly attaching to the workboard lower support surface 12 .
The support plate assembly 50 is joined to the hinge subassembly 30 by joining the support plate holding element cylindrical element toothed side 65 with the hinge subassembly holding element cylindrical element toothed side 45 in a toothed engagement. A conical spring 70 is inserted into the support plate holding element circular channel 69 . A knob 71 with a threaded protrusion 72 is inserted into the hinge holding element central aperture 46 , threaded protrusion first through the flat side 43 , past the toothed side 45 , through the conical spring 70 , into threaded engagement with the support plate holding element cylindrical element threaded central aperture 66 .
Each mount assembly 20 may be directly attached to a flat surface by fasteners inserted through the hinge plate apertures 37 directly into the flat surface. Alternatively, each mount assembly may be attached to a tube 2 , such as a leaning post tube wherein the mount assembly backing plate holding surface central groove 28 and hinge subassembly hinge plate gripping surface central groove 38 form a sandwich arrangement about the tube 2 . Fasteners are inserted through the backing plate apertures 27 and hinge plate apertures 37 , snugly holding both plates 21 , 31 in position about the tube 2 .
The leg assembly 80 is comprised of a leg mounting plate 81 , a holding element 90 , and a leg hinge subassembly 100 . The leg mounting plate 81 has a hinge surface 82 , an opposite flat mounting surface 83 , a top edge 84 , an opposite bottom edge 85 , and two opposite side edges 86 . Four apertures 87 are formed in the mounting plate, said apertures extending from the mounting surface 83 through the hinge surface 82 . The apertures 87 are located near to a junction of the top edge and a side edge, and to a junction of the bottom edge and a side edge.
Extending horizontally and centrally from the hinge surface 82 is a hinge holding element 90 comprised of a generally rectangular portion 91 terminating in a cylindrical element 92 , said rectangular portion 91 having a longitudinal axis defined by said cylindrical element 92 and said hinge surface 82 , said rectangular portion longitudinal axis being perpendicular to said leg hinge plate 81 . The rectangular portion 91 has a rectangular cross section. The cylindrical element 92 has a flat side 93 from which a cylindrical side wall 94 extends toward a toothed side 95 . The cylindrical element sides 93 , 95 radial planes parallel to each other and perpendicular to the plane of the hinge surface 82 . The cylindrical element 92 has a central aperture 96 extending from the flat side 93 through the toothed side 95 . Surrounding the central aperture 96 is a circular channel 99 extending from the toothed side 95 toward but not reaching the flat side 93 . The toothed side 95 has a plurality of radial teeth 97 extending from said circular channel 99 to a side perimeter 98 defined by said side wall 94 . The cylindrical element 92 has a thickness defined as the distance between the cylindrical element flat side 93 and toothed side 95 , said cylindrical element thickness being approximately one-half the cross sectional width of the rectangular portion 91 , said rectangular portion cross sectional width being defined as the distance between opposite rectangular portion sides.
The leg hinge subassembly 100 is comprised of a tubular element 101 having a proximal end 102 and a distal end 103 , said proximal and distal ends defining a tubular element longitudinal axis. The tubular element proximal end 102 is connected to a cylindrical element 104 . The cylindrical element 104 has a flat side 105 from which a cylindrical side wall 106 extends toward a toothed side 107 . The cylindrical element 104 has a threaded central aperture 108 extending from the flat side 105 through the toothed side 107 . Surrounding the central aperture 108 is a circular channel 109 extending from the toothed side 107 toward but not reaching the flat side 105 . The toothed side 107 has a plurality of radial teeth 110 extending from said circular channel 109 to a side perimeter 111 defined by said side wall 106 . The cylindrical element 104 has a thickness defined as the distance between the cylindrical element flat side 105 and toothed side 107 , said cylindrical element thickness being approximately one-half the cross sectional diameter of the tubular element 101 .
The holding element 90 is joined to the leg hinge subassembly 100 by joining the holding element cylindrical element toothed side 95 with the tubular element cylindrical element toothed side 107 in a toothed engagement. A conical spring 112 is inserted into the tubular element cylindrical element circular channel 109 . A knob 113 with a threaded protrusion 114 is inserted into the holding element cylindrical element central aperture 96 , threaded protrusion first through the flat side 93 , past the toothed side 95 , through the conical spring 112 , into threaded engagement with the tubular element cylindrical element threaded central aperture 108 .
The leg hinge assembly tubular element 101 has a cylindrical wall 115 extending from said proximal end 102 to said distal end 103 . The tubular element cylindrical wall 115 has an aperture 116 formed therein. The tubular element distal end 103 is inserted into a first hollow leg tube 120 . The first leg tube 120 has a proximal end 121 , a distal end 122 , a cylindrical side wall 123 extending from the proximal end 121 to the distal end 122 , an exterior side wall surface 124 , said side wall, proximal end and distal end defining a first leg tube hollow interior 125 . The first leg tube cylindrical side wall 123 has an aperture 126 formed therein. The tubular element distal end 103 is inserted through the first leg tube proximal end 121 into the first leg tube interior 125 . The tubular element aperture 116 is aligned with said first leg tube aperture 126 . A fastener 127 is inserted through the apertures 116 , 126 thereby fixedly fastening the tubular element 101 and first leg tube 120 together.
The leg assembly 80 includes a second leg tube 150 having a proximal end 151 , a distal end 152 , a cylindrical side wall 153 extending from the proximal end 151 to the distal end 152 , an exterior side wall surface 154 , said side wall, proximal end and distal end defining a first leg tube hollow interior 155 . The second tube proximal end 151 is inserted through the first leg tube distal end 122 into the first leg tube interior 125 in telescopic engagement. The second leg tube distal end 152 terminates in a rubber footing 4 to protect the boat deck 3 .
A clamp assembly 130 holds the first leg tube 120 in position along the second leg tube exterior side wall surface 154 and is positioned adjacent the first leg tube distal end 122 . The clamp assembly 130 is comprised of a clip element 131 in engagement with a locking clamp 140 . The clip element 131 has an elongated body portion 132 terminating in two ends 133 , said clip element body portion 132 being bent into a circular shape adapted to fit about the leg tube exterior surface 124 , said ends 133 protruding radially away from the circular body portion 132 in a parallel relationship. Each end 133 has an aperture 134 formed therein, said end apertures 134 being parallel with each other. One of said ends 133 ′ has a groove 135 formed on its outer surface.
The locking clamp 140 is an elongated, curved element having an outer convex surface 141 , an concave inner surface 142 , a rounded gripping end 143 and a holding end 144 , said ends defining an elongated locking clamp axis. The holding end 144 is formed into two parallel rings 145 , said rings having a central axis perpendicular to the locking clamp axis. The rings 145 each have off-centered central openings 146 . A cylindrical plug 147 is frictionally inserted into the ring openings 146 . The cylindrical plug 147 has a radial aperture 148 formed therein along an approximate central diameter. A fastener 136 is inserted through the clip element apertures 134 into the plug aperture 147 . The locking clamp rings 145 are positioned against the clip element groove 135 . Because of the off-center ring openings 146 , the locking clamp 140 has a greater ring density when the clamp lays against the leg tube side wall 123 . This greater density provides a locking force holding the leg tube 120 in a desired position along the tubular element 101 .
It is understood that the above-described embodiment is merely illustrative of the application. Other embodiments may be readily devised by those skilled in the art which will embody the principles of the invention and fall within the spirit and scope thereof.
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A collapsible work station. Three locking hinges are used to ensure the work station is secure. The hinges rotate and lock in place. The work station is supported on a telescoping leg, capped with a thick rubber boot to protect the boat deck. A quick release clamp snaps open and shut with the flick of a thumb, firmly locking the leg in place.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to managing locks to assets in distributed data storage systems such as file systems and databases.
2. Description of the Related Art
Distributed file systems are used to provide data sharing in distributed computer systems. Such systems centralize data storage, which improves the scalability and manageability of data access control. Moreover, centralized data storage also facilitates, among other things, easier storage device replacement and data backups, as compared to systems in which data storage is fragmented among local storage devices of many computers. It is to be understood that while, for disclosure purposes, the present discussion focuses on file systems, the principles set forth herein apply equally to other distributed data storage systems, such as distributed database systems.
To synchronize data access such that users share consistent views of shared data, requests from users to read and write data typically are sent to a central file server. The file server then manages access to the data using “locks” to ensure, e.g., that one user is not updating shared data by writing to it while another user might read an out-of-date version of the same data. Thus, users use locks to synchronize access to a distributed resource, and a lock comes with a guarantee as the actions the user can take under that lock and the actions that the lock prohibits other users from performing.
Two main components of locking schemes exist, namely, the locking mode (defining what actions that a lock permits and prevents) and locking protocol (defining who holds a lock, how it is granted, and how it is ceded back). The present invention is directed to methods for dynamically determining lock compatibility in systems using preemptible lock protocols, non-preemptible lock protocols, and most preferably the semi-preemptible lock protocol disclosed in related IBM case no. AM9-99-0079.
Heretofore, to determine whether a requested lock is compatible with outstanding locks, lock compatibility tables have been used. Essentially, a lock compatibility table is a matrix which can be accessed which indicates, for each type of lock, what other locks are compatible with it. As recognized by the present invention, when many combinations of locks are possible the compatibility tables can become excessively large because the size of the table grows with the square of the number of locks. The present invention has recognized the inherent scalability problem of compatibility tables and has provided the solutions noted below.
SUMMARY OF THE INVENTION
A general purpose computer is programmed according to the inventive steps herein to dynamically evaluate lock compatibility in a distributed storage system. The invention can also be embodied as an article of manufacture—a machine component—that is used by a digital processing apparatus and which tangibly embodies a program of instructions that are executable by the digital processing apparatus to execute the present logic. This invention is realized in a critical machine component that causes a digital processing apparatus to perform the inventive method steps herein.
The invention can be implemented by a computer system including at least one general purpose client computer, at least one general purpose server computer, and a distributed data storage system accessible to at least the client computer. The system also includes logic that can be executed by the client computer for undertaking method acts to dynamically evaluate lock compatibility. The method acts undertaken by the client computer include determining whether to grant a system access lock without using a lock compatibility table, with the access lock pertaining to at least one asset in the storage system.
The preferred system uses at least one algorithm, preferably an equation, that is executed to determine lock compatibility. The preferred algorithm is based on respective sets of access privileges granted by at least two locks, and on respective sets of sharing privileges restricted by the two locks. More specifically, a summary string of outstanding locks is accessed, with the summary string defining a first set P S of protected access modes and a first set D S of restricted access modes, and with the requested lock defining a second set P R of protected access modes and a second set D R of restricted access modes. The algorithm determines whether the intersection of at least one of: the first set P S of protected access modes and second set D R of restricted access modes, and the second set P R of protected access modes and first set D S of restricted access modes. More specifically still, the requested lock is granted if (P R ∩D S =0)(D R ∩P S =0). If desired, an upgrade lock can be determined that is represented by a union of outstanding and requested protected modes and outstanding and requested restricted modes.
In another aspect, a computer system includes at least one general purpose server computer, at least first and second general purpose client computers, and a distributed data storage system accessible to at least the client computers. Logic is executable by the server computer for undertaking method acts to manage access to assets in the storage system. These method acts include receiving a request for a first access lock from the first client computer, and determining at least whether the first lock is compatible with a second lock associated with the second client computer based on a bitwise evaluation of respective first and second sets of access privileges and sharing privileges associated with the first and second locks. The request is granted if the first lock is compatible with the second lock. Otherwise, the second lock is demanded.
In yet another aspect, a computer program device is disclosed that includes a program of instructions for evaluating a request for a requested lock. The program includes computer readable code means for determining whether to grant the requested lock without using a lock compatibility table, the requested lock pertaining to at least one asset in the storage system.
In still another aspect, a computer-implemented method is disclosed for managing access among plural client computers to assets in a distributed data storage system associated with at least one server computer. The method includes issuing locks to client computers, with the locks being conditions precedent for the grant of a file lock to open a file. The locks are relinquished upon demand of the server computer when no associated file lock is invoked. The issuing act is based on at least one of: first and second sets of access privileges pertaining to first and second locks, respectively, and first and second sets of sharing privileges restricted by the first and second locks, respectively.
The details of the present invention, both as to its structure and operation, can best be understood in reference to the accompanying drawings, in which like reference numerals refer to like parts, and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing the system of the present invention;
FIG. 2 is a table showing the preferred lock data structure;
FIG. 3 is a flow chart showing the logic of the server in evaluating a requested access lock;
FIG. 4 is a flow chart showing the logic of the server in granting a requested access lock;
FIG. 5 is a flow chart showing the logic of a client in evaluating a requested local lock; and
FIG. 6 is a flow chart showing the logic of a client in processing a server demand for an access lock.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to FIG. 1 , a system is shown, generally designated 10 , for managing data access in a distributed data storage system, such as a storage area network (SAN) having associated client computers and at least one server computer. As shown, the system 10 can include a cluster of server computers, and the network can include plural storage disks and tapes and other storage devices. One or more of the disks can be “local” to a client computer, i.e., the client computer manages one or more disks as though the disks were local to the client computer.
In one intended embodiment, the computers of the present invention may be personal computers made by International Business Machines Corporation (IBM) of Armonk, N.Y., or the computers may be any computer, including computers sold under trademarks such as AS400, with accompanying IBM Network Stations. Or, the computers may be Unix computers, or OS/2 servers or Windows NT servers, or IBM workstations or IBM laptop computers.
The flow charts herein illustrate the structure of the logic executed by the computers of the present invention as embodied in computer program software. Those skilled in the art will appreciate that the flow charts illustrate the structures of logic elements, such as computer program code elements or electronic logic circuits, that function according to this invention. Manifestly, the invention is practiced in its essential embodiment by a machine component that renders the logic elements in a form that instructs a digital processing apparatus (that is, a computer) to perform a sequence of function steps corresponding to those shown.
In other words, the flow charts may be embodied in a computer program that is executed by a processor within the computers as a series of computer-executable instructions. These instructions may reside, for example, in a program storage device 12 of the computers. The program storage device 12 may be RAM of the computers, or a magnetic or optical disk or diskette, DASD array, magnetic tape, electronic read-only memory, or other appropriate data storage device. In an illustrative embodiment of the invention, the computer-executable instructions may be lines of compiled C −− compatible code.
To better understand the flow charts described below that illustrate the present invention, reference is first made to FIG. 2 . As a preferred but non-limiting example of the types of data structures that can be used in the present invention, attention is now directed to FIG. 2 , which shows a preferred data structure 14 for evaluating lock requests without iteration. Sharing restrictions and protected access modes are summarized in binary form in a summary string 16 . The data 20 structure 14 also allows the server to find all locks that must be demanded, without searching, and the structure 14 does not asymptotically increase the space cost. The summary string 16 advantageously makes provision for locks that are compatible yet not strength-related, and operates correctly even when outstanding locks exist that cannot be represented by a single lock.
Additionally, the structure 14 further includes a list 18 of outstanding locks for facilitating calculation of the summary string 16 . A respective bit vector 20 represents each lock. For a locking system with “k” unique access modes, each bit vector 20 contains 2 k bits. The first “k” bits correspond to the set of protected access modes “P i ”, i=1, . . . ,k that the lock protects, with a “1” indicating that the access mode represented by the bit position is protected, whereas the second “k” bits correspond to the set of restricted access modes “D i ”, i=1, . . . ,k that the lock does not permit to be concurrently held, with a “I” indicating that no other lock can protect the mode represented by the bit position.
Each bit vector 20 has an associated lock identifier 22 that is used in processing lock requests. If desired, the lock identifiers 22 can be maintained using extendible hashing for scalability and fast lookup. In any case, it may now be appreciated that the summary string 16 is the union of all protected access modes and the union of all prohibited concurrently held modes as defined by the bit strings 20 in the list 18 . Accordingly, a requested lock L R is compatible with all outstanding locks in the list 18 if it shares all modes protected by the summary string 16 and the summary string 16 shares all modes the requested lock protects, i.e., a requested lock L R =<P R , D R > is compatible with the summary string 16 =<P S , D S > representing outstanding locks iff (P R ∩D S =0)(D R ∩P S =0), equivalently (P R D S )(P S D R )=0, wherein ∩ is the intersection operator, is the logical “and” operator, and is the logical “or” operator.
In addition to the list 18 and summary string 16 , the structure 14 includes a bitlock list 24 to aid in processing lock requests and efficiently maintaining the summary. For each bit in the summary string 16 , the bitlocks list 24 contains a list of the locks (by identifiers 22 ) in the outstanding list 18 that set that bit high. The bitlocks list 24 is used to determine which locks must be demanded when a requested lock is not compatible with the current lock state. Also, each lock in the outstanding list 18 points to locations in the bitlocks list 24 in which the lock appears, such that when a lock is released, the pointers are used to quickly unlist the lock from the bitlocks list 24 .
With the above principles in mind, FIG. 3 shows the server logic that is executed when a request for an access lock L R is received by the server. Commencing at block 24 , the request is received, and then at decision diamond 28 the server determines whether the requested lock is compatible with all outstanding locks by undertaking the bitwise comparisons disclosed above between the requested lock and the summary string 16 . If the requested lock is compatible, it is granted at block 30 using the logic of FIG. 4 .
On the other hand, if the requested lock is incompatible, outstanding incompatible locks are demanded at block 32 using the bitlock list 24 (FIG. 2 ). Specifically, for the “high” bits that caused the test at decision diamond 28 to fail, the locks identified in the bitlock list 24 for those bits are demanded.
Moving to decision diamond 34 , it is determined whether any demands are refused by the client computers in the system 10 . If not, the lock is granted at block 30 ; otherwise, the lock request is denied at block 36 .
FIG. 4 shows that when a lock is granted, at block 38 it is registered in the data structure 14 by adding it to the list 18 of outstanding locks. Also, at block 40 the new lock's contribution to the summary string 16 is determined in accordance with the disclosure above, and the summary string 16 is updated accordingly. The requisite entries into the bitlocks list 24 for the new lock are then made at block 42 . It is to be understood that when a lock is released, its entry in the outstanding list 18 is removed, all of its references in the bitlock list 24 are removed and, if an entry in the bitlock list 24 becomes empty as a result, the corresponding bit in the summary string 16 is set low.
In discussing the client-side algorithms of FIGS. 5 and 6 , it is to be understood that lock upgrades and lock downgrades are treated as combinations of release and request. That is, an upgrade is treated as a release followed by a request for a stringer lock, (with the caveat that if the attempted upgrade fails the released lock is reinstated), while a downgrade is likewise a release followed by a request (but without checking outstanding locks) for a newer, weaker lock.
FIG. 5 shows the logic executed by a client computer when a local demand for a local lock L R is received from a process local to the client. It is to be appreciated that a client obtains an access lock from the server and under that access lock issues local locks as needed. It is to be further understood that each client maintains a data structure for its local locks that is similar to the system data structure 16 shown in FIG. 2 that is maintained by the system server.
First, at decision diamond 44 it is determined whether the requested lock L R is compatible with other local open instances, the modes of which are summarized in a local summary string. Thus, the above-disclosed compatibility equation is used with the summary string bits being embodied by the local summary. If the lock is not compatible with other open instances the request is denied at block 46 .
If, however, the requested lock is compatible with other local open instances at the client, the logic moves to decision diamond 48 to determine whether the lock can be granted under the current access lock L H held by the client. In the preferred embodiment the following test is used. If P R ∩-P H =0D R ∩D H =0, the requested local lock L R can be granted under the held access lock L H at block 50 . The lock is then added to the client's local data structure at block 52 .
If it is determined, however, at decision diamond 48 that the lock cannot be granted under the current access lock L H held by the client, the logic moves to block 54 to determine the required access lock that must be upgraded to protect the requested local lock. To do this, the upgrade lock L U is determined as follows: L U =P Lr ∪P Lh , D Lr ∪D Lh , i.e., the upgrade lock is represented by the union of the bits (that is, the protected modes and the concurrently restricted modes) of the currently held access lock L H and the requested local lock L R . This upgrade lock is requested at block 56 , with the server then processing the request as described above to grant or deny the upgrade lock L U . If the upgrade access lock is granted at decision diamond 58 , the local lock L R is granted at block 50 ; otherwise, it is denied at block 46 .
FIG. 6 shows the logic of a client computer in processing a server demand for an access lock as might be required at block 32 in FIG. 3 pursuant to an access lock request. Commencing at decision diamond 60 , it is determined whether the demanded lock L R is compatible with local locks using the above-disclosed compatibility algorithms. If not, the demand is denied at block 62 .
On the other hand, if it is determined that the demanded lock L R is compatible with local locks using the above-disclosed compatibility algorithms, the logic proceeds to block 64 to determine a downgraded access lock L H . Many tests can be used to downgrade a lock, and two extreme heuristics are presented herein. A MIN downgrade minimally decreases protected access to comply with the requested lock's sharing, and minimally increases sharing to allow requested locks protected access. In contrast, a MAX downgrade heuristic is used in highly shared environments to select the weakest adequate lock.
In the MIN downgrade, a downgraded version L H of a lock to be downgraded is selected that satisfies the following two equations: L H =<P Lh D Lr and D Lh P Lr >. On the other hand, in the MAX downgrade, the downgraded locking mode is exactly the system lock summary.
While the particular SYSTEM FOR DYNAMICALLY EVALUATING LOCKS IN A DISTRIBUTED DATA STORAGE SYSTEM as herein shown and described in detail is fully capable of attaining the above-described objects of the invention, it is to be understood that it is the presently preferred embodiment of the present invention and is thus representative of the subject matter which is broadly contemplated by the present invention, that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular means “at least one”. All structural and functional equivalents to the elements of the above-described preferred embodiment that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. §112, sixth paragraph, unless the element is expressly recited using the phrase “means for”.
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A system and method for managing access to assets in a distributed data storage system includes requesting, from a client computer, a lock from a server computer. The lock is evaluated using a bitwise comparison of the protected access modes and restricted access modes defined by the lock with the protected and restricted modes defined by the currently outstanding locks using an algorithm, such that a potentially large compatibility table is not needed.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No. 09/569,215, filed May 11, 2000, pending, which is a continuation of application Ser. No. 09/388,032, filed Sep. 1, 1999, now U.S. Pat. No. 6,082,605, issued Jul. 4, 2000, which is a continuation of application Ser. No. 08/989,578, filed Dec. 12, 1997, now U.S. Pat. No. 5,988,480, issued Nov. 23, 1999.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to applying solder to a substrate and, more particularly, to the selected placement of solder using a solder jet.
[0003] Depositing solder selectively on a substrate is well known. Different techniques include stenciling or screening a solder paste onto the substrate, using solder balls selectively placed where metal contact is desired, and chemically vapor depositing the metal onto the surface of the substrate. Each one of these methods has advantages and disadvantages.
[0004] The use of a stencil to fabricate a conductive trace pattern on the surface allows for precise alignment and placement of the solder. Unfortunately, the stencils are expensive to design and produce and they wear out after repeated use. When they wear out, solder seeps through the worn stencil areas across those areas where no solder is desired, causing shorts, or no solder is being placed where it is needed, causing a breach or open connection. These areas have to be repaired and if these types of conditions are repeated with any type of frequency, the stencil must be replaced with a new stencil. Additionally, stencils require periodic cleaning, which adds another processing step to clean the stencil as well as lessens the useful life of the stencil.
[0005] The use of solder balls has been a tremendous advance in the art of electrically connecting a device to the surface of a printed circuit board. Solder balls, however, have quality control problems as their critical dimensions continue to decrease. The ability to produce balls of the same diameter consistently decreases as the diameter decreases. Thus, for some diameters of solder balls, the range of acceptable product can be solder balls having diameters more than twice the desired diameter. Or, they can have diameters half the size of the desired diameter. This requires that the tolerances at the surface contact level of a substrate, such as a semiconductor device, must allow for a solder ball having a diameter that is from 50% smaller to 100% larger than the specified size. Further, working with solder balls is difficult because of their size and the methods needed to place them accurately. When they fail to be placed accurately, or are missing entirely, problems occur in the resulting assembly of a semiconductor device attached to a substrate that must be corrected. These problems include shorts or opens that must be fixed. No easy solution yet exists for repairing missing or improperly sized solder balls after a semiconductor device has been mechanically attached in place on a substrate.
[0006] Chemical vapor deposition (CVD) allows for precise alignment of conductive traces and for batch processing. CVD does have limitations however. These limitations include being unable to place the package directly on the surface of the printed circuit board (PCB) immediately after depositing the metal on the surface since a cooling step is typically needed. Further, clean conditions are always necessary when using CVD, which requires expensive equipment and control. Additionally, when clean conditions do not exist, shorts or opens in assemblies can occur that need to be repaired once they are discovered.
[0007] A new approach to deposit solder on a surface, such as a printed circuit board (PCB), is to deposit the solder using a solder jet, similar to the manner in which ink jets deposit ink onto paper for printing. The ink jet technology is well established, but due to different problems associated with solder, ink jet technology is not directly applicable to solder jet technology. For example, solder jets use molten melt as a print agent, whereas ink jets use heated water-based ink. Since the print agent is metal in solder jets, the viscosities and densities are much different as are the operating temperatures. Thus, applying ink jet solutions to solder jet problems is impractical.
[0008] One typical solder jet apparatus has recently been developed by MPM Corporation. The solder jet apparatus takes liquid solder and forms it into a stream of droplets that have a uniform size and composition. The formation of the droplets involves generating a consistent pressure coupled with a vibration force sufficient enough to dislodge the drops from the jet nozzle in a steady state with a uniform size and consistency. Once the solder droplets are formed, gravity forces them downward where they impact on the surface of the substrate. The solder droplets pass through a charging electrode to impart a charge on the metal droplets.
[0009] The system operates using a binary control that either allows the droplets to impact on the surface or to be removed into a droplet catcher for recycling when no droplets are desired. Since the droplets were charged at one point, an electric field or pulse can be asserted, causing the droplets to either continue to the surface or to fall into the catcher. With this system, the exact position of the droplets is known and never varies. Thus, the substrate must be moved to the desired grid for the droplets to impact the area desired to be soldered. This results in a highly inefficient system since the substrate must be stopped for each application of solder to a new location. This also involves greater mechanical complexity since the table holding the substrate, or the solder jet apparatus itself, must be moved and aligned properly before solder can be deposited.
[0010] Accordingly, what is needed is a solder applicator that allows for greater precision in placing the droplets along with increased efficiency in product throughput.
SUMMARY OF THE INVENTION
[0011] According to the present invention, a solder jet apparatus is disclosed The solder jet apparatus is a continuous mode solder jet that includes a blanking system and raster scan system. The use of the raster scan and blanking systems allows for a continuous stream of solder to be placed anywhere on the surface in any desired X-Y plane. This allows for greater accuracy as well as greater product throughput. Additionally, with the raster scan system, repairs to existing soldered surfaces can be quickly and easily performed using a map of the defects for directing the solder to the defects.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0012] [0012]FIG. 1 is a schematic block diagram of a solder jet apparatus according to the present invention; and
[0013] [0013]FIG. 2 is a top plan view of a substrate having solder deposited according to the solder jet apparatus of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0014] A solder jet apparatus 10 is depicted in the schematic block diagram of FIG. 1. Solder jet apparatus 10 deposits metal on substrate 12 in the form of solder droplets 14 . The solder droplets 14 can be directed in an X-Y plane of deflection using a raster scan and blanking system. This allows the solder droplets to be “written” on substrate 12 .
[0015] The solder droplets 14 are formed from melted metal held in liquid metal reservoir 16 . A temperature controller 18 is connected to liquid metal reservoir 16 so that the temperature of the liquid metal held in the reservoir can be kept at a desired temperature that leads to optimum droplet formation and release. For example, the solder eutectic temperature at the point of release is 190° C. and its temperature at impact is 183° C. To prevent solder droplets 14 from cooling too rapidly or from oxidizing, a constant surrounding temperature is provided and, if desired, the apparatus can be placed in a container that is either under vacuum or is filled with an inert gas.
[0016] The solder droplets 14 can be formed by the application of a driving pressure and a sufficient vibration force. The driving pressure can be provided by pressure inducer 20 , which is comprised of a piezoelectric crystal that is driven by a tuning frequency sufficient enough to cause pressure to build up in liquid metal reservoir 16 . The mechanical vibration is generated by vibrator 22 , which comprises a second piezoelectric crystal that is driven by another tuning frequency, causing liquid metal reservoir 16 to vibrate. The timing of the pressure and the vibrations is established so as to produce uniform droplets of the same consistency. Once the solder droplets 14 are formed, the vibration releases them from liquid metal reservoir 16 and the force of gravity draws them down at a predictable velocity.
[0017] Liquid metal reservoir 16 further includes a solder jet nozzle 23 , which is opened and closed via a solenoid 24 . The aperture of solder jet nozzle 23 is selected with a size sufficient enough to generate the droplets of a desired size. The solder droplets 14 are formed having a diameter of micron size, ranging from 40-300. When solenoid 24 is activated, it either closes or opens solder jet nozzle 23 .
[0018] Solder droplets 14 pass through several zones before either being deposited on substrate 12 or recycled back to liquid metal reservoir 16 . The first zone is a charging field driven by charge driver 26 . Charge driver 26 causes charge electrodes 28 to generate an electric field therebetween. As solder droplets 14 pass past charge electrodes 28 , they are imparted with an electric charge. With this charge, solder droplets 14 can be deflected at later stages as appropriate.
[0019] The second zone is a blanking zone that uses blanking electrodes or coil 30 . The blanking electrodes are activated having sufficient electric field so as to cause solder droplets 14 to deflect to a catcher 32 . This is the return function of the scanning function as is described below. Catcher 32 catches the liquid solder and causes the metal to be recycled to liquid metal reservoir 16 . This prevents solder droplets 14 from depositing on the surface of substrate 12 . This blanking can be done in a selective manner so that droplets are deposited in some locations, but not others. Blanking electrodes or coil 30 are controlled by signal controller 34 . Signal controller 34 can be a signal processor such as a computer system. The computer system allows greater control of solder droplets 14 by programming the blanking electrodes or coil 30 to turn on and off in a desired sequence so as to pattern the substrate with a desired solder pattern. An alternative embodiment can include an air jet system if the electrical pulse is insufficient to remove the droplets. A photo cell can be located above the air jet system in order to insure proper timing of electrical pulses or the air pressure.
[0020] The third zone is the raster scan system and includes electrostatic deflection plates or magnetic coil 36 . Electrostatic deflection plates 36 are charged by signal controller 34 so that solder droplets 14 are deflected in either the horizontal X-direction or the vertical Y-direction, or both. Further, the solder droplets 14 can be held in a steady position in the X-Y plane in order to build up the solder to a desired height. Since the droplet stream now scans in the X- and Y-directions, the substrate 12 can now stay stationary throughout the droplet application process. Signal controller 34 can be programmed to perform a variety of soldering patterns for placing solder droplets 14 on substrate 12 . For example, a CAD/CAM system programmed with a desired output sends signals to blanking electrodes 30 and to electrostatic deflection plates 36 to guide the droplet stream in the desired pattern of placing droplets in certain locations, but not in others. Additionally, when the “stream” of solder droplets 14 is returned to the beginning of the horizontal scan, blanking electrodes 30 cause the solder droplets 14 to deflect to catcher 32 so as not to “write” across the substrate during the return scan. The location of blanking electrodes 30 and electrostatic deflection plates 36 can be switched, if desired.
[0021] An electronic light sensor 38 , which connects to signal controller 34 , is positioned so that the solder droplets 14 pass through the electronic light sensor 38 . Electronic light sensor 38 is used to count the number of solder droplets 14 passing by. This allows signal controller 34 to monitor the droplet output and either blank or pass droplets as needed.
[0022] [0022]FIG. 2 is a top plan view of the surface of substrate 12 as solder droplets 14 are deposited. A first line 40 scans across the surface, depositing solder droplets 14 in selected positions and leaving blanks 42 in the remaining positions. A return scan line 44 , which is ghosted, indicates when the stream of droplets is caught by catcher 32 as the stream returns to the beginning of the next line 40 . This process is repeated as often as is necessary with catcher 32 collecting all the blank spots and scan returns. Alternatively, solenoid 24 can be activated to close solderjet nozzle 23 during the return scan. This also prevents unwanted solder droplets 14 from depositing on the surface of substrate 12 .
[0023] The type of solder used with the solder jet apparatus 10 can include any type of metal solder such as, for example, 63/37 PbSN, 62/36/2PbSnAa, In/Sn.
[0024] The solder jet apparatus 10 can be used for many types of solder application. One type of application includes that of applying uniform solder balls, in the form of solder droplets, to the substrate 12 . This provides a universal ball applicator system. Further, the system can repair particular locations where the solder ball application process has failed to insert a desired solder ball. In order to repair any and all solder ball defects, a scan of the surface of substrate 12 can be provided and then a map of the defective areas can be programmed to the signal controller 34 . This allows for a rapid repair of the surface of substrate 12 where solder balls had been omitted. Another application is to pre-tin a location on substrate 12 . Pre-tinning is accomplished by applying one or more droplets to the same location or to apply droplets in such a manner as to thoroughly cover the surface of substrate 12 or a grid section of substrate 12 .
[0025] Similar to pre-tinning is pre-plating a board. Pre-plating a board involves applying solder droplets over the entire surface area of the board to cover it with a metal plate. An exposed portion of the board can be selected where desirable. Typically, this area is along the edge of the board either on one edge, two edges, or all four edges, or can be in the center section of the board. Prior methods of pre-plating a board resulted in a problem known as “measling.” Measling is where small holes exist in the plating surface that lead to electrical defaults. The use of the solder jet apparatus 10 allows the system to eliminate the measling locations by applying solder directly to those openings. Additionally, using the pre-plating process provided by solder jet apparatus 10 eliminates measling entirely. Just as pre-plated boards may have measling problems, boards that had been stenciled with solder paste had similar problems. These problems can include openings or gaps in the stenciled design. Again, a map of the surface defects can be ascertained and then used by the signal controller 34 to make appropriate correction and repair to those particular problem points. Additionally, large areas can be printed using the X-Y motion of the table in combination with the X-Y slowing of the solder application. Also, the final ball size can be changed on demand. Further, in prior ball application systems that apply 7 balls/sec, the board needs to be moved to a new location. With this invention, no relocation time is required, thus reducing processing time.
[0026] While the present invention has been described in terms of certain preferred embodiments, it is not so limited, and those of ordinary skill in the art will readily recognize and appreciate that many additions, deletions and modifications to the embodiments described herein may be made without departing from the scope of the invention as hereinafter claimed.
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A solder jet apparatus is disclosed The solder jet apparatus is a continuous mode solder jet that includes a blanking system and raster scan system. The use of the raster scan and blanking systems allows for a continuous stream of solder to be placed anywhere on the surface in any desired X-Y plane. This allows for greater accuracy as well as greater product throughput. Additionally, with the raster scan system, repairs to existing soldered surfaces can be quickly and easily performed using a map of the defects for directing the solder to the defects.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates in general to a door latch system which latches a door to a fixed member, and more particularly to a door latch operating device which operates the system to assume its door lock or door unlock condition.
2. Description of the Prior Art
In the field of the door latch operating device, there has been proposed a so-called dual knob type operating device which makes it difficult for a thief to open the door from outside. One of the conventional dual knob type operating devices is disclosed in U.S. Pat. No. 4,083,589, which comprises generally a first button slidably mounted in the door for vertical movement from its lowermost lock position to its uppermost unlock position, a second button slidably mounted in the door for horizontal movement from an outer inoperative position to an inner operative position, and a wedge body mounted on the second button and provided with an inclined surface which is slidably engaged with the first button to move it from the lowermost lock position to the uppermost unlock position, and vice versa.
However, since this conventional dual knob type operating device is constructed without taking a deeper consideration on compactness thereof, the device produced has a considerable thickness. Thus, upon assembly to the door, the device is considerably projected into the vehicle cabin thereby reducing the effective space of the same.
SUMMARY OF THE INVENTION
Therefore, it is an essential object of the present invention to provide a compact or thinner dual knob type operating device which is free of the above-mentioned drawback.
It is another object of the present invention to provide a dual knob type operating device which is simple in construction, and inexpensive to manufacture.
According to the present invention, there is provided a door latch operating device for operating a door latch device to lock or unlock a door relative to a fixed member, the door latch operating device comprising a stationary member fixed to the door, a first movable member movable relative to the stationary member, the first movable member being movable from a first position to cause the door latch device to assume its door lock condition to a second position to cause the door latch device to assume its door unlock condition, a second movable member hingedly connected to the stationary member, and a third movable member having one end hingedly connected to the leading end of the second movable member and the other end pivotally connected to the first movable member, so that the movement of the second movable member induces the movement of the first movable member, and vice versa.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the present invention will become apparent from the following description when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is an exploded view of a door latch operating device of a first embodiment of the present invention;
FIG. 2 is a vertically sectional view of the device of the first embodiment in the "lock" position;
FIG. 3 is a view similar to FIG. 2, but showing the "unlock" position of the device;
FIG. 4 is a vertically sectional view of a door latch operating device of a second embodiment of the present invention; and
FIG. 5 is a view similar to FIG. 4, but showing the "unlock" position of the device.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 to 3 of the drawings, there is shown a door latch operating device of a first embodiment of the invention. As is seen from FIGS. 2 and 3, the door latch operating device is mounted on an automotive door. The door herein shown comprises a door inner panel 10, a door outer panel (not shown), a door trim 12 covering over the inner panel 10 with a suitable space therebetween, and a window pane 14 extending upwardly between the inner panel 10 and the outer panel.
The door latch operating device is mounted on the upper portion of the door trim 12. For this, the door trim 12 is formed at its upper shoulder portion with a rectangular aperture 16. The door latch operating device comprises an escutcheon 18 of plastic which is tightly fitted to the rectangular aperture 16 with its upper and lower grooved portions 18a and 18b gripping the edges of the aperture 16. The escutcheon 18 is formed at its upper inclined portion with a rectangular opening 20 through which the after-mentioned locking knob (32) is slidably received. The escutcheon 18 is further formed at its lower portion with another rectangular opening 22. As is best seen from FIG. 1, a flat plate 24 extends downward from the upper edge of the opening 22 and is swingable relative to the escutcheon 18. For achieving this swingable movement, the joint portion 26 between the flat plate 24 and the escutcheon 18 is reduced in thickness to act as a hinge. A pair of arms 28 and 30 extend from the spaced leading ends of the flat plate 24 and are swingable relative to the flat plate 24. For this swingable movement, the joint portion 27 between each arm 28 or 30 and the flat plate 24 is reduced in thickness to act as a hinge. Each arm 28 or 30 is formed at its leading end with an outward pin 28a or 30a. It is to be noted that the escutcheon proper 18, the grooved upper and lower portions 18a and 18b, the swingable flat plate 24, the swingable arms 28 and 30 are of a one-piece construction of plastic. As will become apparent as the description proceeds, the swingable flat plate 24 acts as an unlocking knob.
As is seen from FIG. 1, the locking knob 32 is formed at its lower portion with two spaced side walls 34 and 36 each having at its upper section a slit 34a or 36a of which leading end is enlarged and rounded. Upon assembly, the above-mentioned two pins 28a and 30a of the arms 28 and 30 are pivotally received in the enlarged sections of the slits 34a and 36a respectively so that the movement of the locking knob 32 causes a synchronous movement of the flat plate 24 and vice versa. As is seen from FIGS. 2 and 3, the locking knob 32 is upwardly and downwardly movably received in the space defined between the door inner panel 10 and the door trim 12 with its upper portion slidably held in the opening 20 of the escutcheon 18. The upper portion of the knob 32 has an inclined surface 32a which becomes flush with the outer surface of the inclined upper portion of the escutcheon 18 when the knob 32 is in its lowermost position (that is in the "lock" position), as is seen from FIG. 2. As shown in FIG. 1, the locking knob 32 is formed with two shoulder portions 38 and 40 which are engageable with the frame of the escutcheon 18 to limit the upward movement of the knob 32. The knob 32 is further formed with a flange 42 which is engageable with the back surface of the swingable flat plate 24 to limit the outward movement (that is, the leftward movement in the drawings) of the plate 24, as is seen from FIG. 3. A control rod 44 is threadedly connected to the locking knob 32, which rod extends to a known door latch device (not shown) mounted in the door. The door latch device locks the door when the locking knob 32 is in its lowermost position as shown in FIG. 2, and unlocks the door when the locking knob 32 is in its uppermost position as shown in FIG. 3.
The flat plate 24 and each arm 28 or 30 are so sized and constructed that upon assembly, they define therebetween an acute angle irrespective of the angular positions which the flat plate 24 assumes during its functional operation. In other words, the acute angular relationship between the flat plate 24 and each arm 28 or 30 is maintained even when the locking knob 32 moves from its lowermost position (that is the "lock" position) to its uppermost position (that is the "unlock" position). This means that the movement of the locking knob 32 from its lowermost or "lock" position (FIG. 2) to its uppermost or "unlock" position (FIG. 3) can be carried out by only pressing the flat plate 24 leftward in FIG. 2, and means that pressing the locking knob 32 to move the same from its "unlock" position (FIG. 3) to its "lock" position (FIG. 2) causes the flat plate 24 to move from its depressed position (FIG. 3) to its raised position (FIG. 2). Preferably, the flat plate 24 is so sized and constructed that it becomes flush with the outer surface of the lower portion of the escutcheon 18 when it assumes the raised position, as is understood from FIG. 2.
In the following, operation will be described with reference to FIGS. 2 and 3. For ease with which the explanation is carried out, the description will be commenced with respect to the "lock" condition of the door latch device (not shown). In this lock condition, the locking knob 32 is in its lowermost or lock position as shown in FIG. 2. The inclined upper surface 32a of the knob 32 is flush with the outer surface of the escutcheon 18 so that it is impossible to raise it by lifting up on its upper end. The flat plate or unlocking knob 24 assumes its raised position.
When unlocking the door is required, the unlocking knob 24 (that is the flat plate) is depressed with a finger or fingers of an operator. With this, the unlocking knob 24 is swung from the raised position as shown in FIG. 2 to the depressed position as shown in FIG. 3, moving the arms 28 and 30 to lift up the locking knob 32 to its uppermost or unlock position as shown in FIG. 3. Thus, the door becomes unlocked. Now, it is to be noted that provision of the shoulder portions 38 and 40 and the flange 42 on the locking knob 32 suppresses the excess movements of the knobs 32 and 24.
When the locking knob 32 is depressed for locking the door again, the unlocking knob 24 returns in the reversed manner to its raised position as shown in FIG. 2.
Referring to FIGS. 4 and 5, there is shown a second embodiment of the present invention. For facilitation, substantially the same parts as those of the afore-mentioned first embodiment are designated by the same numerals and detailed description of them will be omitted from the following in which only the parts and construction different from those of the first embodiment are described.
In the second embodiment, the arms 28' and 30' extending from the flat plate (unlocking knob) 24 are somewhat thicker than the arms 28 and 30 of the first embodiment, as is understood from the drawings. Each arm 28' or 30' has a convex outer surface which is slidably engageable with the bottom wall 35 (see FIG. 4) which lies between the two spaced side walls 34' and 36' formed at the lower portion of the locking knob 32. The leading end 28'b or 30'b of each arm 28' and 30' forms a free end which is slidably engageable with the upper wall 37 (see FIG. 5) defined between the major thicker portion of the locking knob 32 and the side-walled portion of the same. Each of the arms 28' and 30' is formed with an outward pin 28'a or 30'a at its middle portion near the convex outer surface. The two spaced side walls 34' and 36' are formed at their generally middle portions with aligned slits 34'a and 36'a into which the above-mentioned outward pins 28'a and 30'a are inserted under a certain condition of the arms 28' and 30'.
In the "lock" condition of the door latch device (not shown), the locking knob 32 and the unlocking knob 24 (that is the flat plate) assume the positions as shown in FIG. 4. Under this condition, the free end 28'b or 30'b of each arm 28' or 30' is in engagement with the upper wall 37 of the locking knob 32.
When, for unlocking the door, the unlocking knob 24 is depressed with the operator's finger or fingers, the free ends 28'b and 30'b of the arms 28' and 30' move up the locking knob 32 until the ends 28'b and 30'b disengage from the upper wall 37 of the knob 32 due to the swingable movement of the arms 28' and 30'. At the time of this disengagement, the outward pins 28'a and 30'a of the arms 28' and 30' are brought into engagement with the slits 34'a and 36'a of the side walls 34' and 36', so that after this, the upward movement of the locking knob 32 is effected by the pins 28'a and 30'a moving together with the arms 28' and 30', and finally, the locking knob 32 comes to its uppermost or unlock position as shown in FIG. 5. Thus, the door becomes unlocked. It is now to be noted that during this operation, the contact point of the convex surface of the each arm 28' or 30' to the bottom wall 35 moves downward keeping the angle defined between the plane of the bottom wall 35 and an imaginary plane which contains both the axis of the hinge portion 27 and the contact point at about 45 degrees. Thus, according to the second embodiment, the movement of the unlocking knob 24 is efficiently transmitted to the locking knob 32 to raise the same. Furthermore, the force required to the unlocking knob 24 for raising the locking knob 32 is kept generally constant for the time the unlocking knob 24 is pressed, so that the handling feeling of the knob 24 is improved as compared with the afore-mentioned first embodiment.
When, for locking the door, the locking knob 32 is depressed, the parts of the locking knob 32 and the unlocking knob 24 move in the reversed manner to return the unlocking knob 24 to its raised position as shown in FIG. 4.
As is understood from the foregoing description, according to the present invention, there is provided a measure in which, for transmitting the movement of one operating knob to the other operating knob and vice versa, a swingable arm (28, 30, 28' and 30') is employed which is hingedly connected to one of the knobs and arranged with respect to the knob to always define therebetween an acute angle. It is to be noted that the acute angle arrangement between the swingable arm and the flat knob (that is the unlocking knob) allows a reduction in thickness of the door latch operating device. Thus, the aforementioned drawback encountered in the conventional dual knob type operating device is solved in the present invention.
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Herein disclosed is a door latch operating device which comprises a stationary member fixed to the door, a first movable member movable from a first position to cause the door to be locked to a second position to cause the door to be unlocked, a second movable member hingedly connected to the stationary member, and a third movable member having one end hingedly connected to the leading end of the second movable member and the other end pivotally connected to the first movable member. With this arrangement, the movement of the second movable member induces the movement of the first movable member, and vice versa.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Chinese Patent Application No. 02148902.5 filed on Nov. 8, 2002. The disclosure of the above application is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to the data transmission field, specifically to a flow control method for a virtual container trunk (VC-Trunk) of metropolitan-area network transmission equipment based on Synchronous Digital Hierarchy (SDH).
BACKGROUND OF THE INVENTION
[0003] In metropolitan-area network equipment based on SDH, IP data packet or ATM cell is mapped to SDH for transmission. When data are dropped from an optical fiber to a VC-Trunk, if the data dropping speed is faster than processing and forwarding speed of the equipment, the dropping data flow must be controlled.
[0004] When conventional SDH equipment transmits data to an optical fiber, the uplink bandwidth is definite; even there is some variant, the variance is within the range of rate adjustment recommended by G.707. Thus the receiving node on the transmission ring has enough processing capability for a VC-Trunk adding data; there is no flow control issue.
[0005] For metropolitan-area network equipment based on SDH, which loads service data, the data flow is changed constantly. Without flow control to a VC-Trunk, data loss will appear, data flow on the network is fluctuation, the network bandwidth cannot be efficiently used; also a VC-Trunk can occupy too much resource and affects other VC-Trunks normal service.
[0006] At present, the IEEE802.3x only provides flow control based on a physical port. There is no VC-Trunks flow control technique based on SDH.
SUMMARY OF THE INVENTION
[0007] The objective of the invention is to provide a flow control method for VC-Trunks in the metropolitan-area network equipment. With this method data flow of every VC-Trunk is controlled individually.
[0008] A flow control method for VC-Trunks in metropolitan-area network transmission equipment comprises at least the following steps:
[0009] A) Receiving-end transmission equipment detects whether there is a service data packet block in its VC-Trunks, if it is, a flow control packet with the VC-Trunk tag is sent out;
[0010] B) The transmission equipment that has received the flow control packet pauses service data packets forwarding of the VC-Trunk according to the VC-Trunk tag in the flow control packet until the timing brought in by the flow control packet expires and there is no other new flow control packet comes.
[0011] Said Step (B) further comprises that initiating flow control timer at the transmission equipment that has received the flow control packet; detecting whether the flow control timing is ended; if it is not, then wait.
[0012] Said Step (A) further comprises that initiating control timer at the receiving-end transmission equipment and send said flow control packet in a timing manner until the service data packet block is disappeared.
[0013] It is better that said Step (A) also comprises that calculating individually number of received service data packets of every VC-Trunk at the receiving-end transmission equipment; detecting whether the number is excess the preset flow control threshold; if it is, send the flow control packet to the transmit-end transmission equipment.
[0014] It is better that Step (A) also comprises that detecting whether the FIFO buffer of a VC-Trunk at the receiving-end transmission equipment is overflow; if it is, send the flow control packet to the transmission equipment physical port of the receiving-end.
[0015] The flow control packet used in this invention is consisted of adding a VC-Trunk tag as a frame header to the 802.3x standard pause frame.
[0016] Said VC-Trunk tags correspond to VC-Trunks one by one, and the VC-Trunk tag length is determined by the number of VC-Trunks.
[0017] The invention applies adding a VC-Trunk tag as a header to the 802.3x standard pause frame to form a flow control packet that individually reflects a VC-Trunk block situation, so each VC-Trunk data flow can be individually controlled without any mutual affection among VC-Trunks. In the invention, the flow control packet can be sent by software or hardware, thus the implementation is flexible. Comparing with the conventional technique, the invention solves both problems: in the SDH system there is no flow control, and previously general flow control technique it is only based on the physical port.
[0018] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0020] [0020]FIG. 1 is a diagram of VC-Trunks flow control.
[0021] [0021]FIG. 2 is a service data packet format in a VC-Trunk.
[0022] [0022]FIG. 3 is a diagram of relationship between a physical port and VC-Trunks.
[0023] [0023]FIG. 4 is a processing flowchart of flow control for a VC-Trunk on the downlink of service data packets.
[0024] [0024]FIG. 5 is a flow control packet format.
[0025] [0025]FIG. 6 is flow direction diagram of service data packets inside the interface logic module on the uplink of service data packets.
[0026] [0026]FIG. 7 is a diagram for interface logic module sending flow control packet to a physical port.
[0027] [0027]FIG. 8 is a processing flowchart of a port during receiving a flow control packet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0029] Usually, a same physical port comprises multiple VC-Trunks in metropolitan-area network transmission equipment. When making flow control for a VC-Trunk, it should be avoided to affect other VC-Trunks. This means that when a VC-Trunk has received flow control information, it should response in time and pause data transmitting without affecting the data stream that sends to other VC-Trunks. Therefore, the invention needs to solve issues including the identification of a VC-Trunk, transmitting and receiving of flow control information for a VC-Trunk, etc.
[0030] [0030]FIG. 1 shows a diagram of VC-Trunks flow control. On a SDH ring, there are four nodes and there is a VC-Trunk between two neighbor nodes. For example, between Node 2 and Node 3 there is a VC-Trunk. Suppose the service data packets are flowed from Node 2 to Node 3 , and when there is an excess service data stream that Node 3 cannot forward; Node 3 will send a flow control signal to Node 2 and Node 2 will pause the service data sending.
[0031] [0031]FIG. 2 shows a service data packet format in a VC-Trunk. In order to differentiate service data packets sent to different VC-Trunks, a VC-Trunk tag is added to the service data packet before the service data packet is mapped to the SDH channel. The length of the VC-Trunk tag depends on how many VC-Trunks the equipment supports. Each VC-Trunk tag corresponds to one VC-Trunk and a VC-Trunk tag value is uniquely set on the SDH ring.
[0032] [0032]FIG. 3 shows the relationship between a physical port and VC-Trunks in metropolitan-area network transmission equipment. A data processing unit in metropolitan-area network transmission equipment includes an interface unit, a service-processing module, interface logic module and a mapping/de-mapping module. The service-processing module is connected with the interface logic module through the physical port that includes several SDH VC-Trunks. On the uplink of service data packets, when a service data packet is mapped from a VC-Trunk to the SDH ring, it is located at different time slots according to the VC-Trunk tag of the service data packet. Since SDH is a time-division multiplexing system, data in a time slot can be sent to any node on the SDH ring; in this way a service data packet with a VC-Trunk tag can be transmitted to a designated node according to a configuration of network management center. On the downlink of service data packets, when data are mapped from the SDH ring to the VC-Trunk, the mapping/de-mapping module adds an appropriate VC-Trunk tag. After service data packets with different VC-Trunk tags enter the same physical port, the service-processing module forwards them according to the VC-Trunk tag and the virtual LAN identifier (VLAN ID) etc.
[0033] In the following, it is described that the receiving-end transmission equipment sends flow control information to the sending-end transmission equipment.
[0034] [0034]FIG. 4 is a processing flowchart of a flow control signal sent by the VC-Trunk of the transmission equipment at receiving-end.
[0035] Step 401 . The receiving-end transmission equipment calculates respectively number of service data packets of every VC-Trunk in the shared packet memory according to the VC-Trunk tag of each service data packet and sets a threshold of service data packets number for flow control.
[0036] Step 402 . Whether the number of service data packets is greater than the threshold is detected. If the number of service data packets is less than the threshold, then go to Step 404 to forward service data packets normally. If the service data packets number is greater than the threshold, then go to Step 403 and initiate a control timer in order to send a flow control packet with VC-Trunk tag to the sending-end transmission equipment in a timing manner. Structure of the flow control packet is shown in FIG. 5 and is consisted by adding a VC-Trunk tag in front of the IEEE802.3x pause frame to implement flow control for different VC-Trunks. Since each service data packet has its own VC-Trunk tag, a VC-Trunk can be differentiated from other VC-Trunks at the same physical port. For example, in FIG. 3 when the service-processing module has received service data packets mapped from SDH ring to VC-Trunks and the service data packets number of VC-Trunk 1 in the packet memory has been excess the threshold, the service-processing module sends a flow control packet with VC-Trunk tag value 1 to its physical port. The flow control packet is mapped from VC-Trunk 1 to the SDH ring by the mapping/de-mapping module, and then is transmitted to the physical port of sending-end transmission equipment. Service data packets with VC-Trunk tag value tag 2 and 3 are normally sent from the same physical port. In this way, a flow control based on VC-Trunk is implemented; there is no any mutual affection among the VC-Trunks.
[0037] The flow control manner mentioned above is implemented by software; threshold can be changed easily, so the flow control is flexible. When a service data packet is sent to a VC-Trunk, the trunk counter increases and when a service data packet is sent out from a VC-Trunk the trunk counter decreases; this will affect the forwarding efficiency in a certain degree.
[0038] Another flow control manner can be implemented by hardware; the interface logic module between the service-processing module and the mapping/de-mapping module in receiving-end transmission equipment will send the flow control packet with a VC-Trunk tag to the physical port according to the size of FIFO buffer of each VC-Trunk.
[0039] [0039]FIG. 6 shows on the uplink of service data packets the flow direction of service data packets inside the interface logic module of FIG. 3. The interface logic of the receiving-end transmission equipment allocates service data packets received from the physical port, to the FIFO buffer of different VC-Trunks according to the VC-Trunk tag of each service data packet; service data packets in the FIFO buffer of different VC-Trunks will be sent to the mapping/de-mapping module. Conversely, on the downlink of service data packets, VC-Trunk tag is added to service data packets according to which VC-Trunk the service data packet is coming from, and then sends to the service-processing module.
[0040] [0040]FIG. 7 shows sending of flow control packets of the interface logic module. When the FIFO buffer of a VC-Trunk is full, the interface logic module sends a flow control packet with the VC-Trunk tag to physical port of the service-processing module to simulate a flow control fame coming from the sending-end transmission equipment. Having received the flow control packet, the physical port pauses sending service data packets to the VC-Trunk; in this way, the flow of VC-Trunk is controlled.
[0041] When a flow control packet has been received, the processing procedure is as follow. After a flow control packet is received, the VC-Trunk tag of the flow control packet is analyzed to know that this flow control is for which VC-Trunk and the data flow for that VC-Trunk is paused. Consequently, the flow of VC-Trunk is controlled.
[0042] [0042]FIG. 8 shows a processing flowchart of flow control packet at the physical port of the receiving-end transmission equipment.
[0043] Step 501 . The physical port receives a flow control packet with a VC-Trunk tag.
[0044] Step 502 . The flow control timer is initiated with the timing brought in by the flow control packet, and the service data packets forwarding is paused.
[0045] Step 503 . Whether the timing set at Step 502 is ended, if it is, execute Step 504 , otherwise return to Step 503 .
[0046] Step 504 . Whether a new flow control packet has been received, if it is, return to Step 502 , otherwise execute Step 505 for forwarding service data packets normally.
[0047] In Step 502 , said pausing service data packets forwarding can be implemented by software or hardware. When implementing with hardware, a switching network chip that supports data flow dispatched and individually paused can be used. For example, the switching network chip within the nP3400 network processor, made by US AMCC Company, can separate a data flow into 16 sub-flows; each sub-flow corresponds to one VC-Trunk or one physical port and service data packets sent to a VC-Trunk or physical port can be paused individually. When implementing with software, one or multiple queues can be set for every VC-Trunk or physical port. When it is necessary to pause data sending from a VC-Trunk or physical port, dispatching the queue of the VC-Trunk or physical port is stopped and the queue is disconnected from the VC-Trunk or port, therefore no service data packet will be sent from the VC-Trunk or physical port.
[0048] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
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The invention discloses a flow control method for VC-Trunks in metropolitan-area network equipment. The method at least includes following steps: Receiving-end transmission equipment determines whether there is a service data packet block in its VC-Trunk, if it is, a flow control packet with the VC-Trunk tag is sent out; The transmission equipment that has received the flow control packet pauses service data packets forwarding of the VC-Trunk according to the VC-Trunk tag in the flow control packet until the timing brought in by the flow control packet is ended and there is no other new flow control packet coming. The method can individually control data flow for each VC-Trunk, and comparing with the present technique the method solves problems that there is no flow control in SDH.
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BACKGROUND OF THE INVENTION
The invention appertains to an air quantity metering apparatus and more particularly, to a fuel injection system of a combustion engine having a barrier flap which is pivotably mounted in a flow path on a shaft extending transversely of the flow path. A first restoring spiral spring element is wound around a free end of the shaft and has one end attached to a cam affixed to the shaft while the other end of the spring element is secured to the inner wall of a rotatable housing member, the outer periphery of which is formed with a plurality of teeth. An additional spring member is arranged to cooperate with the teeth on the rotatable housing member and functions together with the first restoring spring element to provide for pre-tensioning of the barrier flap and flow control in said flow path.
In commonly known air-quantity metering devices of this type, the securing of the spring housing, which is made of a synthetic material, is accomplished by squeezing it against the air metering housing with the aid of a screw. That method entails the danger that in actual usage in a motor vehicle during attendant changes in temperature and in the presence of vibrations the friction between the spring housing and the air-metering housing prove inadequate, thus letting the spring housing deviate from its intended pre-tensioned setting. Furthermore, in order to set the pre-tensioning of the spiral spring, the aforesaid screw must in each instance be first loosened, thereby removing the friction securing the spring housing, and then the screw must thereafter be retightened. As a result, the danger always exists that the threads of the screw connection will be damaged by continued use.
OBJECTS AND SUMMARY OF THE INVENTION
Therefore, it is the primary object of the present invention to develop an air quantity metering apparatus of the commonly known type, which, however, prevents any undesired changes in the pre-tensioning of the spiral spring during operation, and which offers a simple means for the adjustment of the pre-tensioning of the spring.
According to the invention, this objective is achieved through the use of a retention spring which serves to arrest the rotation of the spring housing, one extremity of said spring being attached to the air metering housing, while the other movable extremity of which is twisted in such a manner as to snap into the toothed rim gear of the spring housing parallel to the surfaces of the teeth.
An advantageous refinement of the invention consists in the fact that the retention spring is made of wire having a circular cross section, and the movable extremity of the retention spring extends over the spring housing as it secures the spring housing in its axial position.
A further advantageous refinement of the invention derives from the fact that the retention spring forms a loop, through which a screw enters, thus attaching it to a recess in a shoulder in the air metering housing, and that an integral anchor spring extends out symmetrically from the loop, serving to secure the spring housing in its axial position,
The refinements of the present invention offer the additional advantage that the given unique setting of the spring housing is preserved even during variations of temperature, due to the engagement of the retention spring with the toothed rim gear of the spring housing. To this accrues the simple setting or re-setting of the basic pre-tension of the spiral spring, by means of a simple tooth by tooth turning of the spring housing, without the need of first loosening a screw, or of tightening that screw subsequent to the setting procedure.
The invention will be better understood as well as other objects and advantages thereof become more apparent from the following detailed description of the invention taken in conjunction with the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an electrically controlled fuel injection system with its air quantity metering device in a plan view and includes a partially schematic representation;
FIG. 2 shows the air quantity metering device including its pneumatic damping mechanism, in a side view, and partly in a section II--II of FIG. 3;
FIG. 3 is a sectional view along the line III--III of FIG. 2;
FIG. 4 is a sectional view along the line IV--IV of FIG. 3;
FIG. 5 is a sectional view along the line V--V of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, the illustrated fuel injection arrangement of the invention is intended for a four cylinder, four stroke, internal combustion engine 10. The arrangement essentially comprises four electromagnetic fuel injection spray valves 11 that are connected by respective fuel conveying pipes 13 to a distributor 12, and an electric motor driven fuel pump 15, a pressure regulator 16 that keeps the fuel at a constant pressure, and an electronic control (U.S. Pat. No. 3,750,631) that a triggering means or signal generator 18, which is coupled to the engine cam shaft rotating synchronously with the crank shaft, operates twice during each complete rotation of the crank shaft to produce one rectangular valve opening pulse S. These pulses cause the valves 11 to open. The period T 1 of the pulse S determines the open time of the valve 11 and therefore the amount of fuel that is forced out of a valve at a nearly constant pressure of 2 atmospheres. The magnet coils 19 of the fuel injection spray valves 11 are connected in series with respective decoupling resistors 20, which latter are connected in common to the output of an amplification and power output stage 21. The stage 21 contains at least one power transistor 22, the emitter collector path of this transistor being connected in series with the decoupling resistors 20 and the magnet coils 19, which latter are connected at one end to ground.
With external auto ignition gasoline engines of the kind illustrated the amount of air sucked into a cylinder during a single suction stroke determines the amount of fuel that can be completely burned during the following power stroke. If the engine is to be used efficiently, little air should remain after the power stroke. In order to obtain the desired stoichiometric ratio between air and fuel, there is provided in the intake manifold, between the filter 26 and the throttle valve 28, an air meter LM, which essentially comprises a static plate 30 and an adjustable resistor R of which the movable tap 31 is coupled to the static plate, these components together constituting adjusting means. The position of the throttle valve 28 is controlled by an accelerator 27. The air meter LM operates in conjunction with a transistor switch TS, the output of which delivers the control pulse S for the output stage 21.
When the revolutions per unit time are lower than 2000 rpm, and during periods of heavy loading, the aspirated air flow manifests a strong pulsation; this can lead to a condition wherein the barrier flap oscillates strongly about a median attitude which does not correspond to the actual average instantaneous value of the air quantity QL. In order to avoid this kind of mismatching, the hereinafter described example of the embodiment of an air quantity metering device incorporates a pneumatic damping mechanism, which, on the one hand, prevents any oscillation of the barrier flap 30 beyond the attitude corresponding to the average instantaneous value of the aspirated air quantity, and which, on the other hand, permits the necessary rapid response of the barrier flap 30 to changes in the aspirated air quantity.
In the remaining figures, i.e., FIG. 2 to FIG. 5, the air quantity metering device comprises a die cast zinc housing 41, with a central base plate 42, and integral side walls 43 and 44, which form a metering channel 46 and a damping chamber 62, in conjunction with an inserted die cast zinc cover plate 45. The metering channel 46 contains the barrier flap 30, the integral damping wing 47 which is radially offset some 100° in the downstream direction on their common hub 48. In order to obtain a preferably frictionless and play-free pivoting of the barrier flap 30 and its damping wing 47 as well as to assure the accuracy of the air quantity measurement and to maintain a steady damping effect at the air space 49 formed between the free edge of the damping wing 47 and the cylindrical sector constituting the chamber wall 50, the hub is supported on a shaft 51, which carries two axially spaced ball bearing races 52 and 53. The hub 48 is provided with integral ribs 54 and 55, respectively, which serve to stiffen the barrier flap 30 and the damping wing 47, which includes a cavity for approximately two-thirds of its axial length and into which protrudes a collar 56 that is integral with the base plate 42 and is arranged to receive the two outer surfaces of the bearing races 52 and 53. In order to maintain an air space of approximately 0.2 to 0.3 mm between the sides of the damping wing 47 and the base plate 42, the cover 45 or the shaft 51 is axially secured by means of a snap ring 57, which fits into a groove (not here detailed) and by a spring plate 58 inserted between the snap ring and the inner race of the ball bearing race 53.
In the depicted example of this invention, the metering channel 46 with its rectangular cross section may be associated with a part of the intake manifold thereby connecting the filter 26 to the individual intake passages of the cylinders, and is therefore equipped with an integral, cast flange 60, serving to mate with the segment 25 of the air intake. A rearwardly extending mating flange 61 similarly permits the downstream connection of the metering channel 46 with that section of the air intake pipe which contains the throttle valve 28. Over the pivoting range of the barrier flap 30, the wall 44 of the metering channel 46 is shaped in such a manner as to produce an exponential enlargement of the cross sectional opening which admits the aspirated air with respect to an increase (corresponding in FIG. 4 to a counterclockwise movement) of the pivoting angle of the barrier flap 30. This construction has the advantage that the relative indication error ΔQL/QL remain constant within the pivoting range where QL is the aspirated air flow rate.
The pivoting motion of the barrier flap 30, as well as that of the integral damping wing 47 takes place against the virtually constant force of a spiral spring 65, which is secured within a central cavity of the spring housing 67 by a rivet 68. The other extremity 69 of the spiral spring 65 is attached to a cam 70 in such a way that the spiral spring emanates from the cam practically at a right angle, thus forming a continually large lever arm with respect to the turning axis of the shaft 51, the free end 71 of which is provided with opposing flat surfaces 72 and 73 that protrude beyond the base plate 42 and mate with the cam 70. The spring housing 67 carries an integral toothed rim gear 75, with which the stem of a pinion gear, (not shown) may be made to engage by being positioned in the boring 76, thus providing for a sensitive adjustment of the spring pre-tension to a given predetermined value, and by means of which a counterclockwise turning of the spring housing corresponds to an increase in the spring tension, as is believed clear from the view in FIG. 5. A retention spring 120, one end of which is attached to the air metering housing by a restraining screw 121, serves to secure the given setting of the spring housing 67, and thus the pre-tension of the spiral spring 65, by having its other movable extremity 122 twisted in such a way as to engage the toothed rim gear 75 of the spring housing 67, parallel to the faces of the teeth. The retention spring 120 is preferably made of round steel wire, and incorporates a restraining loop 123 which is held by the screw 121 in a recess 124 formed by spaced shoulders 125 provided on the air metering housing. To secure the position of the spring housing 67 relative to the air metering housing, the movable extremity of the retention spring 120 extends over the spring housing 67, and also features an integral anchor spring 126 which includes a leg that extends out symmetrically relative to the restraining point 121, 123, and which also extends over the spring housing 67. When the spring housing 67 needs to be turned in order to adjust the pre-tension of the spiral spring 65, the toothed rim gear 75 is shifted, tooth by tooth with the aid of the above-described pinion gear, whereby the movable extremity of the retention spring 120 in each case snaps into the corresponding tooth gap, all without having to loosen the restraining screw 123.
The accuracy of the air quantity metering device is influenced, aside from the quality of the bearing and the low hysteresis here achieved, primarily by the stability, durability and indifference to changes in temperature of the spiral spring 65 which is made of a special nickelberyllium alloy.
A slider-carrier 78, also made of synthetic material, is received on the free end section of the shaft 51 adjacent to the cam 70 of the spiral spring 65. The slider-carrier includes an integrally molded bed 79, also made of synthetic material, provided with an equalizing weight 80 and by means of which the metering system is statically balanced. Upon the slider-carrier 78 which forms the wiper 31 of the potentiometer according to FIG. 1, there is provided a slider spring 81, which is die-punched to provide an arcuate portion having a reentrant bend, the contacts 82 and 83 of which lie on an arc-shaped resistance track 84 of the potentiometer wafer 85.
In FIG. 2, the dashed line 86 denotes the periphery of a tongue, which is incised during the die punching of the slider spring 81 and which assumes its more easily recognizable shape in FIG. 3 by being bent twice in two approximately right angle directions. At the free end of this tongue there is provided a pressure contact 87 that is positioned at the imaginary elongation of the turning axis of the shaft 51, and which serves to make, virtually without frictional drag, the electrical connection between the slider spring 81 and a contact arm 88, which terminates in a tongue portion 89. This connector tongue is vulcanized, together with five additional tongue portions 90-94, into a socket member 95 which is made of synthetic material and into which a connecting plug may be inserted to create the electrical connection to the transistor switching circuitry TS. The rightmost tongue portion 94, as shown in FIG. 2, is associated with a spring means 96 which cooperates with an opposing contact 97, joined to the tongue portion 93 and which is lifted from the opposing contact 97 when the barrier flap 30 comes to a rest position, e.g., whenever the combustion engine is not running, all of which is brought about by by movement of the integral arm 99 of the pressure plate 98 which is mounted adjacent to the slider-carrier 78. The slider spring 81 can be adjusted angularly to a limited degree, relative to the barrier flap 30, independent of the pressure plate 98, and is thereafter secured by the screw 101 into the threaded hole in the slider-carrier 78.
To insure that the measuring system of the air quantity metering device will not be damaged when back-firing occurs in the intake manifold of the combustion engine, the barrier flap 30 contains a relief valve, comprising a valve plate 110, a pressure spring 111, and a guide rod 112. The spring holds the valve plate 110 against the rim of the two openings 113 and 114 in the barrier flap 30, thus covering them. Only when the pressure against the back of the barrier flap reaches the magnitude present during backfiring, does the valve plate 110 lift away from the openings 113 and 114, thus permitting the equalization of the pressures.
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Disclosed herein is an air quantity metering apparatus for use in internal combustion engines including a fuel injection system having an air intake manifold provided with a barrier flap which is mounted on a shaft to which is attached, exteriorly of said manifold, a spring loaded mechanism that serves to pretension the barrier flap in dependence upon conditions that exist in said manifold.
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This application claims the benefit of U.S. Provisional Application No. 60/877,634, filed Dec. 29, 2006, which is herein incorporated by reference in its entirety.
BACKGROUND
1. Field of the Invention
The present invention relates generally to powered ISO 7816-compliant cards and, more particularly, to apparatus for mailing powered cards in compliance with applicable postal regulations.
2. Background of the Invention
As a convenience for their customers, businesses (e.g., financial institutions), retailers, and advertisers routinely deliver transactional cards and promotional cards to their customers through the mail. The convenience of receiving a card through the mail saves a customer the trouble of visiting a retail location to pick up a card. As a result, the United States Postal Service (“USPS”) annually handles the mailing of millions of transactional cards, such as credit cards, debit cards, electronic cash cards, gift cards, pre-paid calling cards, Internet access cards, membership cards, identification cards, and smart cards.
Recently, card makers have developed ISO-compliant, self-powered cards, in which batteries, circuitry, and electronic components are embedded. The electronic components give the cards additional functionality, providing features such as sound, lights, and alphanumeric displays for secure token value generation. Powered cards having such features are produced by Innovative Card Technologies of Los Angeles, Calif. and are described, for example, in U.S. Pat. Nos. 5,412,199; 5,434,405; 5,608,203; 5,856,661; 6,176,430; and 6,902,116, which are herein incorporated by reference in their entirety.
Powering the cards, however, has introduced difficulties in complying with USPS postal regulations, which dictate that any device powered by dry-cell batteries must have the batteries removed or deactivated to prevent activation of the device in the mail.
SUMMARY OF THE INVENTION
In accordance with an embodiment of the present invention, a mailing apparatus is provided for maintaining an electronically powered card in a deactivated state. The apparatus includes a housing having a face panel and two side panels attached to the face panel at opposite sides. The side panels extend from the face panel in a direction generally perpendicular to the face panel. The apparatus further includes an electronically powered card that has an activation device on a surface thereof and an offset mechanism that establishes an offset distance between the electronically powered card and the face panel so that a force exerted upon the face panel is resisted by the face panel and prevented from causing activation of the activation device of the card.
In accordance with another aspect of the present invention, a mailing apparatus is provided for maintaining an electronically powered card in a deactivated state. The apparatus includes an electronically powered card that has an activation device on a surface and a prevention element attached to the surface of the electronically powered card. The prevention element is disposed around the activation device and is raised above the surface of the card. The prevention element has a thickness sufficient to prevent the activation of the activation device when a force is applied to a planar substrate disposed over the prevention element in a direction generally perpendicular to the planar substrate.
In accordance with another aspect of the prevent invention, a method of packaging and maintaining an electronically powered card in a deactivated state is provided. In the method, a housing is provided that has a face panel and two side panels attached to opposite sides of the face panel and an electronically powered card is inserted into the housing so that an offset distance is established between the face panel and all activation device located on a surface of the card facing the face panel. The housing with the inserted electronically powered card is mailed. The housing and the card have an interface that establishes the offset distance between the face panel and the activation device during transport so that the activation device is not activated by a force exerted on the face panel in a direction generally perpendicular to the face panel.
In accordance with another aspect of the prevent invention, a method of packaging and maintaining an electronically powered card in a deactivated state is provided. In the method, a prevention element is adhered onto an electronically powered card. The electronically powered card has an activation device on a surface thereof and the prevention element is disposed adjacent the activation device. The electronically powered device and adhered prevention element is inserted into an envelope or mailing container and the envelope or mailing container is mailed with the electronically powered card and adhered prevention element inserted therein. The prevention element has a thickness sufficient to prevent the activation of the activation device when a force is applied to an envelope or mailing container disposed over the prevention element during transport in a direction generally perpendicular to the activation device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a powered card according to an embodiment of the present invention.
FIG. 2A is a schematic diagram of a perspective view of a powered card and a mailing apparatus, with the mailing apparatus having slots that receive the powered card, according to an embodiment of the present invention.
FIG. 2B is a schematic diagram of a partial cross-sectional view of the powered card and mailing apparatus of FIG. 2A , taken along line B-B.
FIG. 2C is a schematic diagram of a partial cross-sectional view of a powered card and mailing apparatus, with the mailing apparatus having a front panel, a back panel, and two side panels, and having slots that receive the powered card, according to an embodiment of the present invention.
FIG. 2D is a schematic diagram of a cross-sectional view of the powered card and mailing apparatus of FIG. 2A taken along line B-B and showing a force applied to the mailing apparatus, according to an embodiment of the present invention.
FIG. 3 is a schematic diagram of a cross-sectional view of a powered card and a mailing apparatus, with the card having slots that receive protrusions of the mailing apparatus, according to an embodiment of the present invention.
FIG. 4A is a schematic diagram of a cross-sectional view of a powered card and a mailing apparatus, with the mailing apparatus having interior protrusions, according to an embodiment of the present invention.
FIG. 4B is a schematic diagram of a partial cross-sectional view of a powered card and a mailing apparatus, with the mailing apparatus having an interior protrusion protruding from its side panel, according to an embodiment of the present invention.
FIG. 4C is a schematic diagram of a partial cross-sectional view of a powered card and a mailing apparatus, with the mailing apparatus having an interior protrusion protruding from its face panel and a side panel, according to an embodiment of the present invention.
FIG. 4D is a schematic diagram of a partial cross-sectional view of a powered card and a mailing apparatus, with the mailing apparatus having a single interior protrusion, according to an embodiment of the present invention.
FIG. 5A is a schematic diagram of a cross-sectional view of a powered card and a mailing apparatus, with the mailing apparatus attached to a face of the card, according to an embodiment of the present invention.
FIG. 5B is a schematic diagram of a powered card and a mailing apparatus, with the mailing apparatus covering only a portion of a face of the card, according to an embodiment of the present invention.
FIG. 6A is a schematic diagram of a cross-sectional view of a powered card and a mailing apparatus, the mailing apparatus comprising one or more projections adhered to a face of card proximate to the switch, according to an embodiment of the present invention.
FIG. 6B is a schematic diagram of a partial perspective view of the powered card and mailing apparatus of FIG. 6A .
FIG. 7 is a schematic diagram of a cross-sectional view of a powered card and a mailing apparatus, the mailing apparatus comprising a compressible release liner adhered to a face of card, according to an embodiment of the present invention.
For clarity and ease of understanding, the components shown in the figures are not drawn to scale.
DETAILED DESCRIPTION
Embodiments of the present invention provide a mailing apparatus for a powered card. The mailing apparatus prevents activation of the powered card during mailing.
An exemplary powered card comprises a thin, flexible substrate (e.g., paper, thin cardboard stock, or plastic) having an embedded battery and electrical circuitry. The powered card is preferably equal in size to a conventional credit card, and may meet at least the flexibility requirements of ISO 7816. Powered by the battery, the circuitry can activate electronic output devices that, for example, display an encrypted light array, display alphanumeric characters or graphics, or play a voice message. From this output, a user can obtain information necessary to complete a transaction, for example, authenticating access to a financial account. The card can be branded or printed and may be traded, collected, or distributed as part of a promotion.
The electrical circuitry can be activated by any means suitable for a particular application. For example, the circuitry can be activated by light sensors, audio sensors, motion sensors, wireless sensors, or mechanical switches (e.g., membrane switches). With light, audio, and motion, the powered card would be activated when the appropriate stimulus is received. With wireless sensors using, for example, radio frequency identification (RFID), Bluetooth™, WiFi, or near frequency communication (NFC) technology, the powered card would be activated by the appropriate wireless signal. With mechanical switches, the powered card can be, for example, activated by a user's pressing a button or multiple buttons, or by a sliding a switch. In some applications, a user-actuated mechanical switch may be preferred to save power and extend the shelf life of the powered card.
In an embodiment of the present invention, the circuitry and battery of a powered card is capable of insertion into a substrate equal in size to a conventional credit card, and meets at least the flexibility requirements of ISO 7816. An appropriate flexible battery for such an apparatus is available from Solicore (Lakeland, Fla.), which produces batteries using polymer matrix electrolyte (PME). The batteries are ultra-thin, flexible, environmentally friendly, and safe, and preferably having the following characteristics:
low profile design—approximately 0.3 mm thick; flexible and will not break or crack when bent or flexed; conformable, in that the electrolyte can be a solid, non-compressible film, which can be shaped and formed into a variety of designs; compatible with high speed printing and binding processes, and card manufacturing processes, and can survive hot lamination processes; operable over a wide temperature range (−20° C. to +60° C.); offer high ionic conductivity over a broad temperature range; feature low self discharge rates (less than 1% per month); provide high energy density (up to 300 Wh/l), thus offering maximum performance in smallest packages; possess self connecting terminals; are non-toxic, disposable, and environmentally friendly; contain solid polymer electrolyte—no volatile liquids or gelling agents; offer overall safety: with no out-gassing, swelling, or thermal runaway; no need for added safety devices; and pass UL requirements for crush test, drop test, and nail test; and enjoy an inherently safe design, which reduces the need for additional battery safety circuitry.
The circuitry of the powered card includes at least one electronic output device that provides the user with information, such as a token value necessary for authentication. For example, the electronic output device can display an encrypted light array, alphanumeric characters, or a graphic, or can play a voice message. The user would then use the information for the purpose of authentication to obtain access to an associated system, such as a banking system or online game system.
FIG. 1 illustrates a powered card 100 according to an embodiment of the present invention. As shown, card 100 comprises a substrate 104 , a battery 106 , and circuitry 108 . Substrate 104 can be paper or any other thin flexible material. Battery 106 and circuitry 108 are embedded in substrate 104 (e.g., sandwiched between a front and back face of substrate 104 ), as represented by the dashed lines. Circuitry 108 includes a controller 102 , which may include, for example, a token value generator, a microprocessor, memory, clock, and any other necessary circuitry or devices. Circuitry 108 is controlled by a switch 110 , such as a press button. Alternatively, circuitry 108 could be controlled by a light, audio, or motion sensor. Circuitry 108 also includes one or more electronic output devices that are activated when circuitry 108 is powered. For example, circuitry 108 can include an illumination device 114 , a display 16 , a speaker 118 , and/or a vibrator 120 .
As one of ordinary skill in the art would appreciate, circuitry 108 is shown only for illustration purposes and could include differently configured wires or conductive traces. For example, conductors to the illumination device 114 could be individually connected to each of the illumination elements (e.g., each LED or each electroluminescent device), or connected collectively such that the elements could be illuminated in unison, or some combination thereof. Similarly, if an alphanumeric or graphic display is used, the circuitry can be configured to drive the individual elements thereof in accordance with any desired sequence or design.
In one embodiment, substrate 104 comprises front and back faces made from cardstock and adhered together using adhesive. Battery 106 , circuitry 108 , and the other components are all sufficiently thin and flexible that the powered card has the same “feel” as a conventional cardstock playing card.
In another embodiment, substrate 104 comprises front and back faces made from plastic sheeting, similar to that used for a credit card-sized ISO 7816 compliant card. Optionally, thinner layers of plastics can be used to allow for increased flexibility.
In operation, powered card 100 activates in response to completion of circuitry 108 , which provides power from battery 106 to the electronic output devices. In this example, circuitry 108 is completed by pressing button 110 . Alternatively, another mechanical switch, such as a slide switch, could be used to activate card 100 .
Once circuitry 108 is closed, controller 102 and circuitry 108 activate one or more electronic output devices 114 , 116 , 118 , and 120 . For example, controller 102 and circuitry 108 can light illumination device 114 in a particular pattern that reveals a code, can display an alphanumeric message or graphic 122 on display 116 , can play a sound, a message, or music through speaker 118 (e.g., a voice stating a code), or can activate vibrator 120 in a pattern that reveals a code. Illumination device 114 can comprise, for example, LED lights, incandescent lights, or electroluminescent devices. Display 116 can comprise, for example, an LCD screen, an electroluminescent display (such as those produced by Philips Electronics of Amsterdam; Sharp of Osaka, Japan; or Planar Systems, Inc. of Beaverton, Oreg.), or a printable electronic ink (such as those produced by E Ink of Cambridge, Mass., or Xerox of Palo Alto, Calif.). Speaker 118 can comprise, for example, a miniature speaker suitable for tight form factor applications. Vibrator 120 can comprise, for example, a miniature vibrator suitable for tight form factor applications, such as applications involving pagers and cellular telephones.
FIGS. 2A-2D illustrate a powered card 200 and mailing apparatus 202 according to an embodiment of the present invention. As shown, mailing apparatus 202 is a sleeve that includes a face panel 204 and two side panels 206 , 208 . Side panels 206 have slots 210 into which the edges of the powered card 200 slide, thereby holding the front face of the card 200 at a fixed distance from the underside of face panel 204 . Mailing apparatus 202 is sufficiently rigid enough to retain card 200 within slots 210 , and can optionally include a second face panel 212 opposing face panel 204 to provide a desired rigidity, as is shown in FIG. 2C . In addition, face panel 204 is itself sufficiently rigid enough to resist a force (especially a point force) in the general direction of arrow 214 , to prevent a switch on the face of card 200 from being activated. As one example, FIG. 2D illustrates face panel 204 yielding slightly to the force 214 , but not allowing contact with switch 216 . Although shown as not contacting switch 216 , the flexibility of face panel 204 could allow some degree of contact, as long as the force 214 is sufficiently dissipated or distributed to prevent actuation of switch 216 . The degree to which the face panel 204 can contact switch 216 or any other portion of the face of panel 204 would of course depend on, for example, the type and sensitivity of the switch. Mailing apparatus 202 could be made of plastic, such as ABS or PVC.
Although FIG. 2A depicts the mailing apparatus 202 covering a majority of the card 200 , mailing apparatus 202 could cover any appropriate length of the card 200 depending on, for example, the location of switches or other electronic components that should not be activated or damaged during mailing. As an example, if only a small switch need be covered, then mailing apparatus 202 could be a narrow band spanning the width of card 202 , with the band just wide enough to cover the small switch.
FIG. 3 illustrates a powered card 300 and mailing apparatus 302 according to another embodiment of the present invention. As shown, card 300 defines slots 310 in two of its opposing edges. Mailing apparatus 302 includes a face panel 304 , two opposing side panels 306 , and two opposing protrusions 307 protruding from side panels 306 . Protrusions 307 are adapted to slide within slots 310 . In this position, the face panel 304 of mailing apparatus 302 is disposed over and spaced apart from the front face of card 300 and its switch 316 . Face panel 304 resists forces applied in a direction generally perpendicular to the front face of card 300 , as described above with reference to FIGS. 2A-2D .
FIG. 4A illustrates a powered card 400 and mailing apparatus 402 according to another embodiment of the present invention. As shown, mailing apparatus 402 is a sleeve that includes a face panel 404 , two side panels 406 , and a back panel 412 . The underside of face panel 404 has one or more protrusions 403 located and adapted to contact portions of the front face of card 400 that do not affect the operation of the card 400 (e.g., areas of the face away from switch 416 ). The card 400 is held in place in the interior of mailing apparatus 402 , with the face panel 404 disposed over and spaced apart from the front face of card 400 and its switch 416 . In this position, face panel 404 resists forces applied in a direction generally perpendicular to the front face of card 400 , as described above with reference to FIGS. 2A-2D .
Although FIG. 4A depicts the cross-sectional shape of protrusions 403 as round, protrusions 403 could have other cross-sectional shapes such as a rectangle, square, or triangle. In addition, protrusions 403 could be isolated protrusions on the underside of face panel 404 , or could be continuous rails along the length of mailing apparatus 402 . In one embodiment, mailing apparatus 402 has one isolated protrusion in each of the four corners of face panel 404 . In another embodiment, mailing apparatus 402 has two continuous rails, each having a rectangular cross-section, with one disposed proximate to a side panel 406 and the other disposed proximate to the opposite side panel 406 . In another embodiment, as shown in FIG. 4B , a protrusion 403 protrudes from a side panel 406 of mailing apparatus 402 , holding an edge of card 400 . In another embodiment, as shown in FIG. 4C , a protrusion 403 protrudes from both a side panel 406 and the face panel 404 , for example, filling the corner of mailing apparatus 402 and holding an edge of card 400 .
Although FIG. 4A shows the use of multiple protrusions, an alternative embodiment of the present invention provides only one protrusion, an example of which is shown in FIG. 4D . In this exemplary configuration, mailing apparatus 452 has a single protrusion 453 , which can be, for example, an isolated round protrusion in the center of the face panel 454 of mailing apparatus 452 . The mailing apparatus 452 has side panels 456 and back panel 462 having similar characteristics as previously described side panels 406 and back panel 412 . The protrusion 453 may alternatively be a continuous round protrusion (e.g., shaped like a road speed bump) extending the length of mailing apparatus 452 along the center of face panel 454 . The protrusion 453 is preferably located to contact the face of card 400 in an area apart from switch 466 . In this manner, protrusion 453 prevents a force 464 applied in a direction generally perpendicular to face panel 452 from deflecting face panel 452 against switch 466 and activating switch 466 .
An alternative embodiment of the present invention provides a mailing apparatus, such as the mailing apparatus 402 , with a closed end. In other words, rather than having a sleeve with two open ends, this alternative embodiment provides a closed end to form a pocket. In this manner, a powered card can be inserted into the pocket sleeve, with the sleeve covering only a portion of the card (e.g., one-third of the card starting from an end). The pocket sleeve could have protrusions or slots as described above, to prevent activation of a switch or other electronic component.
FIG. 5A illustrates a cross-sectional view of a powered card 500 and mailing apparatus 502 according to another embodiment of the present invention. As shown, mailing apparatus 502 is attached to the face of card 500 oh which a switch 516 is disposed, providing a cover over the switch. In this manner, mailing apparatus 502 resists a force 514 applied in a direction generally perpendicular to the front face of card 500 , similar to the embodiments described above with reference to FIGS. 2A-2D . In this example, mailing apparatus 502 is attached to card 500 by a layer of adhesive 517 , which is strong enough to hold the mailing apparatus 502 to the card 500 during mailing, but can be conveniently released by the user after mailing so that the card 500 can be used. Although FIG. 5A shows the mailing apparatus 502 covering a majority of the width of card 500 , mailing apparatus 502 could cover any portion of the width or length of card 500 , depending on the location of the components of card 500 . For example, as shown in FIG. 5B , if a switch is located in only one small portion of the face of card 500 , mailing apparatus 502 could be placed over only the switch, leaving the remaining portion of the face of the card 500 uncovered.
FIGS. 6A and 6B illustrate a further embodiment of the present invention, in which the mailing apparatus 602 comprises one or more projections adhered to the face of card 600 proximate to the switch 616 . The projections 602 help prevent structures, such as the paper of the envelope in which card 600 is mailed, from contacting switch 616 and activating card 600 . Although shown as doughnut-shaped, mailing apparatus 602 could comprise other shaped projections, such as individual raised bumps placed around the switch.
FIG. 7 illustrates a cross-sectional view of a powered card 700 and mailing apparatus 702 according to another embodiment of the present invention. In this configuration, mailing apparatus 702 comprises a compressible release liner that is adhered to the face of card 500 over the switch 716 . Mailing apparatus 702 is made of a material having properties (e.g., hardness, compressibility, and thickness) sufficient to resist the typical forces 714 encountered during mailing, applied generally in a direction perpendicular to the face of card 700 . For example, mailing apparatus 702 could be made of a compressible foam or a compressible gel. Alternatively, mailing apparatus 702 could comprise a chamber filled with a liquid or a gas. In this manner, mailing apparatus 702 can dissipate or distribute forces 714 so that switch 716 is not actuated. In one configuration, mailing apparatus 714 is attached to the face of card 700 by a layer of adhesive that is strong enough to hold the mailing apparatus 702 to the card 700 during mailing, but can be conveniently removed by the user after mailing so that the card 700 can be used.
Embodiments of the present invention therefore provide mailing apparatus that prevent activation of a powered card during mailing, to comply with applicable postal regulations. The mailing apparatus can be temporarily applied to a powered card for mailing, and then conveniently removed by the user so that the powered card can be activated and used. In addition, embodiments of the present invention are inexpensive and conveniently incorporated into high volume printing, card-making, and mailing operations.
Although embodiments of the present invention describe mailing apparatus with respect to powered cards having mechanical switches such as membrane switches, the mailing apparatus of the present invention are equally applicable to other switches, such as sound-activated or light-activated switches. For example, the mailing apparatus 702 of FIG. 7 could be used to seal a light sensor, wireless sensor, or sound sensor that is used to activate a powered card. In this manner, when the user removes mailing apparatus 702 from card 700 , the card is activated, for example, illuminating lights and displays to convey a mailed advertisement. In the case of a wireless sensor, the mailing apparatus could be made of an electromagnetically opaque material to act as a shield, preventing wireless signals from activating the card during mailing.
In one implementation, the powered card and the mailing apparatus are branded (e.g., with graphics, logos, colors, or holography) to associate the card and mailing apparatus with each other and/or with a system to which the card provides access. The powered cards and mailing apparatus may be disposable (in that they may have limited temporal use) or may be intended to be collectors' items.
The powered cards and mailing apparatus in accordance with the present invention may be given away free, given away as part of a related promotion, given as a gift with a purchase of an unrelated item, included in the packaging of a video game, or made available for purchase on their own as products in their own right.
The foregoing disclosure of the preferred embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many variations and modifications of the embodiments described herein will be apparent to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is to be defined only by the claims, and by their equivalents.
Further, in describing representative embodiments of the present invention, the specification may have presented the method and/or process of the present invention as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims. In addition, the claims directed to the method and/or process of the present invention should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied and still remain within the spirit and scope of the present invention.
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Apparatuses and methods for packaging electronically powered cards are provided for maintaining electronically powered cards in a deactivated state. In an embodiment, a housing having a face panel and two side panels attached to the face panel at opposite sides is configured to provide an offset distance between an activation device on the card and the housing so that the activation device is prevented from being activated by a force exerted on the housing. Annular or circular devices can also be provided for establishing an offset distance between activation devices on the card and planar substrates.
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BACKGROUND OF THE INVENTION
The invention relates to an improved method for activating or reactivating potassium nitrate for use in the ion exchange method of strengthening sheet glass.
Glass sheets have previously been strengthened by the well known ion exchange method in which glass sheets are emersed in a molten bath of potassium nitrate. The potassium nitrate, however, must be of a highly purified variety such as that used in the laboratory reagent grades. Untreated commercial grades of potassium nitrate such as NF grade or high "K" technical grade potassium nitrate do not serve to strengthen sheet glass and, additionally, the treatment may result in staining.
In U.S. Pat. No. 3,415,637 a successful commercial method of activating commercial grades of potassium nitrate or reactivating contaminated highly purified grades of potassium nitrate is disclosed. As disclosed in U.S. Pat. No. 3,415,637, potassium nitrate of a commercial grade could be activated or purified by the addition thereto of a small quantity of potassium silicate. The amount of potassium silicate added to the potassium nitrate being dictated by the degree of contamination of the potassium nitrate with impurities, notably lithium. It has now been found that potassium chloride and arsenous sulfide may be advantageously used to activate or purify commercial grades of potassium nitrate.
SUMMARY OF THE INVENTION
A small quantity of As 2 S 3 or KCl is added to a commercial grade of molten KNO 3 to activate or purify the potassium nitrate thus making it suitable for strengthening glass by the ion exchange method. The quantities of arsenous sulfide or potassium chloride used depend upon the degree of contamination of the potassium nitrate and also upon which of the two purifying agents is being used. For example, 0.2% As 2 S 3 will show improved results with N. F. grade potassium nitrate suplied by Stauffer Chemical Company (hereinafter referred to as "A" salt); however, about 0.4% As 2 S 3 is required to fully activate the same. With high K Technical Grade potassium nitrate (hereinafter referred to as "B" salt) supplied by Southwest Potash Company, full activation is achieved using 1.2% arsenous sulfide although lesser quantities do show some improvement. For full activation a 0.6% addition of potassium chloride to the A salt is required and 11% addition of potassium chloride is required for full activation of the B salt.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Arsenous Sulfide in A Salt
A 31/2 quart stainless steel beaker was filled with 2000 grams of the A salt, the salt melted and the temperature of the bath was held at 485°C. 1 × 5 inch single strength window glass samples were treated in this bath for 20 hours. After treatment they were found to be stained and to have zero stress. Four grams of As 2 S 3 were slowly added to the molten potassium nitrate thus giving an equivalent of 0.2% As 2 S 3 in the bath. After complete decomposition had occurred additional 1 × 5 inch samples of single strength window glass were treated in the bath. for 20 hours at 485 C. At the end of this treatment the glass samples were removed, washed, dried and examined. A stress of 0.7950 kg./mm. 2 was measured in each of the samples of those treated; however, all of the samples had a light stain on their surfaces.
Another 4 grams of As 2 S 3 was added to the bath making a total of 0.4% by weight As 2 S 3 in the bath. The test was again repeated with new 1 × 5 inch pieces of single strength glass for 20 hours at 485°C. Upon completion of this treatment, examination of the glass samples showed them to be free from any stain and to have a stress of 0.8215 kg./mm 2 . This value is considered to be normal and is the same as produced in a bath of highly purified grades of potassium nitrate such as a CP grade. The permanence of this activation or purification of the A salt by the 0.4% of As 2 S 3 was tested daily over a period of 21/2 months with a total of 41 treatments. During all of this period no surface stain was noted and the stress in the glass treated was 0.8215 kg./mm 2 .
In another experiment the arsenous sulfide concentration was increased to 0.8% by weight. 1 × 5 inch single strength glass samples were treated at 485°C for 20 hours. The test yielded a stress of 0.8215 kg./mm 2 with no surface stain. It will be seen, therefore, that with the A salt no advantage is gained in adding more then about 0.4% of arsenous sulfide. Although, no disadvantage is experienced either. The upper limit of the quantity of arsenous sulfide employed, is, essentially economical once full action of the salt has been achieved.
Arsenous Sulfide in B Salt
A 2,000 gram bath of the B salt was prepared by melting the same in a 31/2 2 quart stainless steel beaker at 485°C. Then 1 × 5 inch single strength sheet glass samples were treated in this bath for 20 hours at 485°C. Upon completion of the treatment it was found that the samples were heavily stained and with zero stress. Ten grams of arsenous sulfide (equivalent to 0.5% by weight) were added to the molten B salt. 1 × 5 inch single strength glass samples were again treated in the bath for 20 hours at 485°C. Upon completion of the treatment the samples showed a lightly stained surface and a stress of 0.6095 kg./mm 2 . An additional 2 grams of As 2 S 3 was added to the bath leaving a total of 0.6% As 2 S 3 . Again, 1 × 5 inch single strength glass samples were treated in the molten B salt for 20 hours at 485°C. Examination upon completion of the treatment showed these samples to have a good surface with a stress of 0.7400 kg./mm 2 .
The amount of arsenous sulfide was then increased to 0.8% tested and then increased further to 1.0%. At 1.0% the glass samples showed a stress of 0.7950 kg./mm 2 after 20 hours at 485°C. Finally, the arsenous sulfide was increased to 1.2% by weight in the B salt bath and 1 × 5 inch single sheet strength glass samples treated in this bath for 20 hours at 485°C. These samples (in the bath containing 1.2% by weight) showed a stress of 0.8215 kg./mm 2 with stain free surfaces. Thus, it takes approximately three times the amount of arsenous sulfide to activate the B salt as it does to activate the A salt.
Potassium Chloride in A Salt
2,000 grams of the A salt were melted in a 31/2 quart stainless steel beaker at 485°C. 1 × 5 inch single strength window glass samples were treated in this molten A salt for 20 hours at 485°C. Upon examination they were stained and developed no stress. 4 grams (0.2%) of potassium chloride was added to the bath and single strength glass samples 1 × 5 inch were again tested for 20 hours at 485°C but they developed no stress and were stained. An additional 4 grams of potassium chloride was added to the A salt bath making a total of 8 grams (0.4%) then in the bath. Again single strength window glass samples 1 × 5 inch were treated for 20 hours at 485°C and upon examination the samples were found to be stain free and to have developed a stress of 0.7685 kg./mm 2 .
Further addition of 4 grams of potassium chloride was made to the A salt bath making a total of 12 grams (0.6%) in the molten bath. Single strength glass sheets 1 × 5 inch were again treated for 20 hours at 485°C and were found to be free from surface stain and to have the normal stress of 0.8215 kg./mm 2 .
The last bath (A salt having 0.6% by weight of potassium chloride) was then retested 13 times over the succeeding three (3) weeks and in all of the tests the glass treated had good surfaces and the stress remained at 0.8215 kg./mm 2 .
Potassium Chloride in B Salt
2,000 grams of B salt was melted at 485°C in a 31/2 quart stainless steel beaker. Single strength window glass samples 1 × 5 inch were treated for 20 hours at 485°C in this B bath. After treatment they were found to be heavily stained and to produce no stress. An addition of 1.0% potassium chloride by weight (20 grams) was added to this bath and glass samples of the same kind were treated for 20 hours at 485°C and upon completion of the treatment were found to be stained and have no stress. An additional 0.3% potassium chloride was added to the bath making a total of 1.3% by weight in the bath. Glass samples treated for the same time and temperature as previously, developed no stress and were stained. A further addition of 0.7% potassium chloride was made to the bath making a total of 2.0% in the B salt bath. Single strength glass samples were again tested for the same time and temperature. The surface after treatment was found to be slightly etched but not stained. No stress was developed. A further addition of 0.3% potassium chloride (a total of 2.3%) showed a slight surface improvement but still no stress was developed in the glass. With an additional 0.7% potassium chloride (a total of 3.0%) added to the bath, tests showed no improvement either in stain or stress. With the addition of an additional 1.0% potassium chloride (for a total of 4% potassium chloride in the bath) the single strength window glass samples were treated for 20 hours at 485°C, they showed a surface that was lightly pitted and a stress had developed of 0.5890 kg./mm 2 . With the addition of another 1.0% potassium chloride by weight to the bath (a total of 5% potassium chloride in the B salt) the glass samples were shown, after treatment, to have a good surface with no stains or pits and the stress developed was 0.6360 kg./mm 2 . With a still further addition of 1.0% of potassium chloride (a total of 6%) no improvement in the stress was noted over the previous test. At 7% by weight of potassium chloride in the B salt bath the glass treated had good surface and a stress of 0.7420 kg./mm 2 .
Addition of 1.0% potassium chloride was made daily to the bath until there was a total of 10% by weight of potassium chloride in the B salt bath. At this level treatment of the glass samples produced stain free surfaces and a stress of 0.7950 kg./mm 2 .
Finally, with the addition of still another 1.0% potassium chloride by weight (the B bath now having 11% potassium chloride by weight) single strength window glass samples treated in this bath for 20 hours at 485°C developed the normal stress of 0.8215 kg./mm 2 with good surfaces. Thus it takes 11% potassium chloride to completely activate the B salt of potassium nitrate while only 0.6% of potassium chloride is required to activate the A salt bath.
Thus it will be seen that both arsenous sulfide and chloride will fully activate commercial grades of potassium nitrate salt making these salts suitable for chemical strengthening of soda-lime glass by ion exchange. Further, the potassium salts so treated do not stain or attack the glass surface being treated. Tests have also shown that once the potassium nitrate bath has been purified to the extent that it strengthens the glass samples to a value of 0.8215 kg./mm 2 with good surfaces no further improvement is obtained by further additions of arsenous sulfide or potassium chloride.
It is believed that calcium and magnesium impurities in potassium nitrate react with the potassium chloride to form calcium chloride and magnesium chloride respectively. Calcium chloride has a melting point of 772°C and a boiling point of 1600°C and magnesium chloride has a melting point of 712°C and a boiling point of 1,412°C, all of which temperatures are well above the operating range of the potassium nitrate salt bath which is generally operating between about 400°C to about 500°C. It is further believed that the arsenous sulfide combines with calcium and magnesium to form, respectively, calcium sulfate with a melting point of 1,450°C and magnesium sulfate with a melting point of 1,185°C. The precise chemistry involved in supressing the deleterious effects of calcium and magnesium impurities in commercial grades of potassium nitrate is not known; however, as the tests above clearly show the arsenous sulfide and potassium chloride do serve to make these commercial grades of potassium nitrate useable.
For an activator or purifier for such salts to be suitable, it must render the salt capable of producing stress in soda-lime glass equal to that produced by reagent of CP grades of potassium nitrate salts under the same conditions. Further, the activator of commercial grades of potassium salt must produce a suitable bath that will not stain, pit, etch or otherwise attack the surface of the glass being treated. Lastly, the activator should be permanent in the molten potassium nitrate bath.
A number of other compounds have also been tested as possible activators for commercial grades of potassium nitrate salt for use in strengthening of soda-lime glass by ion exchange. Some of the compounds tested were sodium silicate, copper nitrate, potassium chromate, potassium bromide, arsenic pentoxide, arsenic trioxide, potassium bisulfate, stannic oxide and sulfur dioxide. None of these met these requirements for complete activation of commercial grades of potassium nitrate salts.
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By the addition of a small quantity of potassium chloride or arsenous sulfide to commercial grades of molten potassium nitrate, the potassium nitrate may be activated or purified sufficiently to produce strengthened glass by ion exchange equal to glass strengthened by use of highly purified laboratory reagent grades of potassium nitrate.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a cell reagent, an assay method for measuring an analyte and a kit therefor.
2. Description of Related Art
British patent specification No. 2,005,018 describes a method of detecting a toxic substance by forming a suspension of a luminous micro-organism in an aqueous medium, contacting the suspension with the toxic substance, and sensing a decrease in the light output of the luminous micro-organisms caused by the toxic substance. An as-say kit embodying this principle is marketed by Microbics Inc. under the Trade Mark Microtox, and is in routine use in a number of environmental laboratories.
Although the Microtox kit is believed to use a naturally occurring bacterium, there is interest in the use of genetically modified luminous micro-organisms, as they potentially have a wider area of application. For example, different micro-organisms can be made with sensitivities to different ranges of toxic substances or even individual toxic substances. The use of genetically modified organisms for this purpose is described in U.S. Pat. No. 4,581,335.
There is an increasing need to perform these assays at the site of potential pollution, and this may well involve tests outside normal laboratory facilities. But such cells are often pathogenic or subject to controlled use. One potential problem when using genetically modified organisms is the possibility that they might escape into the environment and cause harm by growing in an uncontrolled manner. Legal restrictions on use of genetically modified organisms in the field are, or may be, applied in various countries.
It is an object of this invention to avoid the above problem by using genetically modified organisms which have been killed. But as is explained below, the invention is not limited to genetically modified organisms, nor to organisms that emit light, nor to organisms for use in the stated assay for toxic substances.
When micro-organisms are subjected to increasing doses of ionizing radiation, the organisms viability progressively decreases. Thus, a dose of 26 kGy is recommended for sterilizing micro-organisms, and is amply sufficient to reduce their viability to zero.
Non-recombinant luminescent organisms have been subjected to ionising radiation, and the luminescent property used to monitor the radiation dose (Phys. Med. Biol. 28, 599-602, 1983). But the radiation doses were not sufficient to kill all the organisms present.
SUMMARY OF THE INVENTION
In one aspect, this invention provides an assay reagent comprising bacterial cells which have been killed but which retain a functional metabolic activity, the reagent not containing corresponding bacterial cells which have not been killed.
Cells which have been killed have 0% viability. They are unable to reproduce. Cells preferably retain a detectable functional metabolic activity and structural function including one or more of the following properties: cell-wall integrity; membrane/energy function; co-factor provision; metabolic requirement; gene expression; protein synthesis; cytoplasmic enzyme activity; vegetative metabolic processes involving energy usage and transfers.
Preferably the detectable functional metabolic activity is bioluminescence. It will be appreciated that continued bioluminescence may involve continued protein synthesis. It is surprising that cells which have been killed nevertheless retain a functional metabolic activity, such as bioluminescence, albeit at reduced intensity compared to the non-irradiated cells. More surprising is the fact that the functional metabolic activity in these killed cells is altered in a dose-responsive way by substances which alter the functional metabolic activity in a dose-responsive way in the corresponding living cells. Thus, for example, luminescence of killed bioluminescent organisms is changed in a dose-responsive way in the presence of a substance which is a toxicant for the corresponding living organism.
Preferably the cells used in this invention are micro-organisms which may be genetically modified organisms. Often, the micro-organisms are bacteria. E. coli bacteria were used in the examples below, but other bacteria could have been used with equivalent effect. The cells may be stored and presented in a stabilised state. Preferably this stabilized state may be lyophilized.
The cells may have been killed by radiation e.g. ionizing radiation. The gamma-radiation from a cobalt-60 source was used in the examples below. But gamma-radiation from other sources, or X-rays, or an electron beam, or even ultraviolet radiation, could have been used with equal effect. The radiation damage must be sufficient to kill the cells, but should preferably be not much greater than is necessary for that purpose. This is because the radiation damage also progressively reduces the bioluminescence or other functional metabolic activity of the organisms. The required radiation dose depends on the number of cells present, e.g. on the cell density, and on the nature of the cells, and is quite easily determined by routine experiment, as demonstrated in the examples below. Killing the cells by other means, without at the same time destroying all their functional metabolic activity(ies), is possible but not preferred.
In another aspect, the invention provides use of the cells, which have been killed but which retain a functional metabolic activity, in a bio-assay. One example of a bio-assay is the assay for toxicant mentioned above.
Thus in another aspect, the invention provides a method of assaying an analyte, by the use of a liquid suspension of signal-generating cells, which comprises mixing together a liquid sample possibly containing the analyte and an aliquot of the liquid suspension to form a test mixture and thereafter observing a signal generated by the cells, wherein the cells have been killed, preferably by ionizing radiation, but retain a signal-generating functional metabolic activity, preferably bioluminescence.
In yet another aspect, the invention provides a kit for performing the stated assay, comprising a supply of bacteria, which bacteria have been killed but retain a signal-generating functional metabolic activity such as bioluminescence; a supply of a reconstitution buffer; means for handling the liquid samples and liquid aliquots, such as containers and pipettes for performing the assay; and optionally also an instrument for measuring the signal. The bacteria are preferably in a stabilised state, e.g. by being lyophilized or frozen.
The nature of the analyte is not material to the invention. Many analytes especially toxicants are well known which have the effect of reducing the bioluminescence or other signal generated by living cells. Toxicants--and the inventors have tested a series--have a corresponding effect, of reducing the bioluminescence or other signal generated by the killed cells of this invention. Other analytes may have the property of inducing de novo gene expression in the killed cells (see Example 3).
BRIEF DESCRIPTION OF THE FIGURES
Reference is directed to the accompanying drawings, in which:
FIG. 1 is a graph to show the effect of irradiation on viable count and light output;
FIG. 2 is a graph to show the effect of irradiation on the sensitivity of the light reagent to Bronopol; and
FIG. 3 is a graph to show the effect of irradiation on the induction of bioluminescence in noninduced bioluminescent E. coli.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLE 1
Method
1. Each box was packed with 60 vials of LUX light reagent (a lyophilized sample of genetically modified bacteria in which the LUX gene responsible for bioluminescence was present in a plasmid, the suspension having a starting OD 630 of 0.9 in polypropylene vials), with a dosimeter placed in the center.
2. Boxes were taped securely and subjected to external doses of radiation from a cobalt-60 source in the range of 1-8 kGy.
3. 2 mls of sterile CLPB (controlled log phase broth (Lab M)) was injected aseptically into three vials from each box using a syringe and sterile needle and into 3 vials which had not been irradiated.
4. Duplicate samples were plated onto Luria Agar plates.
5. Plates were incubated overnight at 30° C. before counting. The results are shown in FIG. 1, where the filled squares represent the viability counts.
6. Five vials were reconstituted using 0.5 ml BAR3 buffer (25 mM HEPES pH 6,50 mM NaCl, 12.5 mM MgSO 4 ) and left for 20 minutes at room temperature.
7. The light output was read in a luminometer. The results are shown in FIG. 1, where the filled triangles represent light outputs at different levels of irradiation. As can be seen, an internal radiation dose of 3.5 kGy was enough to kill the cells, but by no means extinguished the light output.
EXAMPLE 2
The addition of different concentrations of biocide to bioluminescent E. Coli RMT1/pBL399 affects the bioluminescence in a dose responsive way. This experiment aims to demonstrate that the dose responsive effect is retained, even when the organisms are irradiated.
Materials
RMT1/pBL399 LUX biocide assay light reagent batch A (unirradiated) and batch B (irradiated).
BAR4 buffer (25 mM HEPES, pH 6, 75 mM NaCl, 12.5 mM MgSO 4 ).
Luminometer
Sarstedt calibration vials.
Bronopol Aldrich 13,470-8.
Analar water BDH.
Method
1.600 vials of the lux biocide light reagent were packed into metal tins in four upright layers. An amber dosimeter was placed into the center of each layer to record the radiation dose received.
2. The tins were exposed to gamma radiation from a cobalt-60 source, until a target dose of 8 KGy had been received.
3. 5% of the vials were selected randomly from each tin for viability testing.
4.0 .5 ml of controlled log phase broth (CLPB LabM,LAB152!) was aseptically injected into each of the vials selected in (3), through the rubber stopper, using a fresh sterile needle for each vial.
5. The vials were inverted to ensure that all of the contents were washed into the CLPB and incubated at 30° C. for 18 hours.
6. After incubation the entire contents of each vial was placed onto a nutrient agar plate and incubated at 37° C. for 18 hours.
7. Each plate was checked for bacterial colonies, which would indicate survival of the radiation treatment.
8. The following concentrations of bronopol were made: 2, 5, 10, 15 and 20 μg/ml.
9. 15 vials of each batch of light reagent were reconstituted using 0.5 ml BAR4 buffer and left for 10 minutes for the light to stabilise.
10. After 10 minutes the light was read and immediately 0.5 ml of biocide was added with each concentration being tested in triplicate.
11. After a biocide contact time of 2.5 minutes the light was again read.
12. The d-values were calculated and plotted on a log log graph against concentration of bronopol.
Results
The radiation dose received ranged from 7.22 KGy to 8.12 KGy, and no viable cells could be recovered from any one of the vials tested, indicating that the radiation dose had killed all of the bacterial cells in the vials.
See FIG. 2 for the results.
Line equations:
unirradiated: log (y)=-0.386log (x)+0.605
irradiated: log (y)=-0.350log (x)+0.602
Both live and dead (irradiated) RMT1/pBL399 respond to bronopol in the same dose responsive way.
EXAMPLE 3
Method
1. Vials of freeze dried luminescent bacteria were irradiated at 8 kGy as in Example 1.
2. All vials of bacteria (irradiated and non-irradiated) were reconstituted with 0.5 ml of CLPB. The non-irradiated reagent was pooled as was the irradiated.
3. 100 μl aliquots of irradiated and non-irradiated reagent were dispensed into 2×8 microtitre wells.
4. 100 μl aliquots of 40 ng/ml inducer was then added to half the wells of each type of reagent, and 100 μl of CLPB added to the remaining wells as a control. The inducer was N-(β-ketocaproyl)-L-homoserine lactone, a compound known to act as an autoinducer regulating expression of LUX genes.
5. The tray was incubated at 22° C. and the light signals measured at 15 minute time intervals, and left at 22° C. overnight to be read the following morning.
The results are given in FIG. 3. These show that it is possible to induce irradiated (nonviable) non-induced bioluminescent E. coli to react metabolically to inducer and to thence produce light.
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The invention is directed to an assay reagent comprising bacteria cells which have been killed but which retain a functional metabolic activity. The assay reagent is useful in a method for assaying an analyte when the functional metabolic activity of the killed cells is signal-generating. A kit for assaying an analyte using the assay reagent of the invention is also provided.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 11/237351, filed Sep. 28, 2005.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a cargo area for a motor vehicle, and more particularly to a device for retaining cargo.
[0003] Many vehicles include cargo areas having a relatively flat floor leading to a door, such a liftgate, tailgate or hatchback. The door typically pivots away from the flat floor to facilitate access to the cargo area. As a result of the relatively flat cargo area floor, some objects stored in the cargo area may shift during vehicle travel or otherwise come to rest against the door. Upon movement of the door away from the floor, these objects may roll, slide or otherwise fall out of the cargo area. Particularly with a hatchback or liftgate that pivots vertically away from the cargo floor, it can be difficult to prevent cargo from falling out of the vehicle upon opening the liftgate.
SUMMARY OF THE INVENTION
[0004] A retainer for a vehicle cargo area is provided that is bounded in part by a floor and a door moveable between open and closed positions includes a retaining member spanning at least a portion of the cargo area, a pivot feature operably associated with the retaining member, and a retaining feature that yieldably retains the retaining member in its second position to facilitate retaining cargo within the cargo area. The retaining member pivots about the pivot feature relative to the cargo area between a first position and a second position wherein the retaining member is inclined relative to the floor of the cargo area. When the door is open the retainer is normally in its second position to facilitate retaining cargo within the cargo area.
[0005] In one exemplary embodiment, the retaining member is displaced from its second position at least partially toward its first position when the door is closed. Under the force of the biasing member, the retaining member automatically moves towards its second position as the door is moved at least partially toward its open position. This automatically raises the retaining member to its second position upon opening of the door to facilitate retaining cargo within the cargo area. In another exemplary embodiment, the retaining member remains in its second position when the door is closed, but can be moved away from that position to facilitate loading and unloading cargo from the cargo area.
[0006] In one exemplary embodiment, the door is a liftgate that pivots upwardly and downwardly relative to the cargo area and the retaining member spans the gap between sidewalls of the cargo area and is disposed adjacent to an end of the cargo area adjacent to the door. Accordingly, upon movement of the door upwardly away from the cargo area from its closed position towards its open position, the retaining member moves to its second position wherein it is raised upwardly from the cargo area floor providing a lip or partial wall to prevent the contents of the cargo area from rolling, sliding or otherwise falling out of the cargo area before the operator of the upwardly swinging door is able to reach them. Although not necessary, the retaining member preferably pivots both inwardly toward the cargo area and outwardly away from the cargo area to facilitate loading and unloading cargo. The retaining device may also include a locking feature, which permits the retaining member to be releasably locked in a desired position, such as generally flush with the cargo floor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] These and other objects, features and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments and best mode, appended claims and accompanying drawings in which:
[0008] FIG. 1 is a fragmentary perspective view of a vehicle cargo area including one presently preferred embodiment of a retaining device;
[0009] FIG. 2 is a fragmentary side view of the vehicle cargo area with a door enclosing a portion of the cargo area shown in its open position;
[0010] FIG. 3 is an enlarged fragmentary view of the encircled portion 3 of FIG. 2 with the vehicle door shown in its closed position;
[0011] FIG. 4 is an enlarged fragmentary view like FIG. 3 showing some round cargo items being retained by the retaining device;
[0012] FIG. 5 is a fragmentary view illustrating a large cargo item being slidably removed from the cargo area; and
[0013] FIG. 6 is an enlarged fragmentary view of a portion of a vehicle cargo area with a vehicle door shown in its closed position.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0014] Referring in more detail to the drawings, FIGS. 1-3 illustrate a vehicle 10 having a cargo area 12 including a floor 14 , opposed sidewalls 16 (only one of which is shown) extending from the floor, usually a roof 18 and a door 20 providing access to the cargo area 12 from the exterior of the vehicle 10 . In the embodiment shown the door 20 is a liftgate which pivots about a hinge 22 adjacent to the roof from a lowered, closed position to a raised, opened position, as is known in the art.
[0015] A retaining device 24 is provided in or adjacent to the cargo area 12 along an outward edge 26 of the cargo area 12 in the area of the door 20 when the door is closed. In one presently preferred embodiment, the retaining member 24 includes a generally flat panel that extends between the sidewalls 16 and is carried by the vehicle 10 generally adjacent to the floor 14 . The retaining device 24 includes a pivot feature 28 which may be one or more shafts 30 that are preferably carried by the retaining member, co-axially aligned and disposed in pockets 31 in the sidewalls 16 , 18 or other structure of the vehicle to permit pivoted motion or rotation of the retaining member 24 about an axis 32 . The retaining member 24 is moveable from a first position ‘a’ that facilitates loading and unloading cargo from the cargo area, and a second position ‘b’ wherein the retaining member 24 is inclined at an acute included angle relative to the floor 14 to facilitate retaining cargo within the cargo area 12 . In the embodiment shown, the retaining member 24 is preferably generally perpendicular to the floor 14 when in its second position ‘b’ to provide a raised or upstanding lip or wall that prevents objects from rolling, sliding or otherwise falling out of the vehicle from the outward edge 26 of the cargo area
[0016] As best shown in FIGS. 1 and 2 , to facilitate loading and unloading cargo from the cargo area 12 , the retaining member 24 may pivot from its second position ‘b’ both inwardly relative to the cargo area to its first position ‘a’ and outwardly of the cargo area to a third position ‘c’. As best shown in FIG. 5 , then in its third position ‘c’ the retaining member 24 is preferably generally flat to permit cargo 35 to be slidably removed from the cargo area 12 . The retaining member 24 is shown in solid lines in its second position, and in its first and third positions is shown in phantom lines. A retaining feature preferably is provided to releasably or yieldably retain the retaining member in its second position ‘b’. The retaining feature may be a biasing member 34 that yieldably biases the retaining member 24 toward its second position ‘b’ and away from its first position ‘a’. In an embodiment wherein the retaining member 24 can also be moved to a third position ‘c’ (such as shown in FIGS. 1 and 2 ), the biasing member 34 may also yieldably bias the retaining member 24 away from its third position ‘c’ and toward its second position ‘b’. Accordingly the normal position of the retaining member 24 is its second position ‘b’ so that unless acted on by another force or object, the retaining member 24 will preferably assume its second position ‘b’. In one embodiment, the biasing member 34 includes a torsion spring 36 which biases the retaining member 24 away from its first position ‘a’, and a second torsion spring 38 which biases the retaining member away from its third position ‘c’ (see FIG. 1 ). The first and second torsion springs 36 , 38 may be disposed on opposite ends of the retaining member 24 such as being disposed generally about oppositely extending and coaxially aligned shafts 30 about which the retaining member pivots. The retaining feature may include structures or apparatus other than springs, such as detent mechanism, or releasable latch that resists at least some force tending to move the retaining member out of its second position ‘b’ but may ultimately be overcome to permit the retaining member to move from its second position.
[0017] As best shown in FIG. 3 , when the liftgate 20 is in its closed position, a portion of the tailgate preferably engages the retaining member 24 and moves the retaining member 24 out of its second position ‘b’ and toward its first position ‘a’ against the force provided on the retaining member by the biasing member 36 . Accordingly, the biasing member 36 provides a force urging the retaining member 24 against the liftgate 20 when the liftgate is closed. As the liftgate 20 is opened, the biasing member 36 maintains the retaining member 24 in contact with the liftgate until the liftgate is sufficiently open that the retaining member 24 assumes its second position ‘b’ under force of the biasing member. Accordingly, the retaining member 24 automatically moves to its second position ‘b’ as the liftgate 20 is opened to provide a barrier against objects 35 (see e.g. FIG. 4 ) falling out of the vehicle as the liftgate is initially opened. The retaining member 24 may be moved fully to its first position ‘a’ by the liftgate 20 when the liftgate is closed, and an outer edge 40 of the retaining member 24 may be generally flush with an inside surface 42 of the liftgate 20 so that objects in the cargo area 12 are not resting on or engaged with an outer surface 41 of the retaining member 24 when the liftgate 20 is closed. Of course, other constructions and arrangements are possible and contemplated herein. For example, as shown in FIG. 6 , when the liftgate 20 is closed, it may not displace the retaining member 24 from its second position ‘b’ at all so that the retaining member 24 remains generally upright and adjacent the cargo area 12 even when the liftgate is closed. Or, the liftgate 20 may engage and move the retaining member 24 any desired angular amount from its second position ‘b’, including all the way to its first position ‘a’, as previously noted.
[0018] To limit intrusion of the retaining member 24 and prevent raising the threshold to the cargo area 12 , the floor 14 may include a recess 44 in which the retaining member 24 is received when moved to its first position ‘a’, and/or its third position ‘c’, as desired. The recess 44 may be the same depth as the retaining member 24 is thick so that when in its first position ‘a’ the retaining member 24 is generally flush with the adjacent portion of the floor 14 . Likewise, when folded into its third position ‘c’ the retaining member 24 may also be generally flush with the cargo area floor 14 . If desired, a lock 50 ( FIGS. 1 and 2 ) can be provided to releasably maintain the retaining member 24 in, for example, its first position ‘a’ wherein it may be generally flush with the cargo floor 14 . The lock 50 may be a resilient finger with a catch that overlies a portion of the retaining member 24 , or a spring-loaded lock which may be set by depressing the retaining member 24 against the spring and released by likewise pressing the retaining member 24 against the spring. The retaining member 24 may be releasably locked in its first position, for example, to facilitate loading cargo into the cargo area 12 . Upon closing or opening the liftgate, the liftgate 20 may release the lock 50 so that when the liftgate 20 is subsequently opened, the retaining member 24 automatically is moved to its second position under force of the biasing member 36 . Of course, the retaining member 24 could remain locked until the lock 50 is manually removed, if desired. The retaining member 24 may also be releasably connected to the vehicle 10 so that it may be removed from the vehicle if desired.
[0019] Accordingly, cargo which is loose and/or shifts during use of the vehicle, and which moves toward or leans against the liftgate 20 prior to opening the liftgate 20 can be effectively retained within the cargo area 12 upon opening the liftgate. The retaining member 24 preferably remains in its second position when the liftgate is closed or is automatically disposed in its second position ‘b’ upon opening of the liftgate. The retaining member preferably can be readily folded to the generally flat first or third positions, or any angle in between, to reduce interference to loading and unloading cargo from the cargo area 12 . The retaining member 24 may also be releasably retained in any position, as desired. In one presently preferred embodiment, the actuation of the retaining member 24 to its second position to retain cargo, is accomplished independent of user interaction and preferably occurs automatically as the vehicle liftgate is opened.
[0020] While certain preferred embodiments have been shown and described, persons of ordinary skill in this art will readily recognize that the preceding description has been set forth in terms of description rather than limitation, and that various modifications and substitutions can be made without departing from the spirit and scope of the invention. The invention is defined by the following claims.
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A retainer for a vehicle cargo area that is bounded in part by a floor and a door moveable between open and closed positions includes a retaining member spanning at least a portion of the cargo area, a pivot feature operably associated with the retaining member, and a retaining feature that yieldably retains the retaining member in its second position to facilitate retaining cargo within the cargo area. The retaining member pivots about the pivot feature relative to the cargo area between a first position and a second position wherein the retaining member is inclined relative to the floor of the cargo area. When the door is open the retainer is normally in its second position to facilitate retaining cargo within the cargo area.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to a temperature measuring device for an internal-combustion engine, and more particularly to a temperature measuring device for an internal-combustion engine, which device is provided not only with a main temperature sensor intended to measure the temperature of the cooling water, for example, chosen as representing the temperature of the internal-combustion engine but also with a secondary or auxiliary temperature sensor intended as a standby for the aforementioned main temperature sensor.
(2) Description of the Prior Art
The temperature of the internal-combustion engine, particularly when the engine is started or while it is being warmed up, is utilized as a parameter for:
(1) control of the duration of fuel injection in an electronic fuel injection device,
(2) adjustment of the timing for ignition,
(3) control of exhaust gas recirculation, and
(4) control of an opening angle of a throttle valve and/or choke valve in an electronically regulated carburetor.
The temperature of the cooling water for the internal-combustion engine is generally adopted as representing the temperature of the internal-combustion engine.
When the main temperature sensor serving to measure the temperature of the cooling water goes out of order and/or the electric wire interconnecting the main temperature sensor and the electronic control unit is broken or short-circuited, therefore, collection of data on engine temperature is interrupted. Particularly when this mishap arises while the ambient temperature is low, there ensues a problem that the engine will be started or warmed up with difficulty.
SUMMARY OF THE INVENTION
This invention has been perfected for the purpose of giving a solution to the problem described above. It is aimed at providing a temperature measuring device for an internal-combustion engine, which is additionally provided with an auxiliary temperature sensor capable of immediately taking the place of a main temperature sensor serving to measure the engine temperature in case the main temperature sensor develops trouble.
To accomplish the object described above, this invention contemplates disposing, near a heat generating element within an electronic control unit (such as, for example, a power transistor), an auxiliary temperature sensor adapted so that when the main engine temperature sensor inherent in the internal-combustion engine happens provide an output falling within an abnormal range, this main temperature sensor wll be immediately switched to the auxiliary temperature sensor to allow the various phases of engine control to proceed without interruption.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit block diagram illustrating a typical embodiment of this invention in electronic fuel control,
FIG. 2 is a graph illustrating typical changes of engine temperature Et and case temperature Ct relative to time,
FIG. 3 is a perspective view illustrating an essential part of one working example of this invention, and
FIG. 4 is a flow chart illustrating this invention as applied to electronic fuel control by the use of a microcomputer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Now, the present invention will be described below with reference to the accompanying drawings.
FIG. 1 is a block diagram illustrating an embodiment of this invention as applied to control of the fuel injection pulse duration in an internal-combustion engine.
An arithmetic unit 1 computes (or reads out of a memory) a basic fuel injection pulse duration signal based on the number of engine rotations Ne, and the opening angle of a throttle valve Th, as parameters, effects compensation (multiplication compensation or addition compensation) on that signal based on the engine temperature Et, i.e. the output of a main temperature sensor, and then feeds out a temperature compensated fuel injection pulse duration signal Ti to an output driver section 2. The output driver section 2 keeps open a fuel injection nozzle 3 for a duration designated by the aforementioned fuel injection pulse duration signal Ti and effects supply of fuel to the internal-combustion engine (not shown).
The procedure of control described above is well known very well to persons of ordinary skill in the art.
In accordance with the present invention, an abnormality discriminating unit 4 monitors the detected engine temperature Et to determine whether or not the temperature sensing operation is proceeding normally. Specifically, this monitoring determines whether or not a given value of the engine temperature Et falls within a prescribed range, i.e. confirming that this value is smaller than the upper limit and larger than the lower limit respectively of the aforementioned range.
In accordance with the outcome of this monitoring, either the engine temperature Et or the case temperature Ct (the output of an auxiliary temperature sensor) is switched by a switching means 5 and fed to the arithmetic unit 1 for use in compensating Ti.
When the engine temperature Et output of the main engine temperature sensor is found to be in the normal range, the aforementioned compensation of Ti is effected by the value of the engine temperature Et detected at the moment by the main engine temperature sensor. When the value Et deviates from the normal range, however, the aforementioned compensation is effected in accordance with the output from a function generator 6 feeds out in response to the case temperature Ct fed therein as the input thereto.
Here, the fact that the aforementioned compensation can be also executed based on the case temperature Ct will be described.
FIG. 2 represents one typical process of elevation of the engine temperature Et and the case temperature Ct (against the vertical axis: °C.) as a function of the elapse of time t (the horizontal axis) from the time that the internal-combustion engine is started.
As is clear from this diagram, the engine temperature Et and the case temperature Ct are substantially correlated and their relation can be determined either empirically or through actual measurement.
By causing the function generator 6 to memorize their relation and consequently enabling it to convert the case temperature Ct into the engine temperature Et and feed out the latter temperature as its output, the case temperature Ct provided by the auxiliary temperature sensor can be used in the place of the engine temperature Et output of the main temperature sensor when the sensed engine temperature Et deviates from the normal range. By this arrangement, the internal-combustion engine can be started or warmed up without trouble even when the ambient temperature is low.
FIG. 3 is a perspective view illustrating a typical configuration of the sensor for case temperature Ct (namely, the auxiliary temperature sensor).
Inside a case body 10 for an electronic control unit, an IC (integral circuit) 11, a power transistor 12 etc. are accommodated. Since the power transistor 12 generates a large amount of heat, it is generally fixed directly or through the medium of a heat radiating fin to the case body 10 in due consideration of the heat radiating property thereof.
An auxiliary temperature sensor 13 in accordance with this invention is fixed near the power transistor 12. Thus, the auxiliary sensor 13 receives, through conduction, the heat generated by the power transistor 12 and has its temperature elevated with the elapse of time as indicated by the curve Ct in FIG. 2.
By causing the aforementioned rising temperature characteristic of the auxiliary temperature sensor 13 to be memorized by the function generator 6 as compared with that of the main temperature sensor for the engine temperature Et, the auxiliary temperature sensor 13 can serve as a standby in case of an emergency, i.e. when the engine temperature Et deviates from its normal range.
FIG. 4 is a flow chart illustrating the aforementioned operation of the computation and compensation of the fuel injection pulse duration signal Ti by the use of an electronic computer. The individual steps involved in the operation illustrated in the diagram are as follows.
Step S1--Such engine data as the number of engine rotations Ne, the aperture of throttle valve Th, and the engine temperature Et are read in.
Step S2--The engine temperature Et is checked to determine whether or not that temperature is lower than the upper limit Lu.
Step S3--The engine temperature Et is checked to determine whether or not that temperature is higher than the lower limit Ld.
Step S4--Step S2 and Step S3 both give positive answers when the operation of the main engine temperature sensor is normal. In this case, the processing advances to Step S4. In this step, the computation of the basic fuel injection pulse duration signal (to be read out of the memory) and the compensation thereof by the engine temperature Et are carried out.
Step S5--In accordance with the fuel injection pulse duration signal obtained in the preceding step S4, the output driver section 2 is actuated to open the valve for the injection nozzle 2 and effect fuel injection.
Step S6--Step S2 and Step S3 both give negative answers when the operation of the main engine temperature sensor is not normal. In this case, the processing advances to Step 6 and the case temperature Ct is read in. Naturally, this reading in of the case temperature Ct may be effected in Step S1 instead.
Step S7--The conversion of the case temperature Ct to the engine temperature Et is effected in accordance with the relation between the Et and the Ct previously determined and meorized (such as by reference to a table).
In other words, when the engine temperature Et is in its normal range of measurement, the processing circulates through the steps S1-S2-S3-S4-S5-S1, and consequently the fuel injection pulse duration signal is compensated by the output of the main engine temperature sensor.
On the other hand, when the engine temperature Et deviates from its normal range of measurement, the process circulates through the steps S1-S2-S3-S6-S7-S4-S5-S1, and consequently the fuel injection pulse duration signal is compensated by the output of the auxiliary temperature sensor.
In accordance with the present invention, as is clear from the description given above, when the engine temperature sensor system goes out of order, the temperature compensation in the system is immediately switched to that by the auxiliary temperature sensor. Thus, the internal-combustion engine can be started or warmed up without entailing any interruption.
Further, because the auxiliary temperature sensor of this invention is fixed to the case 10 for the electronic control unit, a short lead wire suffices for the sensor 13 and the possibility of this lead wire being broken or short-circulated because of external impacts is very remote. Thus, it can be relied on as a perfect standby.
The foregoing embodiment has been described as involving the use of a power transistor in the electronic control unit as a member capable of simulating the temperature elevation of the internal-combustion engine. It is, of course, possible to incorporate, instead, an additional heat generating member (such as, for example, an electric resistance heat generator) for exclusive use in the auxiliary temperature sensor. It will be readily understood by those skilled in the art that although the invention has been described as applied only to the compensation of the fuel injection pulse duration signal, it is effectively applicable similarly to the adjustment of ignition timing or to the control of EGR (Exhaust Gas Recirculation) mentioned in the early part of this specification.
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Temperature measuring device for an internal-combustion engine comprising a main engine temperature sensor to measure the temperature of the cooling water, for example, and a secondary or auxiliary temperature sensor disposed near a heat generating element in an electronic engine control unit, as a standby for the main temperature sensor.
When an output of the main temperature sensor happens to fall outside the predetermined normal range, the main temperature sensor will be immediately switched to the auxiliary temperature sensor to allow the various phases of engine control to proceed without interruption.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a washing machine, more particularly, to a washing machine having a floatage clutch that performs the intermittence of power in cleansing and dehydrating operations by using the floatage thereof.
2. Description of the Related Art
Generally speaking, a washing machine is used to clean, rinse and dehydrate clothes and the like by using a mechanical operation via an electric driving motor. The washing machine includes a cleansing part for performing a cleansing work, and a driving part for driving the cleansing part. The washing machines can be classified into agitator type washing machines, drum type washing machines, and pulsator type washing machines according to a cleansing manner of the cleansing part.
The cleansing part of the pulsator type washing machine as described above, as shown in FIG. 1, includes a water tub 12 installed in a case 10 , a cleansing basket 14 rotatably contained in the water tub 12 , a pulsator 16 disposed at the bottom of the cleansing basket for forming a water stream, a water tab 17 , and a drain valve 18 . The cleansing basket 14 is punched with numerous dehydration holes 14 a in a sidewall thereof.
In addition, the driving part includes a driving motor 20 , a transmission 30 and a clutch mechanism 40 for driving the pulsator 16 and the cleansing basket 14 by receiving a driving force of the driving motor 20 , a belt connection means for transferring the driving force of the driving motor 20 to the clutch mechanism 40 , and a brake means for maintaining the stable fixed state of the transmission 30 .
As shown in FIG. 2, the transmission 30 includes a gear box 32 , an upper and lower pulsator shafts 33 and 34 connected each other via a gear means disposed within the gear box 32 , and a spin shaft 35 fixed to the gear box 32 (See FIG. 4 ). The upper pulsator shaft 33 is designed to be rotatably fitted in the spin shaft 35 and connected to the pulsator 16 . The spin shaft 35 is connected to the cleansing basket 14 and fixed to the gear box 32 . The lower pulsator shaft 34 is formed with a serration part 341 on the lower end thereof and constructed to be protruded exceeding the gear box 32 downwardly (See FIG. 3 .).
As shown in FIG. 3, the clutch mechanism 40 includes a spin shaft block 42 fixed to the lower end of the gear box 32 , a spring block 46 disposed on the one side of the spin shaft block 42 , which is engaged with the serration part 341 of the lower pulsator shaft 34 and fixed to a pulley 44 of the belt connection means, and an one-way spring 48 disposed to be surrounded the spin shaft block 42 and the spring block 46 (See FIG. 1 ). Here, a tight fastening state and a releasing state of the one-way spring 48 is controlled according to the rotating direction thereof.
In addition, as shown in FIG. 4, the gear means constructed in the gear box 32 of the transmission 30 includes a pinion gear 50 attached to the lower end of the upper pulsator shaft 33 , an eccentric crank 52 formed with a rack gear portion 521 to be engaged with the pinion gear 50 , a first gear 54 disposed on the same rotating axial line to be engaged with the eccentric crank 52 , and a second gear 56 attached to the upper end of the lower pulsator shaft 34 to be engaged with the first gear 54 .
The brake means includes a brake disk 60 disposed under the gear box 32 , a brake frictional portion 62 formed on the top surface of a frame 19 of suspension means, which has a corresponding shape to the brake disk 60 , and position adjustment means (not shown) for controlling the separation and contact states between the brake disk 60 and the brake frictional portion 62 by vertically adjusting the position of the gear box 32 according to the operating direction of the driving motor 20 (See FIG. 1 ).
A washing process of the pulsator type washing machine constructed as described above includes the following steps in order: 1) a water supply step for supplying water into the cleansing basket 14 through the water tab 17 ; 2) a cleansing step for circulating the water and laundry during a desired time via the rotating operation of the pulsator 16 ; 3) a rinsing step for rinsing the laundry as much as certain times by supplying clear rinsing water not containing any detergents after draining the water through the drain valve 18 ; and 4) a dehydrating step for driving the cleansing basket 14 at a high speed to dehydrate the laundry.
In the water supply step of the washing process, the water just entered through the water tab 17 is changed into a cleansing water containing a detergent with by passing in a detergent container. Also, in the cleansing step, a removal work of contaminants clinging to the laundry is performed under a chemical operation of detergent contained in the cleansing water as well as a physical operation of the pulsator 16 . The pulsator 16 is repeatedly rotated, that is intermittently reversed, in forward and backward by the transmission 30 , so that a both directional water stream composed of a left-and-right water stream and an up-and-down water stream can be formed to effectively perform the cleansing work of the laundry.
Then, in a state that the clear rinsing water not containing the detergent is supplied during the rinsing step, the detergent clinging to the laundry is also effectively removed by using the both directional water streams formed by the rotation of the pulsator 16 in the same manner with the cleansing step. Finally, in the dehydrating step, the cleansing basket 14 is rotated in one direction at a high speed after the rinsing water is completely drained, then the water contained in the laundry can be discharged via the dehydration holes 14 a due to centrifugal force. In this case, the laundry is tightly contacting with the inner wall of the cleansing basket 14 .
In the dehydrating step, since the cleansing basket 14 and the pulsator 16 are simultaneously rotated in the same direction, it is possible to prevent the damage of the laundry from being caught to the pulsator 16 . Also, the water discharged through the dehydration holes 14 a of the cleansing basket 14 is drained out of the washing machine as soon as the drain valve 18 is opened.
Meanwhile, the rotating operation of the cleansing basket 14 and the pulsator 16 in all steps are performed by the driving part as described above. The operation of the driving part will be explained in detail as follows.
First of all, in the cleansing step, the pulley 44 is rotated in clockwise direction by the driving force of the driving motor 20 , and then the spring block 46 connected with the pulley 44 and the lower pulsator shaft 34 coupled with the serration portion of the spring block 46 are rotated. At this time, the one-way spring 48 loosened, and since the brake disk 60 and the brake frictional portion 62 are in tightly contact with each other, so the gear box 32 is in a fixed state. In addition, as the lower pulsator shaft 34 is rotated, the first gear 54 engaged with the second gear 56 and the second gear 56 within the gear box 32 are rotated, and at the same time, the eccentric crank 52 disposed on the same rotating axial line of the first gear 54 is actuated.
In this case, the eccentric crank 52 is linearly reciprocated about the rotating axial line due to the structural feature thereof, then the upper pulsator shaft 33 can be reciprocated by the pinion gear 50 engaged with the rack gear portion 521 of the eccentric crank 52 , and consequently the pulsator 16 can be achieved in the forward and backward rotation.
Additionally, in the dehydrating step, the driving motor 20 is rotated in counterclockwise direction in opposite to the cleansing step, and the spring block 46 connected with the pulley 44 and the lower pulsator shaft 34 coupled with the spring block 46 are rotated in counterclockwise direction. In this case, the one-way spring 48 is fastened so that the spring block 46 and the spin shaft block 42 can be coupled, and the brake disk 60 and the brake frictional part 62 are separated by the operation of the position adjustment mechanism. Therefore, the gear box 32 and the spin shaft 35 are rotated with the spin shaft block 42 . Since, the upper pulsator shaft 33 is rotated in the same direction, then the cleansing basket 14 and the pulsator 16 are rotated at the same time to perform a dehydrating work.
According to the related pulsator type washing machine, because the pulsator 16 is rotated in forward and backward to generate the complex water stream, the effect of cleansing is relatively high. And, the conversion from the cleansing step to the dehydrating step is automatically performed due to the conversion of operating direction of the driving motor 20 and the linking structure of the transmission 30 and the clutch mechanism 40 .
However, substantial problems exist in this related construction. First of all, the structures of the transmission 30 and the clutch mechanism 40 for transferring the driving force of the driving motor 20 to the pulsator 16 and the cleansing basket 14 have complex structures, which deteriorates the productivity of the washing machine. Also, since the cleansing work is performed only by the simple forward and backward rotation of the pulsator 16 , it is impossible to achieve various cleansing operations suitable for the feature of the laundry, thereby deteriorating a merchant ability of the washing machine.
SUMMARY OF THE INVENTION
The present invention has been made to overcome the above-described problems. Accordingly, it is an object of the present invention to provide a washing machine having a floatage clutch, which can smoothly switch a power transmission state in the conversion between the cleansing step and the dehydrating step by using the floatage thereof, and which can secure the stability of the switching process.
To achieve the above objects, there is provided a washing machine comprises a water tub; a cleansing basket rotatably contained within the water tub; a pulsator rotatably mounted on the bottom surface of the cleansing basket, having a wing part for forming a water stream, a hub part disposed in the center of the wing part, and a hollow shaft part protruded from the bottom of the hub part exceeding the cleansing basket downwardly; a driving motor for generating a driving force required to rotate the cleansing basket and the pulsator; a transmission for transmitting the driving force of the driving motor to the cleansing basket and the pulsator, having a hollow dryer shaft integrated to the cleansing basket; and a washing shaft penetrating the hollow dryer shaft, of which the upper end passes the hollow shaft part of the pulsator and then is fixed to the hub part, and of which the lower end is connected with the driving motor; and a floatage clutch for allowing the cleansing basket to selectively cooperate with the pulsator by being intermittently actuated depending on the existence and nonexistence of water, having a float engaged with the washing shaft to be capable of moving up and down and linked with the hollow shaft part of the pulsator to be capable of moving up and down due to floatage, and a fixed member fixed to the upper end of the hollow dryer shaft to be separated from and coupled with the float at the lower side thereof.
The float of the floatage clutch includes a hub portion inserted into the hollow shaft part of the pulsator, and a tube portion, disposed around the hub portion, for allowing the water to be flown into a space defined between the hub portion and the tube portion, wherein the fixed member is constructed as a shaft of which the lower end is connected with the cleansing basket and of which the upper end is inserted into the hub portion of the float.
The water absorption holes are formed on the top surface of the pulsator, and a centrifugal wing portion is provided on the bottom surface of the pulsator, wherein the water absorbed via the water absorption holes pass a filtering net through a fluid channel between the water tub and the cleansing basket by shaping the tube portion of the float as a conical form to facilitate the smooth movement of the water via the water absorption holes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view illustrating the construction of a related washing machine.
FIG. 2 is a perspective view illustrating the construction of a transmission of the related washing machine.
FIG. 3 is an exploded perspective view illustrating the construction of a clutch mechanism of the related washing machine.
FIG. 4 is a perspective view illustrating the construction of gear means applied in the transmission of the related washing machine.
FIG. 5 is a perspective view illustrating the construction of essential parts of a washing machine in accordance with an embodiment of the present invention,
FIG. 6 is an exploded perspective view illustrating the construction of a floatage clutch applied in the washing machine in accordance with the embodiment of the present invention.
FIG. 7 is a cross sectional view taken on the line VII—VII in FIG. 6 illustrating the construction of a float of the floatage clutch applied in the embodiment of the present invention.
FIG. 8 is a state view illustrating the operation of the floatage clutch applied in the embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the present invention will now be described in more detail with reference to FIG. 5 to FIG. 8 . In the following description, same drawing reference numerals are endowed in the same parts with the related construction.
First, FIG. 5 shows a washing machine in accordance with the embodiment of the present invention. The washing machine includes a water tub 12 , a cleansing basket 14 contained within the water tub 12 , a pulsator 16 rotatably mounted in the cleansing basket 14 , a transmission 70 for controlling the rotating direction of the pulsator 16 and the cleansing basket 14 , a floatage clutch 80 for allowing the cleansing basket 14 to selectively cooperate with the pulsator 16 by being intermittently actuated depending on the existence and nonexistence of water, and a driving motor 22 for generating the driving force required to rotate the cleansing basket 14 and the pulsator 16 .
Here, the pulsator 16 includes a wing part 161 , a hub part 162 disposed in the center of the wing part 161 , and a hollow shaft part 163 formed in the bottom plane of the hub part 162 . The hollow shaft part 163 is constructed to be protruded exceeding the cleansing basket 14 downwardly.
The transmission 70 includes a hollow dryer shaft 72 integrated to the bottom plane of the cleansing basket 14 , several bearings 76 supporting the hollow dryer shaft 72 , and a washing shaft 74 mounted by penetrating the hollow dryer shaft 72 , is fixed to the hub part 162 by passing the hollow shaft part 163 of the pulsator 16 , and is connected with the driving motor 22 .
In addition, the floatage clutch 80 includes a float 82 coupled with the washing shaft 74 to be capable of moving up and down, and a fixed member 83 fixed to the upper end of the hollow dryer shaft 72 . The fixed member 83 is able to be separated from and coupled with the float 82 at the lower side of the float 82 . The float 82 has a hub portion 821 to be inserted into the hollow shaft part 163 of the pulsator 16 , and a tube portion 822 constructed around the hub portion 821 . The fixed member 83 is constructed as a shaft of which the lower end is connected with the cleansing basket 14 and the upper end is inserted into the hub portion 821 of the float 82 (See FIG. 6 ).
Here, the hub portion 821 of the float 82 is formed with an inner top surface of convex-concave shape teethed structure. The tube portion 822 has an opened bottom plane as well as is divided into several sections to form several clearances 82 a as shown in FIG. 7, then the water is capable of flowing around the hub portion 821 .
The washing machine constructed as described above will be operated as follows:
First, if a given quantity of water is supplied into the cleansing basket 14 in the water supply step, the float 82 is floated up and separated from the fixed member 83 due to the floatage thereof, as shown in FIG. 8 a . The floatage clutch 80 is reached to a power cutoff state, so the driving force of the driving motor 22 is transferred only to the washing shaft 74 .
At this moment, the water entered the pulsator 16 upwardly is flown around the hub portion 821 via the several clearances 82 a defined between the separated tube portions 822 of the float 82 . Accordingly, the lower region of a space between the hollow shaft part 163 and the hub portion 821 of the float 82 is closed with the water.
Therefore, the water can't invade to the interior space of the hollow shaft part 163 by virtue of the air pressure within the hollow shaft part 163 .
In this power cutoff state of the floatage clutch 80 , when the driving motor 22 is driven, only the pulsator 16 connected with the washing shaft 74 is rotated in the initial cleansing step. After that, the driving motor 22 is repeatedly driven forward and backward, then the pulsator 16 also is rotated in forward and backward directions in the same manner with the driving motor. The driving motor and the pulsator is intermittently reversed in the forward and backward rotation.
Due to the forward and backward rotation of the pulsator 16 , a rotating water stream can be formed. If the pulsator 16 is continuously rotated in one direction more than a certain time, the cleansing basket 14 is also rotated in the same direction with the pulsator by the water stream. Then, the water can be discharged via dehydration holes 14 a out of the cleansing basket 14 due to the centrifugal force. Furthermore, the discharged water can be again flown into the cleansing basket 14 through the fluid channel between the cleansing basket 14 and the water tub 12 . This washing manner is designated as a centrifugal washing manner (so-called waterfall current washing manner).
The washing process is performed by the cleansing step, a rinsing step, and a dehydrating step in that order. Just before the dehydrating step, as the water used for rinsing laundry is drained, the floatage is gradually eliminated. Thus, as shown in FIG. 8 b , the float 82 begins to drop by the weight thereof, and the hub portion 821 of the float 82 and the fixed member 83 are engaged with each other, so that floatage clutch 80 is switched into the power transmission state.
In this power transmission state of the floatage clutch 80 , when the washing shaft 74 is driven by the driving motor 22 , the float 82 engaged with the washing shaft 74 is rotated. Also, the fixed member 83 engaged with the hub portion 821 of the float 82 and the cleansing basket 14 coupled with the fixed member 83 are rotated in the same direction with the washing shaft 74 .
Therefore, the cleansing basket 14 is rapidly rotated in one direction and then the laundry is tightly contacted with the inner wall of the cleansing basket 14 , then the water contained in the laundry can be discharged via the dehydration holes 14 a due to the centrifugal force. The cleansing basket 14 and the pulsator 16 are simultaneously rotated in the same direction as described above, so it is possible to prevent the laundry from being caught on the pulsator, and consequently to prevent the damage of the laundry.
Meantime, since the water does not invade the interior of the hollow shaft part 163 of the pulsator 16 as described above, the washing shaft 74 disposed within the hollow shaft part 163 does not contact with the water. Accordingly, the operating stability of the floatage clutch 80 can be improved.
Since, various foreign impurities fell down from the laundry may be mixed in the water during the cleansing step, the various foreign impurities mixed in the water is interposed between the float 82 and the washing shaft 74 , if the water is invaded the washing shaft 74 . Consequently, it is possible to prevent the smooth conversion of the floatage clutch 80 by blocking the motion of the float 82 .
Further, in accordance with the present embodiment, several water absorption holes 16 a extended to the fluid channel between the cleansing basket 14 and the water tub 12 are punched on the top surface of the pulsator 16 . A centrifugal wing portion 164 is provided along the bottom of the wing part 161 . The tube portion 822 of the float 82 is constructed as a conical shape so as to facilitate the smooth movement of the water flowing under the pulsator 16 downwardly via the several water absorption holes 16 a.
Here, the water entered the interior space of the pulsator 16 via the water absorption holes 16 a in the cleansing step, and a centrifugal force is generated by the centrifugal wing portion 164 rotating with the pulsator 16 to be applied to the entered water. Thus, the entered water allows to pass a filtering net 90 disposed in the upper part of the cleansing basket 14 via the fluid channel between the cleansing basket 14 and the water tub 12 due to the centrifugal force. In this way, it is possible to effectively filter the impurities mixed in the water.
As described above, the washing machine according to the present invention can provide the following advantages. The power transmission switching in the case of the conversion from the cleansing step to the dehydrating step can be easily performed due to the floatage clutch of simple structure. Also, since the operation stability of the flotage clutch is improved due to the structural feature of the float, the merchant ability and the productivity thereof can be increased.
While the invention has been shown and described with reference to certain preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
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The present invention relates a washing machine having a floatage clutch for performing the conversion of a cleansing step and a dehydrating step. This floatage clutch can be actuated only by using floatage and gravity to be generated during the feeding/draining of water without a separate driving part. Accordingly, the construction of clutch part can be simplified, and consequently the cost of manufacturing of the washing machine can be reduced.
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This is a divisional of application Ser. No. 08/911,954 filed on Aug. 15, 1997, now U.S. Pat. No. 5,951,734.
FIELD OF THE INVENTION
The present invention relates to a semi-convective forced air system and method for heating glass sheets for subsequent processing. More particularly, the system and method of the present invention are used for heating low emissivity coated glass before tempering.
BACKGROUND OF THE INVENTION
Forced air furnaces for heating glass sheets in preparation for subsequent processing, such as tempering, are known in the art. For example, McMaster, U.S. Pat. Nos. 4,529,380 and 4,505,671, discloses a glass sheet processing system which includes a heating furnace and a processing station for processing heated glass sheets to provide bending, tempering, bending and tempering, filming, etc. The furnace of U.S. Pat. No. 4,592,380 and 4,505,671 comprises an array of gas jets spaced above a conveyor within a heating chamber. The gas jets supply a primary gas flow directed toward the conveyor to provide forced convection heating of the glass sheets as the sheets are conveyed through the heating chamber.
The gas jets of McMaster are arranged in linear series perpendicular to the length of the conveyor and the direction of travel of the glass sheets. Each series of jets is connected to a common linear supply manifold or conduit. Each supply conduit also extends widthwise in the heating furnace, perpendicular to the length of the conveyor. McMaster teaches that the array of gas jet pumps are spaced from each other transversely to the direction of conveyance so as to uniformly heat each conveyed glass sheet over its entire width.
Heating systems such as described by McMaster appear to provide acceptable results for heating clear glass prior to tempering. Other known systems provide acceptable results for heating coated glass having an emissivity rating greater than about 0.2 prior to tempering. However, manufacturers have now begun to produce coated glass products having emissivity ratings in the range of 0.15-0.04. Prior art heating systems, including the system disclosed in U.S. Pat. Nos. 4,592,380 and 4,505,671, do not provide acceptable results for tempering glass having such low emissivity ratings. Therefore, it would be desirable to provide a system and method of tempering low “e” glass sheeting having an emissivity rating below 0.2.
When glass sheets are conveyed into a heating furnace, the bottom surface heats at a faster rate than the top surface due to contact with the rolls of the conveyor. This causes the bottom surface to expand at a faster rate than the top surface which results in the glass bowing upward into the shape of a bowl. All of the glass sheet's weight is supported in the center of the glass which causes the center of the glass to be overheated. This results in excessive distortion in the center of the glass which can be described as an elongated bubble. Non-uniform glass temperatures also cause the glass to oil can (or become bi-stable). Oil canning (or by-stability) and bubbling are undesirable conditions produced in the glass when the glass sheeting is not heated uniformly. Therefore, it would also be desirable to provide a method and apparatus for heating low “e” coated glass sheets which minimizes oil-canning and bubbling.
When low “e” glass is tempered in prior art systems, it is typically run lengthwise through the furnace due to the size of the furnace. It is also run lengthwise to mitigate the appearance of inherent distortions because the glass sheets are typically installed lengthwise down a room or hallway. However, low emissivity glass is more sensitive to heating in the longitudinal direction than it is in the widthwise direction. When glass is tempered in prior art systems, heat is only applied uniformly over the width of the glass sheet. This does not allow for separate control from edge to edge across the width of the glass. Without this control, the glass will not be heated as uniformly and the undesirable conditions of center bubble and oil canning will ensue. Therefore, it is also desirable to provide a system and method of tempering which uniformly applies heat over the entire length of the sheet in a longitudinal direction to improve aesthetic quality.
SUMMARY OF THE INVENTION
The present invention relates to a semi-convective forced air system for heating glass sheets during a heating cycle for subsequent processing such as tempering. The system and method are particularly useful for tempering low emissivity coated glass sheeting having an emissivity rating below 0.2. In accordance with the system and method of the present invention, heat is uniformly applied over the entire length of selected widthwise portions of the glass sheet to reduce or eliminate oil canning and bubbling.
The system of the present invention comprises a heating chamber, a longitudinal conveyor extending through the heating chamber, a compressed air source, a plurality of longitudinally-extending air manifolds in fluid connection with the air source, and a controller for restricting the flow of air to selected manifolds at predetermined times during the heating cycle. Each of the air manifolds is oriented parallel to the length of the longitudinal conveyor and constructed and arranged to create a downward flow of heated air toward the conveyor to convectively heat a sheet of glass on the conveyor.
The air manifolds preferably comprise elongate tubes having a longitudinal series of radially extending apertures. The apertures are oriented downwardly toward the conveyor at an angle of about plus or minus 30 degrees from vertical. The air exiting the apertures forms an angle of incidence with the conveyor of about plus or minus 60 degrees. Each of the apertures are oriented oppositely than an adjacent aperture.
The manifolds are preferably located about 4-6 inches above the conveyor. The manifolds are constructed and arranged in longitudinally-extending rows. One of the rows is preferably located above the widthwise center of the conveyor, and one of the rows is preferably located above each of the two widthwise quarter points of the conveyor. The rows, preferably the outer rows, optionally may be adjustable to different widthwise locations above the conveyor.
The conveyor preferably has horizontally-extending rolls constructed and arranged for conveying glass sheets horizontally through the heating chamber.
The air manifolds preferably comprise ½ inch pipe having about 0.04 inch diameter apertures longitudinal spaced about 8½ inches apart. The air manifolds are constructed and arranged to simultaneously convectively heat the entire length of a selected widthwise portion of a glass sheet. A distribution manifold is arranged in fluid connection with the air source and each of the air manifolds.
A solenoid valve and flow meter are arranged in fluid connection between each air manifold and the distribution manifold. An air regulator and filter/dryer are arranged in fluid connection between the air source and the distribution manifold. A programmable computer is used to open and close the solenoids at predetermined times during the heating cycle.
The present invention also provides a method of heating glass sheet for subsequent processing such as tempering. The method comprises the initial steps of loading the glass sheet onto a longitudinally extending conveyor, and orienting the glass sheet such that the lengthwise edge of the sheet is parallel to the length of the conveyor, and conveying the glass sheet into a heating chamber. The glass sheets are then convectively heated in a specified sequence along the entire length of selected widthwise portions of the glass sheet by creating a downward flow of heated air proximate the selected widthwise portion of the glass sheet.
In a preferred embodiment, the lengthwise extending edge portions of the sheet are heated before the lengthwise central portion of the sheet. Preferably, the glass sheet is heated proximate its quarter points before the lengthwise central portion.
In a preferred embodiment, the heating step comprises constantly convectively heating only the quarter points of the sheet for the first 30-40% of the heating cycle; intermittently convectively heating only the quarter points of the sheet for the next 10-20% of the heating cycle; intermittently convectively heating only the lengthwise central portion of the sheet for the next 10-20% of the heating cycle; and, constantly convectively heating only the lengthwise central portion of the sheet for the final 20-50% of the heating cycle.
The method may include the step of transferring the glass sheet from the heating chamber to a second heating chamber of a two zone furnace.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is schematic illustration of the semi-convective forced air system in accordance with an embodiment of the invention;
FIG. 2 is a fragmentary, enlarged side elevational view of an air manifold of the system of FIG. 2;
FIG. 3 is a bottom plan view of the air manifold of FIG. 2;
FIG. 4 is an enlarged, cross-sectional view of an air manifold of FIG. 1 shown relative to a glass sheet on a conveyor;
FIGS. 5 a and 5 b are schematic illustrations of a bank of air manifolds shown relative to a glass sheet on a conveyor in accordance with an embodiment of the invention;
FIGS. 6 a and 6 b are schematic illustrations of arrangements of air manifolds shown relative to a glass sheet on a conveyor in accordance with another embodiment of the invention;
FIG. 7 is a schematic illustration of the control system in accordance with an embodiment of the invention;
FIGS. 8 a-c are schematic illustrations of arrangements of air manifolds shown relative to glass sheets in a two-zone oven in accordance with a further embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is described with reference to FIGS. 1-7 wherein like reference numerals are used to designate the same components throughout.
The semi-convective forced air system of the present invention is schematically illustrated in FIG. 1 and designated generally by reference numeral 10 . The system 10 comprises a furnace with an internal heating chamber 14 in which glass sheets S are heated during a heating cycle in preparation for subsequent processing such as tempering, bending, filming, etc. The furnace housing 12 has a construction known in the art as taught by, for example, U.S. Pat. No. 4,390,359 owned by Tamglass Engineering, Cinnaminson, N.J., incorporated herein by reference. The furnace housing 12 is preferably made of a heat resistant ceramic material. The furnace includes electric resistance heating elements 16 on the top and bottom which provide radiant heat to a work piece located therein.
A longitudinal conveyor 18 extends lengthwise through the heating chamber 14 . The conveyor 18 preferably includes a series of rotatably fixed horizontally extending rolls 19 which are driven in unison to convey a work piece, such as glass sheeting S, through the chamber. A conveyor 18 of this type is well known in the art as taught, for example, by U.S. Pat. No. 4,390,359, owned by Tamglass Engineering, Cinnaminson, N.J., incorporated herein by reference. The system 10 has a plurality of longitudinally-extending air manifolds 20 which are arranged in fluid connection with a compressed air source 22 preferably located external to the heating chamber 14 . The air manifolds 20 are arranged parallel to the length of the longitudinal conveyor 18 and create a downward flow of heated air toward the conveyor 18 to convectively heat a sheet S of glass supported on the conveyor 18 . The convection heat provided by the air manifolds 20 supplements the radiant heat provided by the electric resistance elements 16 .
The compressed air source preferably includes a compressor 23 which is capable of supplying about 17 CFM at about 50 psi, which is the equivalent of about a 10 H.P. compressor for the largest system. The air source also preferably includes a 120 gallon stationary air tank 25 . The stationary tank has an automatic bottom drain 27 which relieves oil and water build-up from the tank 25 .
The system 10 includes a controller 24 which controls the flow of air through each of the plurality of air manifolds 20 . The controller 24 selectively restricts or allows a flow of air to each of the air manifolds 20 , or rows of manifolds, at predetermined times during the heating cycle to control the heating process and minimize oil canning and bubbling in the glass sheets.
The air manifolds are shown in greater detail in FIGS. 2-4. In a preferred embodiment, each manifold comprises a pair of elongate tubes 26 connected at one end by a hollow “T” connector 28 . The other ends of the elongate tubes 26 are sealed with a cap, plug or other means.
Each elongate tube 26 has a longitudinal series of radially extending apertures 30 . Preferably, the apertures 30 have a diameter of about 0.04 inches and are spaced about 8½″ from each other along the entire length of the elongate tubes 26 . The elongate tubes preferably comprise ½″ schedule 40 , type 304 stainless steel hollow pipe.
Referring to FIG. 4, the apertures traverse the walls of the tubes 26 and are oriented downwardly towards the conveyor 18 at an angle theta θ from vertical. Preferably, the angle theta θ is plus or minus 30 degrees from vertical. The angle theta θ is selected to create a compromise wash effect and turbulent effect on the glass sheet. Air is discharged from the apertures (depicted by arrows) and impinges the sheet S at angle of incidence alpha α of about plus or minus 60 degrees.
As best seen in FIG. 3, the apertures 30 are alternatively oriented in opposite directions. For example, the first, third, fifth, . . . aperture on the air manifolds are oriented at an angle theta θ of plus 30 degrees and direct air towards one side of the glass sheet; the second, fourth, sixth, . . . apertures are oriented at an angle theta θ of minus 30 degrees and direct air toward the opposite side of the glass sheet.
Each air manifold 20 includes a supply tube 32 which is connected at one end to the third port of the “T” connector 28 and at the other end to a distribution manifold 34 . The distribution manifold 34 is arranged in fluid connection with the compressed air source 22 and distributes compressed air to each of the air manifolds 20 .
A solenoid valve 36 and a flow meter 38 are arranged in fluid connection between the distribution manifold 34 and each of the air manifolds 20 . Each solenoid valve is connected to a controller 24 which selectively opens and closes each solenoid valve at different times during a heating cycle. Each flow meter 38 controls the volume of air entering the respective air manifolds 20 . Preferably, each flow meter 38 comprises a Dwyer Rate Master Flowmeter, model No. RMC-104-BV having ½ NPT connections and is set at a flow rate of 200 standard cubic feet per hour. Preferably, the solenoid valves comprise Asco two way solenoid valves, model No. 8210C94 having ½ NPT connections and ⅝″ orifice with a maximum operating pressure differential of 100 psi. The controller is preferably a programmable logic computer which is well known in the art.
A filter/dryer 40 , air regulator 42 and solenoid valve 44 are arranged in fluid connection intermediate the compressed air source 22 and the distribution manifold 34 . Preferably the filter/dryer 40 comprises a 40 micron filter manufactured by ARO, part number F25242-111 and a coalescing filter manufactured by ARO, part number F25242-311; the air regulator is preferably manufactured by ARO, part number R27241-100 and the pressure gauge is manufactured by ARO, part number 100067; and, the solenoid valve 44 is manufactured by Burkert, part number 453058.
The air manifolds 20 are arranged in banks. The air manifolds are capable of providing forced air convective heating over the full length of a glass sheet S during the entire time which the glass sheet S is being heated. However, as described below, typically convective heating is sequentially provided over the entire length of selected widthwise portions of the glass sheet.
The system may be used in a batch type furnace or in a continuous furnace during the heating period only. In a continuous furnace, the air manifolds 20 would not extend over the full length of the continuous system. In a preferred embodiment, ambient compressed air is supplied to the air manifolds 20 ; however, heated compressed air may also be supplied to the air manifolds 20 in the system of the present invention.
A preferred location of each manifold is illustrated for two different furnaces in FIGS. 5 and 6. FIGS. 5 a and 5 b shows the location of the air manifolds in a 48″-60″ furnace. In this embodiment, the air manifolds have a widthwise spacing W of about 15″ and are located at a height H of about 4″-6″ above the surface of the glass sheet S. Referring to FIG. 5 b, in a preferred embodiment, the bank of air manifolds 20 comprises three longitudinally extending manifolds. The approximate location of each air manifold above the glass sheet S is illustrated in FIG. 5 b and shows that the entire glass sheet S or the entire length of a selected widthwise portion of a glass sheet S can be heated by the air manifolds.
Preferably, one manifold is located proximate the widthwise center of the sheets, and one manifold is located proximate each widthwise quarter point i.e., the location ¼ the width of the sheet from each edge. For example, if the sheet is 36″ wide, a manifold is 210 preferably located 9 inches from each lengthwise edge of the sheet.
The location of the air manifolds 20 for an a 72″ or 86″ or 96″ furnace is shown in FIGS. 6 a and 6 b. Preferably, this arrangement comprises two separate banks of air manifolds 20 for simultaneously heating a first glass sheet S 1 and a second glass sheet S 2 . The air manifolds 20 have a widthwise spacing W and a heightwise spacing H similar to the spacing of the 60″ furnace described above. In this embodiment, each bank comprises three longitudinally extending manifolds. The furnace may also have a seventh air manifold 20 c located proximate the center of the furnace for use in heating a single, large glass sheet.
During the heating process, the controller 24 restricts or allows the flow of air to selected manifolds at predetermined times during the heating cycle. In the method of the present invention, the entire length of selected widthwise portions of the glass sheet is convectively heated in a specific sequence by controlling the flow of air to selected air manifolds 20 .
For example, as described above, when glass sheets are conveyed into a heating furnace, the bottom surface heats up and expands faster than the top surface due to contact with the rolls of the conveyor. As a result, the glass sheet curls up on the lengthwise outer edges. Therefore, in a preferred embodiment, the manifolds proximate the lengthwise edges of the glass sheet are initially turned on to create top side convective heating of the glass sheet edges to prevent the sheet from curling up. Later in the heating cycle, the manifolds proximate the lengthwise outer edge of the glass sheet are turned off and the manifold proximate the center of the glass sheet is turned on to provide convective heating of the center portion of the sheet. By using this general technique, the glass sheet can be heated more uniformly to mitigate oil canning and bubbling.
The method of the present invention can be used on small (for example, 20″×20″) or large (for example, 34″×76″) sheets of glass. However, the improved results of the present invention are most noticeable in large pieces of glass since small pieces of glass do not generally tend to exhibit oil canning and bubbling.
The actual amount of time during which convective heating is applied to a glass sheet by each of the manifolds will vary depending on the coating emissivity of the glass sheet. Convective heating is preferably only intermittently applied during the transition phase of the heating cycle where convective heat is moved from one part of the glass to another. Preferably, intermittent heating is done by time proportioning up or down the supply of air to a selected row of manifolds. During time proportioning, air is supplied to the selected manifolds for an ascending or descending amount of time per time interval. For example, during time proportioning up, air is supplied to the manifolds for 6 seconds out of every 10 second interval, then for 7 seconds out of every 10 second interval, . . . then for 10 seconds out of every 10 second interval.
EXAMPLE
A glass sheet measuring 30″×75″ may be heated in a single zone furnace having the manifold arrangement shown in FIGS. 5 a and 5 b using the following sequence steps:
1) Constantly heat the longitudinal edges of the sheet by supplying full air flow to the rows of manifolds above the quarter points for the first 30-40% of the heating cycle. During this time, air flow to the center row of manifolds is restricted;
2) Intermittently heat the edges of the sheet by time proportioning down air flow to rows above the quarter points for the next 10-20% of the heating cycle. Then, restrict all air flow to the rows above the quarter points;
3) Intermittently heat the center portion of the sheet by time proportioning up air flow to the center row manifolds for the next 10-20% of the heating cycle; and,
4) Constantly heat the center of the sheet by supplying full air flow the center row manifolds.
The system and method of the present invention may be used in a single zone or two zone ( 21 , 22 ) furnace. In a two zone furnace, each zone would preferably have a bank of manifolds, although the arrangement of the banks would not necessarily be the same. For example, the location of the air manifolds in a 48″-60″, two-zone ( 21 , 22 ) oven is shown in FIG. 8 a. The location of the air manifolds in a 72″ or 86″ or 96″, two-zone oven arranged for simultaneously heating two glass sheets is shown in FIG. 8 b. The location of the air manifolds in a 72″ or 86″ or 96″, two-zone oven arranged for heating a single large glass sheet is shown in FIG. 8 c.
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A method of heating low emissivity glass sheet for subsequent processing. The glass sheet is loaded onto a longitudinally extending conveyor and oriented such that the lengthwise edge of the sheet is parallel to the length of the conveyor and the direction of conveyance of the glass sheet. The sheet is conveyed into a heating chamber. The glass sheet is then convectively heated in a specified sequence along the entire length of the glass sheet at selected areas measured along the width by creating a downward flow of heated air proximate the selected areas.
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BACKGROUND OF THE DISCLOSURE
The following disclosure relates to energy management, and more particularly to energy management of household consumer appliances, as well as other energy consuming devices and/or systems found in the home. The present disclosure finds particular application to a hot water heater.
Basic hot water heaters generally include a water reservoir, a heating element such as a gas or electric burner, and a thermostat that controls the burner to maintain a set temperature of the water in the reservoir. In general, the temperature of the water is maintained at a relatively constant level corresponding to a set point of the thermostat, for example 140 degrees F, until it is needed. As hot water is dispensed from the reservoir, cold water is admitted thereby lowering the temperature of the water. Once the temperature drops below the set point of the thermostat, the heating element is activated to raise the temperature of the water.
Hot water heaters, and electric hot water heaters in particular, consume a significant amount of household electrical power. By way of example, in some instances a hot water heater consumes more energy than a several other appliances (e.g., washer, dishwasher, refrigerator, etc.) combined. Many consumers are not aware of the amount of energy a hot water heater consumes, or of the impact of the set point temperature on the efficiency and/or energy consumption of a hot water heater.
SUMMARY OF THE DISCLOSURE
A hot water heater is provided that includes power consumption reporting to enable consumers to better understand and control the energy usage and/or efficiency of the hot water heater. By providing the consumer with power consumption information, the consumer can make decisions regarding the set point temperature and/or other scheduling that can not only reduce energy consumption, but also save the consumer money.
According to one aspect, a method of monitoring energy consumption of an electric hot water heater, the hot water heater having at least one electrical load that is selectively activated by a controller of the hot water heater comprises sensing the amount of time the at least one electrical load is activated, multiplying the amount of time by a known value corresponding to a power rating of the electrical load to determine energy consumed, and displaying on a display device an indicator corresponding to the energy consumed.
The sensing can be performed by a microprocessor that senses when the controller activates the load. The hot water heater can have a plurality of electrical loads, and the sensing step can include sensing the amount of time each of the plurality of electrical loads is activated, and the multiplying step can include multiplying the amount of time sensed for each load by a corresponding power rating to determine energy consumed. The method can further comprise the step of summing energy consumed as computed for each load to determine total energy consumption of the hot water heater. The method can further include accessing a lookup table having values corresponding to the power ratings for the at least one load. The displaying step can include displaying at least one of total energy consumption, annual energy consumption, monthly energy consumption, weekly energy consumption, daily energy consumption, hourly energy consumption, and instantaneous energy consumption. The displaying step can include displaying an indicator on a display that is remote from the water heater. The displaying step can include displaying at least one of a numerical value, graphical representation, color, or shape corresponding to energy consumed.
In accordance with another aspect, an electric hot water heater for supplying hot water comprises a cold water inlet; a hot water outlet; an electric heat source for applying heat to a volume of water between the inlet and the outlet; a controller for selectively activating the heat source to heat the water, and a processor configured to: sense an amount of time the electric heat source is activated; and multiply the amount of time by a known value corresponding to a power rating of the electrical load to determine energy consumed by the electric heat source.
The water heater can further comprise a display for displaying an indicator corresponding to the energy consumed by the hot water heater. At least one of total energy consumption, annual energy consumption, monthly energy consumption, weekly energy consumption, daily energy consumption, hourly energy consumption, and instantaneous energy consumption can be displayed on the display. The display can be remote from the water heater. At least one of a numerical value, graphical representation, color, or shape corresponding to energy consumed can be displayed on the display. The hot water heater can have a plurality of electrical loads including the electric heat source, and the processor can be configured to sense the amount of time each of the plurality of electrical loads is activated and multiply the amount of time sensed for each load by a corresponding power rating to determine energy consumed, and further configured to sum the energy consumed as computed for each load to determine total energy consumption of the hot water heater. A lookup table stored in a memory associated with the processor can have at least one value corresponding to the power ratings of the electric heat source. The lookup table can further include power ratings for a plurality of electric loads of the hot water heater.
According to another aspect, a device for monitoring energy usage of an electric hot water heater comprises a processor for sensing an amount of time at least one electrical load of the hot water heater is activated and multiplying the amount of time sensed by a power rating to determine energy consumed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of an exemplary hot water heater in accordance with the present disclosure.
FIG. 2 is a schematic diagram of another exemplary hot water heater in accordance with the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to the drawings, FIG. 1 illustrates an electric hot water heater 10 including a housing 12 in a which a reservoir 14 tank and a heat source 16 are enclosed. The heat source can be in the form of a resistive heating element, heat pump, or other electric heating device (or any combination thereof). The heat source 16 receives power from an electric power supply 18 and converts the power to thermal energy for heating the water in the tank 14 . Cold water is admitted to the reservoir 14 via cold water inlet 22 . Hot water is dispensed via a hot water outlet 24 for distribution to one or more hot water taps (not shown) or other hot water discharge (e.g., washing machine).
As will be appreciated a controller 30 , such as a thermostat, microprocessor or the like, controls the operation of the heat source. Such controller 30 typically operates to activate the heat source 16 to apply heat to a volume of water within the reservoir 14 to heat the water to a desired set point. The basic components and basic operation of the water heater 10 , as described to this point can be conventional, and further details of such conventional water heater are well-known and will not be described further.
In accordance with an aspect of the disclosure, a sensor unit 40 includes a processor 42 , a memory 44 and a sensor 46 . The sensor 46 is in communication with the controller 30 for sensing energy consumption by the heat source 16 and/or by other electrical loads of the hot water heater. Although the sensor unit 40 is shown in FIG. 1 as a separate component, it will be appreciated that in practice the sensor unit 40 can be integrated with the controller 30 , and/or the controller itself can be adapted to perform the functions of the sensor unit as described herein.
As will be appreciated, the hot water heater 10 may have a plurality of electrical loads. For example, some hot water heaters may have a resistive heating element that can be operated at multiple output levels. In many hot water heaters, two or more resistive elements are employed (e.g., upper and lower heating elements). A hybrid electric water heater may include a heat pump and one or more resistive heating elements. The heat pump may typically include both a compressor and a fan, each constituting an electric load. Each of the resistive elements, compressor, fan etc., represent an electrical load.
In operation, the sensor 46 is configured to sense the amount of time each of the one or more electrical loads is activated. This can be done by detecting when the controller 30 activates/deactivates a respective load. That is, the sensor unit can be configured to assume a load is activated when commanded by the controller and likewise deactivated when commanded to deactivate by the controller. Thus, the sensor unit may be configured simply to receive a signal from the controller indicative of activation/deactivation of a given load.
In some embodiments, the sensor may include a device for measuring directly the power consumption of the water heater. Such device could be a submeter adapted to measure power flowing to the hot water heater via the electric power supply line 18 , for example.
Each of the electrical loads correspond to a respective power rating that may be stored in memory 44 . For example, activation of both resistive heating elements in a standard water heater may draw 5 kW of power, each resistive element drawing approximately 2.5 kW. In a hybrid electric water heater having a heat pump, the resistive heating elements may draw 4.5 kW, while the compressor draws 600 W and the fan 50 W. For a given water heater, the values corresponding to the power rating of each electrical load would be programmed or stored in the memory 44 of the sensor unit (e.g., a lookup table).
Once the sensor 46 has detected activation of one or more loads over time, energy consumption can be calculated by the processor by multiplying the power rating value by the amount of time a particular load is activated. Thus, if the compressor is running for 1.5 hours at a power rating of 600 W, the processor would determine that 900 Wh of energy was consumed by the compressor. By way of further example, consider the following table which illustrates the determination of power consumption by a hot water heater over a 24 hour period.
TABLE 1
Time active
Power
Power
Load Name
over last 24 h
Rating
Consumption
Res. Heat element 1
1.2 hour
2.5
kW
4.5
kWh
Compressor
4.6 hour
600
W
2.76
kWh
Fan
4.2 hour
50
W
210
Wh
TOTAL
7.47
kWh
In the table above, the sensor detects activation of the one or more loads over a 24 hour period. As will be appreciated, each load may be activated/deactivated multiple times over the 24 hour period, and the second column displays the total time activated for each load over the 24 hour period. Then the processor 42 , for each load, multiplies the time active by the power rating (column 3) for the respective load. The power consumption for each load is then provided in the fourth column. To calculate the total energy consumption of the hot water heater over the 24 hour period, the power consumption of each load (column 4) is then summed, resulting in 7.47 kWh of energy consumed over the 24 hour period.
It will be appreciated that the processor 42 can provide power consumption data over any period of time, for example, total energy consumption (lifetime of unit), annual energy consumption, monthly energy consumption, weekly energy consumption, daily energy consumption, hourly energy consumption, as well as instantaneous power consumption.
This energy consumption data is then displayed on the display 50 for viewing by a consumer. The display may be provided as part of the hot water heater, such as part of a control panel or the like, and may optionally display other information in addition to the energy consumption data. For example, the display could be used for programming operation of the hot water heater, such as setting a set point, or turning off the unit. In this regard, the display 50 could be a touchscreen display for allowing a user to input data to the system.
The display 50 can be configured to display a wide variety of data relating to energy consumption. Raw energy consumption data can be displayed, such as the total kWh consumed etc. Some consumers, however, may not find such raw data useful. Accordingly, the display 50 can be configured to display graphical representations of energy consumption. Such graphical representations can include, charts, graphs, colors, shapes, etc. that correspond to energy consumption.
By way of example, when the hot water heater is consuming a small amount of energy, a green image may be displayed to indicate low power operation. As energy consumption increases, the green image can be transitioned to, or replaced by, a red image. Alternatively, a graph showing energy consumption of the hot water heater over time may be displayed, or a chart illustrating energy usage over the past week, month, year, etc. Of course, other types of graphical display can be employed as desired.
Turning to FIG. 2 , another exemplary hot water heater 60 is illustrated as part of a home energy management system 62 . Home energy management (HEM) systems are becoming a key to reducing energy consumption in homes and buildings, in a consumer friendly manner. Existing HEMs are commonly in the form of a special custom configured computer with an integrated display, which communicates to devices in the home and stores data, and also has simple algorithms to enable energy reduction.
Key functions of a HEM include:
Creates a network of energy consuming devices within the home, Measures the consumption of the whole home/building or individual devices, Records and stores energy consumption information in a database, and Enables consumer interface with all energy consuming devices in a home to:
view consumption data of individual devices set preferences for operation of energy consuming devices at different times during the day or at different energy pricing levels control/program energy consuming devices.
Returning to FIG. 2 , the hot water heater includes a reservoir 64 and a heat source 66 connected to an electric power supply 68 . A cold water inlet 72 admits water to the reservoir 64 , while hot water flows from the reservoir 64 via hot water outlet 74 . As will be understood, a controller 80 controls the heat source 56 in a conventional manner to heat the water in the reservoir 54 .
A sensor 96 is provided for sensing the activation of one or more loads of the hot water heater 60 , as previously described. In this embodiment, however, the sensor 96 is a separate unit that includes a communication interface 98 for communicating with a home energy manager (HEM) unit 100 that includes a processor 102 and a memory 104 . A display 106 is connected to the HEM 100 for displaying information related to energy consumption of the hot water heater 60 to a consumer.
The sensor 96 can be installed on the water heater 60 and can communicate data sensed to the HEM for use by the HEM 100 . In this regard, the communication interface 98 can be any suitable wired or wireless interface such as WIFI, Bluetooth, Zigbee, Ethernet, etc.
As will be appreciated, the sensor 96 operates in the same manner as the previously described sensor to detect activation of one or more electrical loads of the hot water heater 60 by the controller 80 . The sensor 96 then relays such information to the HEM 100 via the communication interface 98 , and the processor 102 calculates the energy consumption of the hot water heater 60 in the manner set forth previously. As with the embodiment of FIG. 1 , it will be appreciated that the sensor 96 can be integrated with the controller 80 and/or the controller 80 can be configured to perform the functions of the sensor 96 .
By providing the information to the HEM unit 100 , the energy usage of the hot water heater 60 can be calculated and displayed to a consumer in the same manner as described in connection with FIG. 1 . This can provide a more convenient interface for a consumer since, unlike a water heater that is often installed in a basement or closet (or otherwise out-of-sight), the display 106 associated with the HEM unit 100 is more likely installed in a readily accessible location. For example, a HEM unit 100 may be installed in a kitchen or laundry room. Accordingly, display of energy consumption information is more likely to be seen by a consumer in such configuration.
Moreover, the energy consumption data can be utilized by the HEM unit 100 in its functions to actively manage energy use within the household. For example, given that the HEM unit 100 is uniquely aware of energy consumption of other devices in a household that consume hot water, such as a dishwasher, clothes washer, etc., the HEM unit 100 can utilize such information in combination with the energy consumption data relating to the water heater to usage to customize control of the water heater. For example, starting the dishwasher could be delayed until late in the evening after evening showers are taken. In a home having a hybrid electric water heater, delaying operation of the dishwasher can represent more efficient operation since it may be possible to utilize only the more efficient heat pump rather than the resistive heating elements. Other uses of the energy consumption data are also possible.
As will be appreciated, the processor 102 and memory 104 of the present embodiment are housed within the home energy management unit 100 , separate from the sensor 96 . However, it will be understood that the sensor 96 , communication interface, 98 , processor 102 and memory 104 could all be provided as a separate sensor unit, similar to the sensor unit 40 of FIG. 1 . Further, such sensor unit could be integrated with the controller 80 and/or the controller 80 can be configured to perform the various functions of the sensor/sensor unit as described above.
The disclosure 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 disclosure be construed as including all such modifications and alterations.
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A hot water heater and method that includes power consumption reporting to enable consumers to better understand and control the energy usage and/or efficiency of the hot water heater. Monitoring energy consumption of an electric hot water heater having at least one electrical load that is selectively activated by a controller of the hot water heater includes sensing the amount of time the at least one electrical load is activated multiplying the amount of time by a known value corresponding to a power rating of the electrical load to determine energy consumed, and displaying on a display device an indicator corresponding to the energy consumed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a clock recovery circuit, and more particularly, to an over-sampling type clock recovery circuit which performs sampling of a data signal based on a plurality of clock signals having different phases.
2. Description of the Related Art
In recent years, a high-speed protocol is proposed such as Gbit Ethernet and Fiber Channel for data transmission. For this purpose, high speed processing is requested in a clock recovery circuit to extract a clock signal from a data signal in a high speed transmission and in a PLL circuit to establish frequency synchronization between the clock signal used in the circuit and the transmitted clock signal. In order to respond to such a request, as disclosed in 1996 IEEE International Solid-State Circuits Conference, an over-sampling type clock recovery circuit is proposed in which the transmitted data signal is sampled based on a plurality of clock signals with different phases generated by an internal circuit.
FIG. 1 shows a circuit block diagram of a clock recovery circuit which is disclosed in the conventional example. A data signal is supplied to eight phase comparators TIPD0 to TIPD7. The respective phase comparators TIPD0 to TIPD7 are supplied with 24 clock signals having fixed delays outputted from a fixed delay circuit for every set of three clock signals.
Each phase comparator detects the phase state between the data signal and the set of three clock signals. When the set of clock signals and the data signal are matched in phase to each other, the phase comparator detects a locking state to set a corresponding one of up signals up0 to up7 to an disable state and a corresponding one of dn signals dn0 to dn7 to a disable state, as shown in FIGS. 2A to 2F. When the set of clock signals leads the data signal, the phase comparator detects the leading of the clock signals to set a corresponding one of up signals up0 to up7 to the disable state and a corresponding one of dn signals dn0 to dn7 to an enable state. Similarly, when detecting the delay of the clock signal compared to the data signal, the phase comparator sets the up signal to the enable state and the dn signal to the disable state, as shown in FIGS. 3A to 3F.
Charge pumps CP0 to CP7 increase the output voltages when the up signals are set to the enable state and decrease the output voltages decrease when the dn signal is set to the enable state. The output voltages are supplied to a low pass filter LPF. The low pass filter LPF integrates the changes of the voltages supplied from the charge pumps CP0 to CP7 and outputs the integrated voltage to a variable delay circuit VD. A voltage controlled oscillator VCO oscillates and generates a reference clock signal to output to the variable delay circuit VD. The variable delay circuit VD delays the reference clock signal from the voltage controlled oscillator VCO in accordance with the integrated voltage from the low pass filter LPF. Then, a fixed delay circuit FD receives the delayed clock signal from the variable delay circuit FD and generates the 24 clock signals having fixed delays from the delayed clock signal.
In the clock recovery circuit, the up signal or dn signal is set to the enable state in each phase comparator, as described above. As a result, the voltage outputted from the corresponding charge pump CP increases or decreases, when the leading or delaying state of the set of clock signals is detected. Therefore, the delayed clock signal is outputted from the variable delay circuit VD based on the phase leading or delaying state, and the 24 clock signals are generated by the fixed delay circuit FD based on the delayed clock signal. As a result, the leading or delaying state of the clock signals to be supplied to each of the phase comparators TIPD0 to TIPD7 is controlled so that the appropriate sampling of the data signal can be realized.
However, in this clock recovery circuit, the data sampling cannot be correctly performed, when the phase differences are generated between the 24 clock signals due, to the influence of the wiring layout of the circuit. Especially, when a phase difference is generated between three clocks supplied to the phase comparator, the data sampling cannot be correctly performed. For example, when delay of a clock signal clkn+1 is generated as shown in FIG. 3D, the phase comparator detects a clock delaying state so that the up signal is set to the enable state. For this reason, owing to the operation in the stage subsequent to the charge pump CP receiving the enable state of the up signal, the delay of the 24 clock signals generated in the fixed delay circuit FD is controlled. As a result, the correct data sampling cannot be performed in the whole clock recovery circuit, including other phase comparators.
Also, in such a clock recovery circuit, the number of bits of the transmitted data signal continuously having the same value is limited. Therefore, in a locking state in which any phase difference is not detected, even if the number of clock signals used for the sampling is decreased, the phase difference can be correctly detected.
However, in the above-mentioned clock recovery circuit, the eight phase comparators TIPD0 to TIPD7 are always in the operating state regardless of whether or not they are in the locking state. As the result, in the locking state, ones of the phase comparators other than the phase comparators necessary to detect phase differences perform unnecessary operation. Therefore, the eight phase comparators with the relatively large power consumption operate continuously at the same time. Thus, the power consumption as the whole clock recovery circuit cannot be ignored. Also, each of the charge pumps CP0 to CP7 subsequent to the phase comparators TIPD0 to TIPD7 operate based on phase difference data outputted from the respective phase comparators. Moreover, the power consumption in the low pass filter LPF and the subsequent circuits cannot be ignored.
In addition to the above conventional example, a disqueque apparatus is disclosed in Japanese Examined Patent Application (JP-B-Showa 61-18274). In this reference, the disqueque apparatus is composed of first and second sections and a memory section. The first section determines a majority of sync signals for channels to produce a signal. The second section produces a synthetic signal in response to an output obtained by adding clocks for the channels. The memory section executes performs a read operation in response to the signal and the synthetic signal. Thus, when a data block is composed of a plurality of tracks each of which includes a frame sync signal and a data, the disqueque apparatus can remove a time shift of data between the tracks in a multi-track digital magnetic recording and reproducing apparatus.
Also, a digital signal receiving apparatus is disclosed in Japanese Laid Open Patent application (JP-A-Showa 61-145945). In this reference, the digital signal receiving apparatus is composed of a reproducing section and a majority determining section and a conversion section. The reproducing section reproduces clock signals having a basic clock signal frequency fr and a frequency n (n is a positive integer equal to or larger then 3) times of the basic clock signal frequency fr locked to a digital reproduction signal in phase. The majority determining section extracts n samples values during one bit of the digital reproduction signal based on nfr clock signals, and determines binary values of the n sample values on the majority side as a value during the bit. The converting section converts the determined value to have 1/fr width. Thus, the digital reproduction signal is shaped in units of basic clocks fr of the digital reproduction signal.
Also, a data sampling converting circuit is disclosed in Japanese Laid Open Patent application (JP-A-Showa 61-214842). In this reference, the data sampling converting circuit includes a clock reproducing circuit, a frequency dividing circuit and a determining circuit. The clock reproducing circuit reproduces a clock pulse from a character multiplexed signal. The frequency dividing circuit divides the reproduced clock signal in frequency to 1 to n-th, and generates n sampling pulses with different phases. The determining circuit performs sampling of the character multiplexed signal with the n sampling pulses and determines based on majority determination of m continuous sampling results whether a digital data is in a high level or a low level.
Also, a demodulation data identifying and determining apparatus is disclosed in Japanese Laid Open Patent application (JP-A-Heisei 3-69238). In this reference, the demodulation data identifying and determining apparatus is composed of a detecting and demodulating circuit, a comparator, a clock reproducing circuit, a timing determining section, a latch circuit. The detecting and demodulating circuit demodulate an input signal to output a base band signal. The comparator converts the base band signal into a binary signal. The clock reproducing circuit reproduces a reproduction clock signal having the same frequency as a bit rate of a transmission data, and generates a clock signal faster than the reproduction clock signal. The timing determining section performs sampling of the binary signal using the clock signal and performs majority determination to a plurality of values corresponding to a plurality of sampling points to output the result of the majority determination. The latch circuit latches the output from the timing determining section in accordance with the reproduction clock signal to output as a reproduced digital data.
Also, a digital signal reproducing circuit is disclosed in Japanese Laid Open Patent application (JP-A-Heisei 4-11431). In this reference, the digital signal reproducing circuit is composed of a demodulating section, a sampling section and a majority determining section. The demodulating section demodulates a digital modulated signal. The sampling section performs sampling of the demodulated digital signal in accordance with clock signals from a clock source. The majority determining section performs majority determination to a plurality of sampling values supplied from the sampling section.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an over-sampling type clock recovery circuit which can correct phase differences between a plurality of clock signals used for sampling of an input data signal.
Another object of the present invention is to provide an over-sampling type clock recovery circuit in which an unnecessary operation in each of the sections of the circuit is stopped in a locking state so that power consumption can be reduced.
In order to achieve a first aspect of the present invention, an over-sampling type clock recovery circuit includes a phase difference detecting section, a phase adjusting section and a signal selecting section. The phase difference detecting section detects a phase difference between a data signal and each of a plurality of active sets of clock signals, and generates a phase adjustment signal from a plurality of phase difference data corresponding to the detected phase differences using a majority determination approach. The phase adjusting section generates N (N is an integer equal to or larger than 2) sets of clock signals and adjusts phases of clock signals of the N sets based on the phase adjustment signal. The signal selecting section selects a part or all of the N sets of clock signals based on the detected phase differences from the phase difference detecting section and supplies the selected sets of clock signals to the phase difference detecting section as the plurality of active sets of clock signals.
The phase adjusting section may include an oscillator for generating a reference clock signal, a delay unit for delaying the reference clock signal based on the phase adjustment signal, and a clock signal generating section for generating the N sets of clock signals from the delayed reference signal such that each of the plurality of clock signals has a predetermined delay.
Also, the phase difference detecting section may include a N phase comparators, a majority determining circuit and an adjustment signal generating section. The plurality of active sets of clock signals are supplied to selected N phase comparators. Each of the selected phase comparators compares a corresponding one of bits of the data signal and a corresponding one of the plurality of active sets of clock signals in phase to detect the phase difference. The majority determining circuit determines majority of the phase differences and changing ones of the phase differences on a minority side to match to ones of the phase differences on a majority side to generate the plurality of phase difference data. The adjustment signal generating section generates the phase adjustment signal from the plurality of phase difference data from the majority determining circuit. In this case, non-selected phase comparators of the N phase comparators other than the selected phase comparators stop their operations to reduce power consumption. Also, a portion of the adjustment signal generating section corresponding to the non-selected phase comparators stops its operation to reduce power consumption.
Also, each of the selected phase comparators detects one of a clock leading state, a clock locking state and a clock delaying state to generate one of a clock leading state signal, a clock locking state signal and a clock delaying state signal. A corresponding one of the plurality of active sets of clock signals leads the data signal in the clock leading state, the corresponding active set of clock signals matches the data signal in phase in the clock locking state, and the corresponding active set of clock signals lags the data signal in phase in the clock delaying state. The majority determining circuit determines the majority of the clock leading state signals and the clock delaying state signals for the N phase comparators, and corrects one of the clock leading state signals and the clock delaying state signals on a minority side to the other on a majority side to generate the plurality of phase difference data.
The part of the N sets of clock signals is predetermined.
The signal selecting section selects all of the N sets of clock signals when any one of the plurality of phase difference data indicates that the data signal and a corresponding one of the plurality of active sets of clock signals are not matched to each other in phase, and the part of the N sets of clock signals when all of the phase differences indicate that the data signal and a corresponding one of the plurality of active sets of clock signals are matched to each other in phase.
Also, the signal selecting section may include a locking state detecting circuit and a switch circuit. The locking state detecting circuit determines based on the plurality of phase difference data supplied from the phase difference detecting section whether the data signal and each of the plurality of active sets of clock signals are matched to each other in phase. The switch circuit supplies all of the N sets of clock signals to the phase difference detecting section as the plurality of active sets of clock signals, when the locking state detecting circuit detects that the data signal and at least one of the plurality of active sets of clock signals are not matched to each other in phase. In this case, the switch circuit fixes the clock signals of non-selected sets as ones of the N sets other than the selected sets to a high or low level, when the locking state detecting circuit detects that the data signal and each of the plurality of active sets of clock signals are not matched to each other in phase, and supplies the selected sets of clock signals and the non-selected sets of clock signals to the phase difference detecting section.
In order to achieve another aspect of the present invention, a method of adjusting phases of clock signals in an over-sampling type clock recovery circuit includes:
detecting a phase difference between a data signal and each of a plurality of active sets of clock signals, to generate a phase adjustment signal from a plurality of phase difference data corresponding to the detected phase differences using a majority determination;
adjusting phases of clock signals of N (N is an integer equal to or larger than 2) sets based on the phase adjustment signal; and
selecting a part or all of the N sets of clock signals as the plurality of active sets of clock signals based on the plurality of phase difference data from the phase difference detecting section.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating the structure of an example of a conventional clock recovery circuit;
FIG. 2A to 2F are timing charts illustrating a data signal, clock signals and phase difference data in a locking state;
FIG. 3A to 3F are timing charts illustrating a data signal, clock signals and phase difference data in a clock delaying state;
FIG. 4 is a circuit block diagram showing the structure of a clock recovery circuit according to an embodiment of the present invention;
FIGS. 5A to 5Y are timing charts illustrating a data signal and clock signals;
FIGS. 6A to 6F are timing charts to explain an operation of a phase comparator in a locking state;
FIGS. 7A to 7F are timing charts to explain an operation of the phase comparator in a clock delaying state;
FIGS. 8A to 8F are timing charts to explain an operation of the phase comparator in a clock leading state;
FIGS. 9A to 9P are timing charts to explain a first operation of the phase comparator;
FIGS. 10A to 10P are timing charts to explain a second operation of the phase comparator;
FIG. 11 is a diagram illustrating the input-output characteristic of a variable delay circuit; and
FIGS. 12A to 12AA are timing charts to explain an operation of a switch circuit in response to the output of a locking state detecting circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Next, an over-sampling type clock recovery circuit of the present invention will be described below in detail with reference to the accompanied drawings.
FIG. 4 is a block circuit diagram illustrating the structure of the over-sampling type clock recovery circuit according to an embodiment of the present invention. The over-sampling type clock recovery circuit is composed of a plurality of phase comparators TIPD0 to TIPD7, a majority determining circuit DEC, a plurality of charge pumps CP0 to CP7, a low pass filter LPF, a voltage controlled oscillator VCO, a variable delay circuit VD, a fixed delay circuit FD, a locking state detecting circuit LDEC, and a switch circuit SW. It should be noted that the same reference symbols are allocated to the same components as those of the conventional clock recovery circuit.
In the embodiment, each of eight phase comparators TIPD0 to TIPD7 is provided to perform sampling of a data signal of 8 bits with three clock signals. That is, each of the phase comparators TIPD0 to TIPD7 inputs the 3 clock signals having fixed delays and the data signal transmitted thereto and detects the phase state between the data signal and the clock signals. When the data signal lags the clock signal, the phase comparator detects the leading of the clock signal to the data signal to set a corresponding one of up signals up0 to up7 to an disable state and to set a corresponding one of dn signals dn0 to dn7 to an enable state. In the same way, when detecting the clock signals lags the data signal, the phase comparator sets the corresponding up signal to the enable state and the corresponding dn signal to the disable state.
FIGS. 6A to 6F show a locking state in which the phases of the data signal and the clock signals are coincident with each other in phase. FIGS. 7A to 7F show the clock delaying state in which the data signal leads the clock signals. When the data signal leads the clock signals, the phase comparator detects the clock delaying state to set an up signal of the phase difference data to an enable state and to set a dn signal of the phase difference data to a disable state. FIGS. 8A to 8F show the clock leading state in which the data signal delays lags the clock signals. When the data signal delays lags the clock signals, the phase comparator detects the clock leading state to set the up signal to a disable state and to set the dn signal to an enable state.
The majority determining circuit DEC is connected with the output terminals of the respective phase comparators TIPD0 to TIPD7. The majority determining circuit DEC determines the majority of the up or dn signals of the enable state from the phase comparators TIPD0 to TIPD7 to determine whether the clock signals leads in phase than the data signal as the whole circuit. As the result of the majority determination, the states of the up signals and dn signals on the minority side are corrected to match those of the up signals and dn signals on the majority side. Then, the majority determining circuit DEC outputs the upd signals and dnd signals on the majority side and the corrected up signals and dn signals on the minority side to the charge pumps CP0 to CP7 and the locking state detecting circuit LDEC as upd signals and dnd signals, respectively.
The respective charge pumps CP0 to CP7 and the single locking state detecting circuit LDEC are connected to the output terminals of the upd signals and the dnd signals of the phase comparators TIPD in parallel. The locking state detecting circuit LDEC recognizes the locking state of each phase comparator from the states of the upd signal and the dnd signal outputted from the majority determining circuit DEC, and detects whether all the phase comparators, i.e. the whole circuit is set to the locking state. Then, the locking state detecting circuit LDEC outputs to the switch circuit SW, a locking state detection signal switched between the enable state and the disable state based on the detection result of the locking state.
Each of the charge pumps CP inputs corresponding ones of the upd signals and dnd signals from the majority determining circuit DEC and changes the output voltage in accordance with the input signals to outputs to the low pass filter LPF. The low pass filter LPF integrates the changes of the output voltages from the charge pumps CP0 to CP7 to output to the variable delay circuit VD. The variable delay circuit VD inputs a reference clock signal having a predetermined frequency supplied from the voltage controlled oscillator VCO and the output of the low pass filter LPF. The variable delay circuit VD delays the reference clock signal in accordance with the output voltage from the low pass filter LPF. Moreover, the fixed delay circuit FD inputs the output of the variable delay circuit VD, and generates 24 clock signals having fixed delays from the inputted clock signal. The 24 clock signals are supplied to the phase comparators TIPD0 to TIPD7 in sets of three, through the switch circuit SW.
Moreover, the switch circuit SW is connected to the output terminals of the fixed delay circuit FD for the 24 clock signals such that the level of each clock signal is selectively set to a high level or a low level, to the high level in this example.
When a locking state detection signal supplied from the locking state detecting circuit LDEC indicates the locking states of the phase comparators, the switch circuit SW fixes predetermined ones of the 24 clock signals clk00 to clk23 as selected clock signals to the high level. In this case, the clock signals fixed to the high level are predetermined in units of sets of three clock signals to be supplied to the phase comparator. Therefore, only the clock signals supplied to the selected ones of the phase comparators TIPD0 to TIPD7 are fixed to the high level. Non-selected clock signals of the 24 clock signals other than the selected clock signals are supplied, as they are, to non-selected ones of the phase comparators TIPD0 to TIPD7 other than the selected phase comparators through the switch circuit SW.
The operation of the clock recovery circuit having the above-mentioned structure will be described. FIG. 5A to 5Y are time charts to explain the data signal supplied to the eight phase comparators TIPD0 to TIPD7 and the 24 clock signals used to perform sampling of the data signal. Also, FIGS. 6A to 6F, 7A to 7F, and 8A to 8F are timing charts to explain the operation of the each of the phase comparators TIPD0 to TIPD7. As described in the conventional example, each phase comparator detects the phase state between the data signal and corresponding set of three clk n-1 , clk n , and clk n+1 of the 24 clock signals.
FIGS. 6A to 6F show a locking state in which the phases between the data signal and the clock signals are coincident with each other. Since there is no need to change the phases of the clock signals in the locking state, both of the up signal and the dn signal are set to the disable state, as shown in FIGS. 6E and 6F.
FIGS. 7A to 7F show the leading state of the data signal to the clock signals in phase. When the clock signals delay than the data signal, the up signal is set to the enable state as shown in FIG. 7E and the dn signal is set to the disable state as shown in 7F. As a result, the phases of the clock signal are led.
FIGS. 8A to 8F show the delay state of the data signal than the clock signals. When the clock signals lead than the data signal, the up signal is set to the disable state as shown in FIG. 8E and the dn signal is set to the enable state as shown in FIG. 8F. As a result, the phases of the clock signals are delayed.
Then, the up signal and dn signal of each phase comparator are supplied to the majority determining circuit DEC. The majority determining circuit DEC inputs the up signals and dn signals supplied from the respective phase comparators TIPD0 to TIPD7. The majority determining circuit DEC determines the majority of the detecting results of the respective phase comparators TIPD0 to TIPD7 based on the supplied up signals and dn signals.
As described above, in the over-sampling type clock recovery circuit, sampling of the data signal with the clock signals having the fixed phase differences. Therefore, if the data signal is not to be high or low continuously, the phase difference data detected in each phase comparator becomes the same value even though there is any delay due to the phase difference of the clock signals. When the data signal is high or low continuously, there is no rising edge in the data signal. Therefore, the phase comparator determines that the data signal is in the locking state and sets the up signal and dn signal to the disable state. However, because there is a limitation of the number of data bits continuously having the same value depending upon a transmission system, the phase of the data signal can be necessarily detected in a certain bit unit. Therefore, in this embodiment, the data in units of 8 bits is used.
From the result of the majority determination of the number of up signals or dn signals set to the enable state or disable state, it is determined whether the clock signals in the circuit leads to or delays than the data signal as the whole clock recovery circuit.
FIGS. 9A to 9P show the data signal and the clock signals clk00 to clk08, the up signals up01 to up02 outputted from the phase comparators TIPD0 to TIPD2 supplied, and the upd signals upd00 to upd02 corrected by the majority determining circuit DEC. In the state shown in FIGS. 9A to 9P, if there is not a phase shift in each clock signal, the clock signals are detected by all the phase comparators TIPD0 to TIPD7 to be in the phase delay state. As a result, the up signals are set to the enable state, and the dn signals are set to the disable state.
However, because there is a phase shift, i.e., the phase leading (proceeding) in the clock signal clk08 of FIG. 9J, the phase comparator TIPD2 supplied with the clock signals clk06 to clk08 determines to be in the locking state. Therefore, the phase comparator TIPD2 sets the up signal to the disable state, as shown in FIG. 9M, and the dn signal to the disable state. However, when the up signals are inputted from all the phase comparators TIPD0 to TIPD7 shown in FIG. 4, the majority determining circuit DEC determines the majority of the up signals and the dn signals. Therefore, the majority determining circuit DEC determines that the clock recovery circuit is in the phase delay state of the clock signals as the whole circuit. Thus, the upd02 signal as the output signal of the majority determining circuit DEC corresponding to the up02 signal is set to the enable state. Therefore, in the operation since then, an influence due to the phase shift of the clock signal clk08 is canceled.
FIGS. 10A to 10P show timing charts of the data signal, the clock signals clk00 to clk08, the up signals up0 to up2, and upd signal upd00 to upd02. Here, a case is shown where a phase shift of the data signal occurs at a certain bit to delay the phase of the data signal. When the phase shift occurs in the bit of the data signal, the majority determining circuit DEC could correct the phase shift, as in the above case where the clock signal is shifted in phase. That is, if there is not a phase shift in the bit of the data signal, the clock delaying state of the clock signals is detected by the phase comparators TIPD0 and TIPD1. Therefore, the up signals up01 and up02 are set to the enable state. However, in this case, because there is a phase delay sift in the third bit of the data signal, the phase comparator TIPD2 inputting the third bit determines to be in locking state and sets the up signal to the disable state and the dn signal to the disable state. The majority determining circuit DEC determines the majority of the up signals and the dn signals outputted from all the phase comparators TIPD0 to TIPD7 shown in FIG. 4. Therefore, the majority determining circuit DEC determines that the clock signal delays than the data signal as the whole circuit. As a result, the majority determining circuit DEC sets the upd signal upd02 corresponding to the up02 signal outputted from the phase comparator TIPD2 to the enable state and the dnd signal dnd02 to the disable state. Therefore, in the operation since then, an influence due to the phase shift of the data signal is canceled.
In this way, the phase shift of the clock signal or data signal is corrected by the majority determining circuit DEC. Therefore, the respective charge pumps CP0 to CP7 supplied with the upd signals upd0 to upd7 and dnd signals dnd0 to dnd7, converts the phase difference data obtained from the upd signals and dnd signals into the voltage values. That is, when the upd signal is set to the enable state, the output voltage is increased, and when the dnd signal is set to the enable state, the output is decreased. The low pass filter LPF is supplied with the output voltages of the charge pumps PC0 to PC7 and integrates the change of this voltage. The variable delay circuit VD is supplied with the output voltage of the low pass filter LPF and the reference clock signal outputted from the voltage controlled oscillator VCO. The variable delay circuit VD delays and outputs the reference clock signal in accordance with the output voltage of the low pass filter LPF. FIG. 11 shows relation of a delay quantity to the input voltage of the variable delay circuit VD. The reference clock signal delayed by the variable delay circuit VD is supplied to the fixed delay circuit FD. Then, the fixed delay circuit generates the 24 clock signals having the same phase difference between the clock signals from the delayed reference clock signal, to output the clock signals to each of the phase comparator.
Therefore, when a phase shift is generated in a part of the clock signals having the fixed phases, or when the phase shift is generated in a part of the data signal, the majority determining circuit DEC corrects the phase differences detected by the phase comparators, even though the erroneous phase difference is outputted from a part of the phase comparators TIPD0 to TIPD7. Therefore, it is possible to avoid the generation of inappropriate leading or delay of the clock signals in the fixed delay circuit FD owing to the erroneous phase difference, resulting in the correct sampling of the data signal.
On the other hand, the locking state detecting circuit LDEC inputs the upd signals and the dnd signals as the phase difference data from the majority determining circuit DEC. The locking state detecting circuit LDEC recognizes the detection results of the respective phase comparators TIPD0 to TIPD7 based on the upd signals and the dnd signals, that is, the respective phase states indicated by the corrected phase difference data. Then, when all the upd signals and all the dnd signals are set to the disable, in other words, the locking states are detected, the locking state detecting circuit LDEC outputs a locking state indication signal set to an enable state to the switch circuit SW. It should be noted that when at least one of the upd signals and dnd signals outputted from the majority determining circuit DEC is set to the enable state, i.e., in a non-locking state, the locking state detecting circuit LDEC outputs a locking state indication signal set to a disable state.
FIGS. 12A to 12AA show timing charts to explain the operation of the switch circuit SW based on the enable state and the disable state of the locking state indication signal from the locking state detecting circuit LDEC. When the non-locking state is detected by the locking state detecting circuit LDEC, the switch circuit SW supplies all of the 24 clocks supplied from the fixed delay circuit FD to the respective phase comparators TIPD0 to TIPD7 in response to the locking state indication signal of the disable state. On the other hand, when the locking state detecting circuit LDEC detects the locking states of all the phase comparators, the switch circuit SW sends only the selected ones of the 24 clock signals to selected ones of the phase comparators TIPD0 to TIPD7, just as they are, in response to the locking state indication signal of the enable state. The switch circuit SW fixes the non-selected clock signals to the high state. In the example shown in FIGS. 12A to 12AA, the switch circuit SW supplies 24 clock signals clk00 to clk23 to the phase comparators TIPD0 to TIPD7 in case of the locking state. However, the switch circuit SW fixes the 15 clock signals clk09 to clk23 other than the clock signals clk00 to clk23 to the high level and supplies them to the phase comparators TIPD3 to TIPD7, respectively. That is, these phase comparators TIPD3 to TIPD7 are set to the states equivalent to the state in which any clock signal is not supplied.
Generally, the number of data bits of the transmitted data signal which continuously have the same value is defined depending upon the transmission system. Therefore, even if the number of clock signals used for sampling in the locking state is reduced, the detection of the phase difference is normally performed. The phase comparators TIPD0 to TIPD2 to which the clock signals clk00 to clk09 are supplied in the locking state performs the phase detection as in the non-locking state.
When any clock signal is not supplied, the phase comparator does not perform the phase difference detecting operation and the phase comparator TIPD maintains the locking state regardless of the phase difference between the data signal and the clock signals. As shown in FIGS. 7A to 8F, the phase comparator needs the change point (the edge) of the clock signals supplied for the sampling of the data signal. Therefore, when the clock signals supplied to the phase comparator are fixed to the high or low level so that the phase comparator is set to the state equivalent to the state in which any clock signal is not supplied, the phase difference detecting operation of the phase comparator can be restrained. Therefore, the phase comparators TIPD3 to TIPD7 are set to the state in which the phase detecting operation is stopped so that power consumption can be reduced. It should be noted that when the clock leading or delaying state is detected in the phase detecting operation by either one or all of the phase comparators TIPD0 to TIPD3 performing the phase difference detecting operation, the switch circuit SW again supplies all the clock signals which are not fixed to the high level, to the respective phase comparators TIPD0 to TIPD7. This is because the locking state detecting circuit LDEC outputs the locking state indication signal of the disable state. This is performed until all the phase comparators TIPD0 to TIPD7 are set to the locking state again.
In this way, the locking stated of the phase comparators are detected by the locking state detecting circuit LDEC. In the non-locking state, all the clock signals generated by the fixed delay circuit FD are supplied to the phase comparators TIPD0 to TIPD7, whereas, only the selected ones of the clock signals are supplied to the selected ones of the phase comparators in the locking state. Thus, in the locking state, the operations of the selected phase comparators are set to the stopped state. Also, the charge pumps connected with the selected phase comparators are set to the state in which the operations are set to the stopped state. Therefore, it is possible to decrease the power consumption of the whole clock recovery circuit in the locking state. The total power consumption of the whole circuit can be reduced.
It should be noted that the embodiment shows an example of the present invention only. The locking state detecting circuit LDEC may input the phase differences outputted from the respective phase comparators TIPD0 to TIPD7 before they are inputted to the majority determining circuit DEC. In this case, the locking states are detected based on the phase differences outputted from the respective phase comparators TIPD0 to TIPD7. Also, it is possible to suitably set the number of clock signals to be fixed to the high level in the locking state and the number of phase comparators. Also, in the locking state, the selected clock signals may be fixed to the low level. Further, it would not need to say that the number of bits of the data signal and the number of phase comparators associated with this number of bits of the data signal and the number of clock signals having the fixed phases used for phase comparison can be set suitably in accordance with the required speed.
As described above, according to the present invention, a majority determining circuit DEC is provided to input a plurality of phase difference data which are the outputs from a plurality of phase comparators TIPD0 to TIPD7. Also, the majority determining circuit DEC determines the majority of the phase difference data, and to correct and output the phase difference data on the minority side to the phase difference data on the majority side. Therefore, even if phase shifts of the plurality of the clock signals or the phase shift of the data signal are generated due to the influence of the layout, the phase difference data on the minority side generated from this phase difference can be corrected to the phase difference data on the majority side.
As described above, in the present invention, the locking state of each phase comparator is detected by the locking state detecting circuit based on the phase difference data between the data signal and the clock signals outputted from the plurality of phase comparators. In the non-locking state, all clock signals are supplied to the respective phase comparators. In the locking state, the selected clock signals are fixed to the high level or the low level and the selected clock signals are supplied to only the selected phase comparators. Therefore, in the locking state, the operations of the selected phase comparators are set to the stopped state. Also, the circuit elements connected with the phase comparators are set to the state in which the operations are set to the stopped state. Therefore, it is possible to reduce the power consumption of the whole clock recovery circuit in the locking state. The total power consumption of the whole circuit can be reduced.
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An over-sampling type clock recovery circuit includes a phase difference detecting section, a phase adjusting section and a signal selecting section. The phase difference detecting section detects a phase difference between a data signal and each of a plurality of active sets of clock signals, and generates a phase adjustment signal from a plurality of phase difference data corresponding to the detected phase differences using a majority determination. The phase adjusting section generates N (N is an integer equal to or larger than 2) sets of clock signals and adjusts phases of clock signals of the N sets based on the phase adjustment signal. The signal selecting section selects a part or all of the N sets of clock signals based on the detected phase differences from the phase difference detecting section. The selected sets of clock signals are supplied to the phase difference detecting section as the plurality of active sets of clock signals.
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This is a continuation of application Ser. No. 08/748,898, filed Nov. 15, 1996.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of and apparatus for inspecting slight defects in a photomask pattern.
2. Description of the Prior Art
A photomask 1 is used in the production of semiconductor integrated circuits. As shown in FIG. 1, the photomask 1 has a transparent base 2 on which, for example, two chips 3 each size of which is 10 mm×20 mm are formed. A circuit pattern 4 of a light intercepting film made of chromium (Cr) or the like is formed in the chips 3 in high density. The width of the circuit pattern 4 is, for example, 1 μm to 3 μm.
As shown enlargedly in FIG. 2, cases occur in which a part of the circuit pattern 4 has defects, such as a pin hole 5 or a projection 8, or has flaws, such as a crack 6 or a nick 7, or has foreign substances. If exposure is performed using such a defective photomask 1, a circuit pattern different from a predetermined circuit pattern 4 is formed on a semiconductor substrate (i.e., a wafer). In other fords, a semiconductor integrated circuit having pattern defects is formed. For this reason, an inspection of whether the formed photomask 1 has defects is beforehand undergone.
There are various kinds of methods of inspecting defects in the pattern of the photomask 1. Typically, an adjacent-pattern comparison method and a design-data comparison method are well known.
1 Adjacent-Pattern Comparison Method
According to this method, two adjacent chips 3 are compared with each other and, when disagreements therebetween are found, it is judged that defects exist. This method is followed on the supposition that there is little probability that two adjacent chips 3 have the same defects in the same circuit patterns of the chips 3.
2 Design-Data Comparison Method
According to this method, a circuit pattern is observed by a defect inspection apparatus, and the observed positions are compared with design-data corresponding to the positions.
These defect inspection methods 1 and 2 are properly used depending on purposes and uses.
FIG. 3 shows an example of the apparatus for inspecting defects in the pattern of the photomask 1. This inspection apparatus comprises a data processing system which includes a CPU 10, a magnetic disk unit 11, a magnetic tape unit 12, a floppy disk drive unit 13, a console CRT 14, a pattern monitor 15, a magnetic card unit 16, a miniprinter 17, an RS-232C adapter 18, and the like, a detective optical system which includes an autoloader control circuit 19, a table control circuit 20, an X-motor M1, a Y-motor M2, a θ-motor M3, an autofocus control circuit 21, a piezo-element 21a, a positioning circuit 22, a control circuit 22' of, for example, a laser length measuring system, a bit developing circuit 23, a pattern comparative inspection circuit such as a data comparison circuit 24, an autoloader 25 accommodating various kinds of photomasks 1, an illumination light source 26, an illumination field diaphragm 27, a condenser lens 28, an X-Y table 29, an objective lens 30, a photodiode array 31, a sensor circuit 32, and the like, and an observing scope which includes reflection mirrors 33, 34, an eyepiece 35, and the like (see a reference entitled "Mask Defect Inspection Method by Database Comparison with 0.25˜0.35 μm Sensitivity", in Jpn. J. App. Phys, Vol 33(1994)7156). As shown in FIG. 4(a), the width of about 300 μm of the photomask 1 is observed by the photodiode array 31. The photodiode array 31 is disposed at a position where the circuit pattern is imaged. The photomask 1 is mounted on the X-Y table 29 and is illuminated with light from the illumination light source 26.
As shown in FIG. 4(b), the X-Y table 29 is transferred in the direction of arrow A1 at intervals of a predetermined pitch p. When measurements in the direction of arrow A1 are completed, the X-Y table 29 is transferred by the width W in the direction of arrow A2 and thereafter the X-Y table 29 is transferred at intervals of the predetermined pitch p in the direction of arrow A3. In the same manner, the X-Y table 29 is transferred successively in the directions of arrows A4, A5 . . . so as to inspect the whole range of the photomask 1.
The autofocus control circuit 21 drives autofocusably the objective lens 30 in the axial direction of the objective lens 30 so as to keep a distance between the objective lens 30 and the photodiode array 31 constant, and thereby accurate data can be obtained. The θ-motor M3 controls the X-Y table 29 to keep the photomask 1 parallel to the photodiode array 31.
Graphic data is beforehand stored as a circuit pattern in the magnetic disk unit 11. The circuit pattern 4 of the photomask 1 is projected enlargedly onto the photodiode array 31 by means of the objective lens 30, and an image of the circuit pattern 4 is formed on the photodiode array 31. The image of the circuit pattern 4 is photoelectrically transferred by the photodiode array 31 and is output to the sensor circuit 32 in the form of measured data. The measured data is converted from an analog signal to a digital signal and is input to a first input terminal of the data comparison circuit 24.
On the other hand, the graphic data is transmitted to the bit developing circuit 23 in accordance with a detected output of she positioning circuit 22. The graphic data is converted into a binary number system by means of the bit developing circuit 23 and is transmitted to a second input terminal of the data comparison circuit 24. The output of the positioning circuit 22 is input to a third input terminal of the data comparison circuit 24. The data comparison circuit 24 processes the binary bit pattern data through proper filters and thereby converts the binary bit pattern data into a multivalue system.
The reason why the binary bit pattern data is processed through the proper filters is that the measured data is being filtered by the resolution characteristic of the objective lens 30 and the aperture effect of the photodiode array 31.
Data in an observed position is compared with data in a corresponding position of pattern design data in accordance with a predetermined algorithm by means of the data comparison circuit 24. Thereby, disagreeing positions between the design data and the measured data are regarded as defects. In this type of pattern comparative defect inspection, in order to detect slight defects, the resolution of an optical system of an inspection means is enhanced, the algorithm for comparison is improved, or the processing of measured signals is improved.
However, the detection sensitivity to pattern defects largely depends upon the kinds of the defects. Especially, if a pattern defect of the circuit pattern 4 is a pin hole as shown in FIG. 2, it is difficult to detect it, and it is almost impossible to detect the defect of a pin-hole less then 0.35 μm in diameter.
In recent years, a phase shift type of photomask shown in FIG. 6(a) has been used instead of a conventional amplitude type shown in FIG. 5(a). In the amplitude type of photomask, illumination light P1 is completely intercepted by light intercepting portions 36 made of chromium (Cr), as shown in FIG. 5(a). The illumination light P1 which has passed only through light transmitting portions 37 is guided to the photodiode array 31, and a circuit pattern is then imaged on the photodiode array 31 in accordance with the amplitude intensity of light. The luminous intensity distribution of a circuit pattern image at an imaging position 38 is shown in FIG. 5(b), where reference numeral 36' denotes a position of an intercepted image corresponding to the light intercepting portions 36, reference numeral 37' denotes a position of a transmitted image corresponding to the light transmitting portions 37, and reference numeral 39 denotes a luminous intensity distribution of the circuit pattern image at the imaging position 38.
In the conventional amplitude type of photomask 1, in order to enhance the detection sensitivity to slight defects in the circuit pattern 4, the light amplitude intensity of the circuit pattern image of the photomask 1 which is formed on the photodiode array 31 is heightened to the utmost. In other words, in order to heighten the resolution, the wavelength λ of the illumination light P1 with which the photomask 1 is illuminated is shortened, and the numerical aperture NA of the objective lens 30 is enlarged. This is based on the optical theory that, if illuminating conditions are fixed, the optical intensity of an image becomes larger as the value λ/NA becomes smaller.
The photomask 1 which has been regarded as having no defects in the circuit pattern 4 is attached to an exposure unit. The circuit pattern 4 is then imaged on a wafer by the illumination light P1 of the exposure unit having an objective lens with a large numerical aperture NA. However, it is unallowable to make the value λ/NA smaller than a predetermined value, for the following reason.
A resist serving as a photosensitive agent is applied to the wafer. The film thickness of the resist is 1 μm and over, as a result of considering the etching of a ground after exposure. A depth of focus equal to or larger than 1 μm is required to, with respect to the direction of the film thickness, expose the resist to light while keeping the contours of the image clear.
However, the depth of focus, the wavelength λ, and the numerical aperture NA have a relationship to each other in that the depth of focus becomes smaller in proportion to λ/(NA) 2 . Especially, the numerical aperture NA contributes to the depth of focus by the square of the numerical aperture NA. The limited value of the depth of focus is approximately 0.6μm. Thus, the conventional exposure method is limited in enhancing the resolution of a circuit pattern image.
Consequently, the phase-shift photomask 40 (e.g., attenuated photomask) shown in FIGS. 6(a) and 6(b) has been used to obtain higher resolution than hitherto by the use of the conventional exposure unit.
The structure of the phase-shift photomask 40 will now be described.
As shown in FIG. 6(a), on a glass base, light intercepting portions 42 are formed which are made of a material having a higher refractive index than that of light transmitting portions 41. The light intercepting portions 42 transmit part of the illumination light P1. A phase of the part of the illumination light P1 which has passed through the light intercepting portions 42 is delayed with respect to that of the illumination light P1 which has passed through the light transmitting portions 41.
The phase difference between the illumination light P1 which has passed through the light transmitting portions 41 and the illumination light P1 which has passed through the light intercepting portions 42 causes interference therebetween. As a result, a circuit pattern image at the imaging position 38 is formed not only by the light amplitude intensity but also by the interference caused by the phase difference.
FIG. 6(b) shows the luminous intensity distribution of the circuit pattern image at the imaging position 38. In FIG. 6(b), reference numeral 41' denotes a transmission image position corresponding to the light transmitting portion 41, reference numeral 42' denotes an interception image position corresponding to the light intercepting portion 42, and reference numeral 43 denotes a distribution of the luminous intensity of the circuit pattern image at the imaging position 38.
According to the photomask 40, the minimum value δ of a luminous intensity distribution 43 can be made smaller than the minimum value δ' of a luminous intensity distribution 39. As a consequence, the contrast of the circuit pattern image having a wavelength equal to or shorter than the wavelength λ of the illumination light P1 can be expected to be improved. Thus, the contours of the circuit pattern image become clear. Since the resist applied to the wafer has the property of strengthening a contrast, this effect can be heightened even more.
However, in the phase-shift photomask 40, part of light can pass through the light intercepting portions 42. This makes it more difficult to detect pattern defects, such as a pin hole with a diameter below 0.35 μm, if inspection is carried out with inspection light same in wavelength as exposure light.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a method of and an apparatus for inspecting slight defects in a pattern of a photomask, by which slight defects, such as a pin hole with a diameter of 0.35 μand less, can be inspected closely and with certainty.
In a method of inspecting slight defects in a pattern of a photomask according to an aspect of the present invention, the pattern whose image is projected onto an imaging position by using illumination light with an exposure wavelength for exposure comprises light transmitting portions formed on a transparent base and light intercepting portions formed on the transparent base which transmit part of the illumination light a phase of which is delayed with respect to a phase of the illumination light passing through the light transmitting portions. The method includes the step of detecting defects in the pattern on the basis of a signal obtained by illuminating the pattern with inspection light having a wavelength different from the exposure wavelength. The inspection light satisfies the formula
T≧(Thr-0.01).sup.1/1.8
where T is a transmittance of the light intercepting portion with respect to the inspection light with the inspection wavelength, and Thr is a signal detection limit of an inspection circuit, on the supposition that a signal level of the inspection light passing through the light transmitting portions is 1.
According to the present invention, a photomask is illuminated with illumination light having a longer wavelength than that of exposure light when inspection is carried out.
The phase of the illumination light which passes through light intercepting portions is delayed with respect to the phase of the illumination light which passes through light transmitting portions. When inspection is carried out using the illumination light having a longer wavelength than that of exposure light, a luminous intensity distribution of the illumination light is largely varied if slight defects in a pattern exist.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially sectional view of a photomask.
FIG. 2 is a partially enlarged view of the photomask, showing an example of defects in a circuit pattern in a chip formed in the photomask.
FIG. 3 is a descriptive drawing of an apparatus for inspecting defects in a pattern of a photomask.
FIGS. 4(a) and 4(b) show a relationship between a photodiode array shown in FIG. 3 and the photomask. FIG. 4(a) is a plan view of the photodiode array, and FIG. 4(b) is a perspective view of an X-Y table where the photomask is mounted.
FIGS. 5(a) and 5(b) show an example of amplitude-type photomasks. FIG. 5(a) is a sectional view of the amplitude-type photomask, and FIG. 5(b) shows a luminous intensity distribution at an imaging position.
FIGS. 6(a) and 6(b) show an example of phase-shift photomasks. FIG. 6(a) is a sectional view of the phase-shift photomask, and FIG. 6(b) is a luminous intensity distribution at an imaging position.
FIG. 7 is a graph showing a difference in the luminous intensity distribution depending on the size of a pattern defect.
FIG. 8 is a graph showing the variation of a luminous intensity when the size of the pattern defect is varied.
FIGS. 9(a) to 9(h) are graphs showing the variation of a luminous intensity distribution when the size of the pattern defect is varied using illumination light which serves as inspection light and has a longer wavelength than a wavelength of exposure light.
FIG. 10 is a graph showing differences in output.
FIG. 11 is a graph showing a relationship between a difference in output and a detection limit.
FIG. 12 is a graph shoving a relationship between the size of a pattern defect and differences in output when a transmittance of a light intercepting portion is 50%.
FIG. 13 is a graph showing a relationship between the size of the pattern defect and the differences in output when the phase difference is varied at intervals of 0.2 π from 0.3π to 0.9π on the condition that the transmittance of the light intercepting portion is 10%.
FIG. 14 is a graph showing a relationship between the size of the pattern defect and the differences in output when the phase difference is varied at intervals of 0.2π from 0.3π to 0.9π on the condition that the transmittance of the light intercepting portion is 20%.
FIG. 15 is a graph showing a relationship between the size of the pattern defect and the differences in output when the phase difference is varied at intervals of 0.2π from 0.3π to 0.9π on the condition that the transmittance of the light intercepting portion is 30%.
FIG. 16 is a graph showing a relationship between the size of the pattern defect and the differences in output when the phase difference is varied at intervals of 0.2π from 0.3π to 0.9π on the condition that the transmittance of the light intercepting portion is 40%.
FIG. 17 is a graph showing a relationship between the size of the pattern defect and the differences in output when the phase difference is varied at intervals of 0.2π from 0.3π to 0.9π on the condition that the transmittance of the light intercepting portion is 50%.
FIG. 18 is a graph showing a relationship between the size of the pattern defect and the differences in output when the phase difference is varied at intervals of 0.2π from 0.3π to 0.97π on the condition that the transmittance of the light intercepting portion is 60%.
FIG. 19 is a graph showing a relationship between the size of the pattern defect and the differences in output when the phase difference is varied at intervals of 0.2π from 0.3π to 0.9π on the condition that the transmittance of the light intercepting portion is 70%.
FIG. 20 is a graph showing how to ascertain whether pattern defects can be detected according to differences in output.
FIG. 21 is a graph showing how to ascertain whether pattern defects can be detected according to differences in output.
FIG. 22 is a graph showing how to ascertain whether pattern defects can be detected according to differences in output.
FIG. 23 is a graph showing a relationship between a signal detection limit Thr and the minimum value of the transmittance T in the light intercepting portions at which the difference |Ss-Bs| on a level with the signal detection limit Thr is obtained when the phase difference is π.
FIG. 24 is a graph showing isoplethic curves of the signal detection limit Thr which are calculated according to Table 1.
FIG. 25 is a graph showing isoplethic lines Q of the signal detection limit Thr which are obtained by transforming the phase difference φ into a sine formula.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Generally, a phase-shift photomask 40 is designed to meet the following two conditions. One of them is that the transmittance of light waves in light intercepting portions 42 is 1 to 4% in a case where the wavelength of illumination light P1 for exposure is an exposure wavelength λ, and the other is that the phase or the illumination light P1 transmitted by the light intercepting portions 42 has a phase lag of π with respect to the phase of the illumination light P1 transmitted by light transmitting portions 41. Consideration will be given to a case where defects in a circuit pattern of the phase-shift photomask 40 are inspected using a pattern defect inspection apparatus shown in FIG. 3.
The minimum dimensions of the circuit pattern of the phase-shift photomask 40 are larger than a resolution limit in a detection optical system. An image of the circuit pattern thrown on a photodiode array 31 retains the configuration of the circuit pattern.
In contrast, pattern defects, such as an extraneous substance or a flaw, are much larger and smaller in dimensions than the pattern. An image of a large pattern defect is thrown onto the photodiode array 31 while retaining the configuration corresponding to the pattern defect.
Therefore, a luminous intensity distribution 44 (an image) becomes the configuration equivalent to the large pastern defect (see FIG. 7). When an image based on a small pattern defect becomes below the resolution limit the configuration corresponding to the small pattern defect cannot be retained. In other words, the image based on the small pattern defect becomes a spot image which is determined by the resolution in the detection optical system. Reference numeral 45 in FIG. 7 denotes a luminous intensity distribution formed by pattern defects having the dimensions smaller than the resolution limit. We will discuss not large pattern defects but small pattern defects because the large pattern defects are possible to detect with sufficient ease by the conventional pattern defect inspection method.
As shown in FIG. 8, the luminous intensity 46 which reaches the photodiode array 31 varies according to the size of the pattern defect. In principle, pattern defects can be detected when the luminous intensity whose value of S/N is equal to or greater than 1 reaches the photodiode array 31. Herein, the noise of the photodiode array 31 is denoted by reference character N and a photoelectric transformation signal of the light which has reached the photodiode array 31 by S. The minimum size Q of a detectable pattern defect equates with the size of a pattern defect which can obtain a luminous intensity equivalent to S/N=1.
The refractive index and transmittance of a high refractive substance out of which the light intercepting portions 42 are made are varied according to the variation of the wavelength of the illumination light P1. If an inspection wavelength λ0 greater than the exposure wavelength λ is selected properly, the transmittance at which the illumination light P1 used as inspection light is transmitted by the light intercepting portions 42 can be made higher than the transmittance in the exposure wavelength λ. Silicon nitride (SiN), molybdenum siliside (MoSi), silicon carbide (SiC), or the like is used as the high refractive substance out of which the light intercepting portions 42 are made. For example, the transmittance at which the illumination light P1 used as the inspection light is transmitted in the wavelength λ0 by the light intercepting portions 42 is designed to become 50%, and the phase difference between the illumination light P1 transmitted by the light transmitting portions 41 and the illumination light P1 transmitted by the light intercepting portions 42 is designed to become π. As shown in FIGS. 9(a) to 9(h), the luminous intensity distribution 47 varies when the diameter of a pin hole 5 is successively varied. In FIGS. 9(a) to 9(h), reference numeral 48 is regarded as a luminous intensity (a base output in a case where photoelectric transformation is carried out by the photodiode array 31) obtained by the illumination light P1 which is transmitted by the light intercepting portions 42, reference numeral 49 is regarded as the luminous intensity obtained by the illumination light P1 which is transmitted mainly by the pin hole 5, and reference numeral 50 is regarded as a luminous intensity obtained by the interference between the illumination light P1 which is transmitted by the light intercepting portions 42 and the illumination light P1 which is transmitted mainly by the pin hole 5.
As shown in FIG. 10, a base output based on the illumination light P1 which is transmitted by the light intercepting portions 42 is designated by reference character Bs, the maximum value of the detected output which is larger than the base output Bs is designated by Sb, and the minimum value of the detected output which is smaller than the base output Bs is designated by Ss. From the luminous intensity distribution 47 shown in FIGS. 9(a) to 9(h), there are calculated the absolute value |Sb-Bs| of a difference between the detected output maximum value Sb and the base output Bs in the inspection wavelength λ0, and the absolute value |Ss-Bs| of a difference between the detected output minimum value Ss and the base output Bs in the inspection wavelength λ0. There are also calculated the absolute value |Sb-Bs|' of a difference between the detected output maximum value Sb and the base output Bs in the exposure wavelength λ, and the absolute value |Ss-Bs|' of a difference between the detected output minimum value Ss and the base output Bs in the exposure wavelength λ. The calculation results are plotted into curved lines to obtain a graph shown in FIG. 11, wherein a solid line denotes the absolute value |Sb-Bs| of the difference between the detected output maximum value Sb and the base output Bs, and an alternate long and short dash line denotes the absolute value |Ss-Bs| of the difference between the detected output minimum value Ss and the base output Bs.
Broken lines in FIG. 11 denote the absolute value |Sb-Bs|' of the difference between the detected output maximum value Sb and the base output Bs in the exposure wavelength λ, and the absolute value |Ss-Bs|' of the difference between the detected output minimum value Ss and the base output Bs in the exposure wavelength λ.
The absolute value |Sb-Bs| of the difference in the inspection wavelength λ0 can be obtained as a much larger signal level than the absolute value |Sb-Bs|' of the difference in the exposure wavelength λ in the range where the pin hole 5 is small in diameter. Supposing that, as shown in FIG. 11, a signal detection limit Thr is set between the absolute value |Sb-Bs| of the difference in the inspection wavelength λ0 and the absolute value |Sb-Bs|' of the difference in the exposure wavelength λ in a range to be measured, the diameter of the pin hole which is determined on the basis of the intersecting point between the absolute value |Sb-Bs|' in the exposure wavelength λ and the signal detection limit Thr is equivalent to the minimum size Q of the pin hole 5 which can be detected in the exposure wavelength λ. The diameter of the pin hole which is determined on the basis of the intersecting point between the absolute value |Ss-Bs| of the difference between the detected output minimum value Ss and the base output Bs and the signal detection limit Thr is equivalent to the minimum size Q' of the pin hole 5 which can be detected in the case where the illumination light P1 having a greater wavelength λ0 than the exposure wavelength λ is used. Thereby, the diameter of the pin hole can be made much smaller than the minimum size Q in the exposure wavelength λ.
Hence, design data which is compared with the detected outputs is transformed into difference data in consideration of the transmittance and the phase difference in the inspection wavelength λ0. The difference between the detected outputs is compared with the difference data by means of a data comparison circuit 24 so that slight defects of a pattern can be detected.
Consideration will now be given in more detail to the relationship between a phase difference and a transmittance of the light intercepting portions 42 in the inspection wavelength λ0 of the illumination light P1 used for the inspection of pattern defects.
FIG. 12 is a graph showing a relationship between the differences |Sb-Bs|, |Ss-Bs| and the size of a pattern defect when the phase difference is varied from 0.3π to 1.7π on the condition that the transmittance at which the illumination light P1 is transmitted in the wavelength λ0 by the light intercepting portions 42 is 50%. As obviously shown in FIG. 12, the differences are symmetrical about the central point of the phase difference π (e.g., the difference at 0.3π is the same value as that at 1.7π). The difference |Ss-Bs| becomes maximum at the phase difference π. Therefore, slight defects can be detected in higher probability when the phase difference is π between the phase of the illumination light P1 which is transmitted by the light intercepting portions 42 and that of the illumination light P1 transmitted by the light transmitting portions 41.
FIGS. 13 to 19 are graphs resulting from varying the transmittance at which the illumination light P1 is transmitted in the wavelength λ0 by the light intercepting portions 42 from 10% to 70%, respectively, and plotting the differences about each of the phase differences 0.3π, 0.5π, 0.7π and 0.9π. As can be seen evidently in FIGS. 13 to 19, the higher the transmittance becomes and/or the closer the phase difference comes to π, the larger the difference |Ss-Bs| becomes and, on the other hand, the smaller the difference |Sb-Bs| becomes.
Thus, when the difference in output is varied by the transmittance and/or the phase difference, cases occur in which the difference |Ss-Bs| becomes equal to or less than the signal detection limit Thr in the range where the size of a slight defect is larger, depending upon the selection of the transmittance and/or the phase difference in the light intercepting portions 42, as shown in FIG. 20. In this case, the slight pattern defect cannot be detected between α and β. As shown in FIG. 21, however, the absolute value of the difference |Ss-Bs| becomes larger than the signal detection limit Thr when the transmittance in the light intercepting portions 42 is made sufficiently high. In this case, the slight pattern defect can be detected merely by using the difference |Ss-Bs|. When the difference Ss-Bs| is substantially equal to the signal detection limit Thr because of the low transmittance in the light intercepting portions 42, as shown in FIG. 22, the pin hole defect can be detected by using the difference |Sb-Bs| in combination with the difference |Ss-Bs|.
FIG. 23 shows a relationship between the signal detection limit Thr and the minimum value of the transmittance T in the light intercepting portions 42 which allows obtaining the difference |Ss-Bs| same in level as the signal detection limit Thr when the phase difference is π. A curved line in FIG. 23 is obtained from the following equation:
T=(Thr-0.01).sup.1/1.8
Then, it is possible to detect slight defects in the pattern on the basis of a signal obtained by illuminating the pattern with inspection light having an inspection wavelength different from the exposure wavelength. The inspection light satisfies the formula
T≧(Thr-0.01).sup.1/1.8
where T is a transmittance of the light intercepting portions with respect to the inspection light with the inspection wavelength, and Thr is a signal detection limit of an inspection circuit, on the supposition that a signal level of the inspection light passing through the light transmitting portions is 1.
As can be seen in FIG. 23, the curved line is not extended to the range where the signal detection limit Thr is larger than 0.3. The difference |Ss-Bs| does not exceed the signal detection limit Thr at a lower value than this transmittance.
The minimum values of the difference |Ss-Bs| are then calculated with respect to the respective values of the phase difference in a case where the transmittance T is varied from 10% to 100%. In Table 1 (see the following attached sheet), those calculated values are shown on the supposition that the intensity of light which reaches the photodiode array 31 is 1 when the photomask 40 is not set.
As shown in FIG. 24, isoplethic curves Q1 to Q5 of the signal detection limit Thr are obtained by plotting the values of Table 1 on a graph. In FIG. 24, the isoplethic curves Q1 to Q5 are drawn by tracing the plotted values when the signal detection limit Thr is 0.03, 0.05, 0.1, 0.2, and 0.3, respectively. The difference |Ss-Bs| can be detected in the right-side area of each of the isoplethic curves Q1 to Q5.
Each line on the graph of FIG. 25 is obtained by transforming the numerical values on an ordinate axis (i.e., the phase difference φ) into values on sin (φ/2) with respect to the isoplethic curves Q1, Q2, Q3, and 5 in FIG. 24. The transmittance T iihich is obtained by transforming the phase difference φ into a sine formula becomes a linear relational expression.
From Table 1, wavelengths are selected by which the phase difference φ can satisfy the following relational expressions:
When Thr=0.03 and T<25 (%),
sin (φ/2)=1.17-1.4T;
when Thr=0.03 and T≧25 (%),
sin (φ/2) 1.0-0.75T;
when Thr=0.05 and T<30 (%),
sin (φ/2)=1.2-1.25T;
when Thr=0.05 and T>30 (%),
sin (φ/2)=1.06-0.77T;
when Thr=0.1,
sin (φ/2)=1.19-0.81T; and
when Thr=0.3,
sin (φ/2)=1.40-0.72T.
If the phase difference obtained when the relations are solved is designated by φ the phase difference φ is between (2nπ+φm ) and (2(n+1)π-φm), wherein reference character n denotes a positive integral number or 0 (zero). If the phase difference obtained by interpolation in the transmittances is designated by φm in a case where the detection limit Thr is an intermediate value thereof, the phase difference φ is between (2nπ+φm) and (2(n+1)π-φm), wherein reference character n denotes a positive integral number or 0 (zero).
As described above, when inspecting the slight defects of the circuit pattern of the phase-shift photomask 40, use is made of inspection light having a longer wavelength than an exposure wavelength. Thereby, defects of a pin hole with the diameter below 0.35 μm can be detected with certainty. It is desirable that the photomask 40 is made of a substance whose transmittance increases in the range of the longer wavelength than the exposure wavelength λ. For example, in the photomask 40 where the i-line (having the wavelength of 365 nm) of a super-high-pressure mercury lamp is used as the exposure wavelength λ, it is preferable that slight defects of the circuit pattern are inspected by using visible rays of light. As another example, in the photomask 40 where a KrF excimer laser (having the wavelength of 249 nm) is used as the exposure wavelength, it is preferable that the i-line (having the wavelength of 365 nm) of a super-high-pressure mercury lamp is used as inspection light and that the light intercepting portions 42 are constructed by a substance which satisfies the relation shown in FIG. 23 in the wavelength range of the i-line. In addition to the two examples mentioned above, in the photomask 40 where a KrF excimer laser having the wavelength of 193 nm is used as the exposure wavelength, it is preferable that the KrF excimer laser having the wavelength of 249 nm is used as inspection light and that the light intercepting portions 42 are constructed by a substance which satisfies the relation shown in FIG. 23 in the wavelength range of the KrF excimer laser having the wavelength of 249 nm.
Since this invention is constructed as described above, slight defects in the circuit pattern of the phase-shift photomask, namely, defects of a pin hole with the diameter of 0.35 μm or less can be detected without fail.
According to this method of inspecting slight defects of the photonask 40, a pattern defect inspecting apparatus can be developed which can cope with the correction of chromatic aberration and a heightened numerical aperture (N.A.), from the point of view of optical materials, if use is made of the i-line (having the wavelength of 365 nm) of a super-high-pressure mercury lamp as the inspection wavelength λ0 of inspection light.
In the embodiment mentioned above, there was described the method in which pattern defects are inspected by using the absolute value of the difference |Ss-Bs|. However, this invention is not limited to this method.
For example, an output of the photodiode array 31 is differentiated and, based on the differentiation result, pattern defects are inspected. In this case, a differentiation value Δ n in the n-th position ("th" is a suffix designating an ordinal number) of the photodiode array 31 is obtained from the following equation:
Differentiation value Δn=(S(n+1)-S(n-1))/d
where S(n+1) is an output in the (n+1)-th position of the photodiode array 31, S(n-1) is an output in the (n-1)-th position thereof, and d is a pitch between picture elements. In other words, based on a difference between output values before and after a picture element, a differentiation value in its intermediate position is calculated.
A method of obtaining a differentiation value Δ n is not limited to the above-mentioned method. Another method can be adopted, of course.
If the adjacent-pattern comparison method is used as the pattern defect inspection method, pattern defects can be inspected by comparing a signal obtained from a circuit pattern to be inspected with a signal obtained in a circuit pattern adjacent thereto.
Further, if the design-data comparison method is used as the pattern defect inspection method, a basic signal is generated and stored which is obtained when an ideal circuit pattern is illuminated with inspection light having a wavelength different from that of exposure light, and thereafter pattern defects can be inspected by comparing a signal obtained from the circuit pattern to be inspected with the basic signal.
TABLE 1__________________________________________________________________________TRANSMITTANCE T (%) PHASE DIFFERENCE φ 10 20 30 40 50 60 70 80 90 100__________________________________________________________________________0.9 n 0.02 0.06 0.12 0.18 0.25 0.33 0.40 0.48 0.57 0.65 0.7 n 0.01 0.03 0.07 0.12 0.17 0.24 0.30 0.37 0.45 0.53 0.5 n 0.001 0.004 0.02 0.03 0.06 0.10 0.14 0.20 0.26 0.33 0.3 n -- -- -- -- 0.001 0.005 0.02 0.04 0.08 0.13 0.1 n -- -- -- -- -- -- -- -- -- 0.02__________________________________________________________________________
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A photomask defect inspection method is provided by which defects of pin holes with the diameter equal to or less than 0.35 μm can be detected with certainty. According to the inspection method, a pattern whose image is projected onto an imaging position by the use of illumination light (P1) for exposure consists of light transmitting portions (41) formed on a glass base (2) and light intercepting portions (42) which transmit part of the illumination light (P1) in such a way that a phase of the part of the illumination light (P1) passing through the light intercepting portions (42) is delayed with respect to a phase of the illumination light (P1) passing through the light transmitting portions (41). Slight detects in the photomask pattern are detected on the basis of a signal obtained by illuminating the pattern with inspection light having an inspection wavelength in which the transmittance (T) of the light intercepting portions (42) is defined in the following formula on the basis of a signal detection limit (Thr). When the signal detection limit (Thr) of an inspection circuit is calculated on the supposition that a signal level of the inspection light passing through the light transmitting portions (41) is equal to 1, the relational expression is T≧(Thr-0.01) 1/1 .8.
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BACKGROUND OF THE INVENTION
Extremely large earth digging buckets, such as used in dragline and large shovels, have increased in size to the point where many such buckets dig upwardly of 100 cubic yards of earth in a single bite. Such buckets have an open front with a digging lip at the bottom equipped with forwardly projecting teeth to aid in penetrating the earth in loading the bucket. The teeth on the bucket digging lip are cast metal of a type which is resistant to abrasion, yet, in use, the severe circumstances of operation do wear the teeth, requiring replacement from time to time to maintain the bucket's efficiency in digging. In many typical installations, a tooth base is welded to the bucket lip and extends forwardly therefrom, and has a nose part at the front upon which a tooth holder is removably mounted. This holder, in turn, has a nose part at its front upon which a replaceable toothpoint is held with a fastener in such a fashion that it can be replaced. The assemblage of the tooth base holder and toothpoint extend forwardly from the bucket lip a considerable distance. In a 60 cubic yard size bucket, this assembly may extend typically about 26" forwardly of the cutting lip of the bucket, and for a 120 cubic yard size the extension of the assemblage may be as much as 30" in front of the bucket lip. These teeth are subject to quite large stresses even though the parts are quite large and quite heavy. In the larger size, a typical 10" wide toothpoint would weigh as much as 150 pounds, its mounting holder about 390 pounds, and the tooth base welded to the bucket lip as much as 850 pounds. The size and the weight of the teeth is such that it is desired not to increase the same to provide resistance to breakage. The abrasion on the toothpoint is such that experience has taught that toothpoints are replaced in about a 4:1 ratio to the tooth holder. Even though the parts are quite large and heavy, experience has also indicated that breakage of the assembly most often occurs at the base of the toothpoint where the tooth holder nose will be fractured in its largest section at the base of the nose. It would be desirable to provide internally of the assembly of the toothpoint to its holder, a structure which would be more resistant to this breakage.
In the past, various attempts have been made to design the internal fitting parts of a tooth and its base to adequately resist the forces to which it is applied in use. Typical of such attempts are interfitting tangs and grooves, such as shown in U.S. Pat. No. 2,483,032; the provision of a spherical interfitting surface between the parts to reduce bending stresses, such as shown in U.S. Pat. No. 2,919,506; an arrangement of contact areas between a tooth and its support in an attempt to prevent force reaction and stress concentration points, such as shown in U.S. Pat. No. 3,508,352; and the provision of multiple fastening devices between a tooth and its base to reduce stresses, such as shown in U.S. Pat. No. 3,774,324.
SUMMARY OF THE INVENTION
It has been found in a dragline bucket tooth structure, by the provision of internal structural changes between a toothpoint socket and the nose of a toothpoint adapter to which it is interfitted, that the section modulus of the base of the nose on the adapter may be increased against bending stresses, a considerable amount without requiring an overall larger size or weight of tooth. By making the internal changes in what has been a typically used tooth on large dragline buckets, resistance to breakage has been achieved.
It is the principal object of this invention to provide the internal structure between a digging toothpoint and its tooth holder so as to resist bending stresses against breakage without materially increasing the overall size of the tooth and its mounting base.
It is a detailed object of this invention to provide a nose upon a tooth holding adapter or holder with raised ribs, particularly at the base of the nose, so as to increase the section modulus of the nose by about 18 to 23% over typical constructions, all without materially increasing the overall size of the toothpoint or its mounting adapter.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an upright side view of an assembled tooth base, a toothpoint holder and replaceable toothpoint, with the holder and toothpoint being in section to better illustrate the fastening devices for holding the assembly together;
FIG. 2 is a side elevational view of a replaceable toothpoint showing its socket in phantom;
FIG. 3 is a sectional view through the center of the replaceable toothpoint of FIG. 2, taken substantially along line 3--3 in FIG. 2;
FIG. 4 is a plan view of the toothpoint holder illustrated in FIG. 1, for cooperation with the replacement toothpoint of FIGS. 2 and 3;
FIG. 5 is a sectional view through the nose portion of the holder, taken substantially along the line 5--5 in FIG. 4, and turned 90° for upright illustration and with the rearward parts of the holder broken away, and
FIG. 6 is a view of a replaceable toothpoint similar to FIG. 3, illustrating an alternate construction of the rib and grooves therein.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the assembly of a toothpoint illustrated in FIG. 1, the tooth base 10 has a rearwardly extending part 11 spaced from a lower rearwardly extending part 12 to embrace the lip of a dragline bucket, which lip would abut the end surface 13 within the holder. This holder is welded to the bucket lip, it being understood that a 120 cubic yard bucket would have several such teeth, spaced one from the other, along the length of the digging bucket lip. In the size illustrated, the holder base would weigh about 850 pounds and the distance from the surface 13 in the base to the outer end 15 of the digging lip would be a distance of about 29 to 30". Mounted upon the tooth base is a toothpoint holder 16 to which a replaceable toothpoint 17 is, in turn, mounted. The tooth base is provided with a nose portion 18 generally of a wedge shape in which the nose might be typically about 10" wide with only a sufficient draft on the sidewalls to be properly cast. Important surfaces on the nose are those which support the toothpoint adapter 16, and in this case there is provided a flat planar surface 19 across the top of the nose, a similar flat surface 20 across the bottom of the nose in the base section adjacent the juncture 21 of the nose and the body of the base. The nose has a smaller extremity including similar flat surfaces 22 across the top surface of the nose and a similar flat surface 23 across the bottom of the nose part and an upright flat end surface 24. It is the surfaces 19, 20, 22 and 23 which mate with corresponding flat surfaces within the socket of the toothpoint holder 16 which mounts the holder to the base. When these surfaces within the socket of the holder 16 engage upon the surfaces on the base nose, as will occur as the holder is moved longitudinally over the nose, the surface 24 on the end of the nose should abut the corresponding surface 25 at the base of the socket in the holder. A very large pin 26 may be driven in central openings, such as opening 27 (FIG. 4) in the holder and through a mounting hole in the nose of the base to drive the holder upon the nose of the base. It may be noted that the pin engages particularly against surface 27 at the top of the holder, surface 28 at the bottom of the holder and the surface 29 within the opening provided through the center of the nose on the tooth base. Typically, upon installation on a digging bucket, the assembly of the tooth holder and the replaceable toothpoints will be made substantially as illustrated in FIG. 1. A pin, such as 26, will be driven through the openings of the holder and base nose and allowed to protrude, as illustrated in the dotted lines above and below the holder in FIG. 1, and perhaps even utilized through an 8-hour working shift. Thereafter, an attempt to drive the pins further to more tightly wedge the holders upon the tooth bases will be made, whereupon the dotted portion of the pins may be torched off and welding performed to secure the pins in place. At some later time, should the tooth holder have to be replaced, the welds would be chipped away in order to allow the pin to be driven backwardly out of the hole, permitting the removal of the holder.
In the typical illustration of the invention as shown in FIG. 1, the replaceable toothpoint has a socket which is mounted upon a nose on the tooth holder 16 similar in configuration to the holder nose. This nose is also equipped with planar surfaces across the nose on the upper side near the base of the nose, such as surface 30 and a planar surface 31 at the bottom. The nose also tapers to an end portion 32 also equipped with planar surfaces 33 on the top and 34 on the bottom, which are the mounting surfaces between the toothpoint and the base. The socket within the toothpoint is provided with complementary planar surfaces (FIG. 2), such as 36, which mates with a surface 30 on the nose; surface 37 which mates with the surface 31 on the bottom of the nose near its base part, as well as surface 38 to mate with surface 33; and surface 39 to mate with surface 34. Once the toothpoint is placed over the nose on the tooth holder, it may be pounded lengthwise over the nose until the surfaces mentioned come into face to face contact. At this point in the assembly, the blunt end surface 40 on the nose of the holder should engage the mating and socket surface 41 within the socket of the toothpoint. In the assembly, a composite metal and rubber retaining pin 42 is mounted through aligned upper and lower holes in the toothpoint, such as illustrated at 43 (FIGS. 3 and 6) and a corresponding opening in the nose of the opening 44 in the nose of the holder (FIG. 4). This composite pin provides a constant urging of the toothpoint upon the nose of the tooth holder. Typically, in the size of tooth illustrated, the nose on the tooth holder is about the same width as the nose on the tooth base, but obviously of smaller thickness in an upright direction. Typically, in the size illustrated, the width of the base portion of the nose on the holder taken along a plane illustrated by the lines 45 (FIGS. 1 and 4) is about 101/4" in width by 51/2" in depth. It is the experience in the field that bending stress failures resulting in breaking of the tooth holder most often occurs at about the plane indicated by the lines 45. The present invention provides a solution for such breakage without materially increasing the outer dimensions of the toothpoints, their holders or bases.
It has been found that not only may the moment of inertia of the section at the plane 45 be increased, but that the section modulus which provides additional strength against bending failure may be increased by placing ribs lengthwise over the nose portions of a certain relative size to the size of the nose itself. The construction of the ribs must be chosen to provide an increase in section modulus, whereas some ribs of improper size and location can result in a reduction of the resistance to bending. In the present invention, it is preferred to provide the nose of the holder with a pair of ribs which extend over the base part 50 of the nose through the transition section 51 and onto the extremities portion 53 (FIG. 4). It is preferred that one such rib 55 be provided to one side of the centerline 56 and another such rib 57 be provided on the other side of the centerline 56, such centerline being that through the center of the tooth holder.
Referring to FIG. 5, it may be noted that the rib 55 extends upwardly from the upper flat surface 30 and an opposite lower rib 58 extends outwardly from the lower surface 31 on the nose. On the right-hand side, the rib 57 likewise extends upwardly from the surface 30 and a lower opposite counterpart 59 extends outwardly from the surface 31. These ribs, at the base section 50 of the nose, may most appropriately have a semi-circular cross sectional shape. The diameter of the cross section should be of the order of at least 1" and preferably 11/4" for a 101/4" wide nose, where the upright thickness of the nose at the base section is about 51/2". It has been found that a smaller diameter rib, such as 1/2", will actually reduce the section modulus and thus the strength against bending by about 7.2%. The 1" diameter ribs actually increase the resistance to bending about 6% and the 11/4" ribs increase such resistance by 19.9% in the size of tooth and nose referred to.
Again referring to FIGS. 3 and 4, it is acceptable that the ribs, such as 55 and 57, begin at the base section 50 of the nose with the full diameter and be decreased gradually to a lesser diameter of the order of one-half size at the section over the surface 33. Within the toothpoint, grooves are cast to mate with the ribs, such as the groove 68 which will mate with the rib 58 and the groove 69 to mate with the rib 59. Similar grooves are formed in the upper portion of the toothpoint socket to mate with the upper ribs 55 and 57 on the nose, such as illustrated by the phantomed groove 65 (FIG. 2), which would mate, one each, for the ribs 55 and 57. Thus, it has been found that increased strengthening against bending stress failures can occur by the providing of ribs extending lengthwise over the nose portions of the holder. Semi-circular section is not the only shape acceptable, though easy to accomplish. A square rib is acceptable and would be rounded at the corners to allow mold formation and avoid stress concentration at the outer edges of the rib. Heighth of such "square" ribs should be at least equal to the heighth of semi-circular section ribs.
Referring to FIG. 6, an alternate form of the toothpoint is shown in which the same size of tooth is provided with generally constant size grooves 70 and 71 to fit over similar constant size ribs provided upon a mating nose portion on a holder. It should be understood that sufficient draft must be provided in both the grooves and the ribs for their removal from casting molds. The toothpoints shown in FIG. 2 typically may have a blunt end 72 of about 3/4" thickness by 12" in width. The upper surface 73 and lower surface 74 of the tooth take the brunt of abrasion in the digging process, so that the dimension from the upper rear corner 75 to the lower corner 76 of the tooth may typically be about 81/2". Such a toothpoint would weigh about 150 pounds, and should be reversible 180° so that either the surface 73 or 74 is uppermost as it is installed on the typical toothpoint holder nose.
A similar construction to that described in detail for the nose of the holder may be applied to the nose of the tooth base where it interfits into the socket of the holder. As illustrated in FIG. 1 by the dotted lines above the surfaces 19, 20, 22 and 23, similar ribs to those illustrated in FIGS. 4 and 5 are provided. Such ribs on the nose 18 of the toothpoint base are formed of the same relative size extending longitudinally over the upper and lower mating surface with similar grooves formed in the socket of the holder to fit thereover. Completing the assembly illustrated in FIG. 1 is a removable wear plate 77 which is subject to much abrasion because most of the material loaded into the bucket passes thereover. This wear plate is removable and replaceable upon the removal of the tooth holder 16 from the nose of the tooth base.
By providing strengthening ribs on the nose of the tooth base and on the nose of the tooth holder where such ribs are provided one on each side of the centerline through the assembly and are semi-circular in cross section with a section diameter at the base of the nose in a ratio of the order of 1" to 11/4" for a nose base having an upright thickness of 51/2" and a width of 101/4", it has been found that the additional strengthening against bending is increased about 20% over the structure without such ribs. The cross-sectional height of the rib effective to provide the increased sectional modulus against bending stress is about 18 to 23% of the depth of the nose of 51/2" at the critical plane. Such size of ribs in the relative size of the parts described does not require additional material on either the tooth holder 16 or replaceable toothpoint 17 since there is sufficient metal over the ribs for operational strength. If desired, some additional metal over the ribs may be provided in the toothpoint in the nature of a raised smoothly contoured curved surface over the rib area. Thus, the toothpoint may be improved against the failures that have been experienced without adding material size or bulk to the tooth since the changes are all internal of the mating structures of the toothpoint to its holder and the holder to its tooth base.
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An earth digging bucket toothpoint construction with a tooth base having a tooth holder removably attached thereto and a toothpoint removably secured to the tooth holder in which an internal rib structure on noses of the interfitting parts with mating grooves in the interfitting parts of a particular specified size increases the section modulus against bending stresses to increase the bending strength of the noses against breakage.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the management of data files, such as large object binary files, for temporary access by a requesting application.
2. Relevant Technology
Databases are computerized information storage and retrieval systems. A Relational Database Management System (RDBMS) is a database system which uses relational techniques for storing and retrieving data. Relational databases are organized into tables of rows and columns of data. A database typically includes many tables, and each table includes multiple rows and columns. The tables are conventionally stored in direct access storage devices (DASD), such as magnetic or optical disk drives, for semi-permanent storage.
Users communicate with an RDBMS using a Structured Query Language (SQL) interface. The SQL interface allows users to create, manipulate, and query a database by formulating relational operations on the tables, either interactively, in batch files, or embedded in host languages such as C and COBOL. SQL has evolved into a standard language for RDBMS software and has been adopted as such by both the American National Standards Institute (ANSI) and the International Standards Organization (ISO).
A common application for databases relates to their interaction with Internet web browsers. In responding to a web browser query, a table may need to be created on the web browser. This requires the transfer of data files and the formatting of a table on the web browser. As the database is responsive to SQL and a web browser requires an HTML format, an interface module is required to enable interaction between the web browser and the database. One example of such a interface module is Net.Data available from IBM Corp., Armonk, N.Y.
Net.Data enables Internet and intranet access to relational data on a variety of platforms. Net.Data incorporates a marcrolanguage which supports both HTML and SQL and allows for interaction with universal web browsers and relational database systems. Net.Data operates in conjunction with a web server interface and supports client-side processing as well as server-side processing with languages such as Java, REXX, Perl and C++. Net.Data provides database connectivity to a variety of data sources including information stored in relational databases and flat files. Net.Data may support a variety of operating systems, including OS/2, AIX, Windows NT, HP-UX, Solaris, SCO, OS/390 and OS/400. Net.Data is further able to cache web pages to improve application performance, particularly when repeated requests are made for the same web page. Although the invention is compatible for use with an interface module such as Net.Data other common gateway interface applications may be used with the present invention as well.
The interface module, which may be resident on a server, receives a query from a web browser and formats the query into SQL and interacts with the database to create the table. The interface module then uses its macrolanguage to present the table to the web browser in HTML format. The web browser, in turn, displays the table to a remote user. In this manner, the interface module serves as an Internet gateway for accessing a database.
In creating and formatting a table, the interface module retrieves files from the database for inclusion in the table. Small files, such as character values, may be passed directly from the database, converted into HTML format, and displayed on the browser. However, large files such as large object binary files (LOBs) are difficult to pass directly. A necessary feature of the interface module, such as found in Net.Data, is the ability to retrieve and incorporate LOBs into HTML format. A LOB may be a picture file, a video file, an audio file, as well as executable code. A LOB may be stored in the database and the database may extend across one or more servers. In accessing a LOB, a datalink may be used to point to actual location of the LOB.
Rather than passing LOBs directly to the web browser directly, the LOBs are stored in a temporary directory, commonly termed a “tmpblobs directory.” The temporary directory is termed such because it must store LOBs for a short duration, such as for a web session. The temporary directory is a public directory which may be resident on the server side and is accessible by a web server. The web browser is only able to view files which the web server makes public to a web browser. Thus, the web browser does not have access to the database and must go through web server to access files in a public directory. A representation or link of a LOB is incorporated into the HTML document. As the table is generated on the web browser, the web server retrieves LOBs from the temporary directory.
In order to accommodate numerous web browsers, multiple applications of an interface module may be running. Each interface module may store numerous LOBs to satisfy requests from the web browsers. Given the volume of potential Internet use and the size of LOBs, a temporary directory may rapidly fill up even relatively large memory devices. Full temporary directories would no longer be accessible and would prevent the retrieval and use of additional LOBs. Furthermore, because the temporary directory is a public directory, a hacker may be able to access LOBs in the temporary directory, which are stored in the temporary directory beyond a reasonable time.
Periodic deletions of LOBs in the temporary directory are required to free up space and to reduce the opportunity for unauthorized viewing. Ideally, LOBs actively displayed on a web browser should not be deleted. Premature deletions may be avoided by shutting down the web server, but this prevents access to and use of the web site. A web site must be constantly accessible to accommodate the large number of users and to encourage its use. In some instances, shutting down a web site even momentarily may produce devastating consequences to users.
Thus, it would be an advancement in the art to provide a system and method for automatically removing LOBs to increase space in a temporary directory.
It would be a further advancement in the art to reduce the likelihood of deleting active LOBs without shutting down a web server.
Such an invention is disclosed and claimed herein.
SUMMARY OF THE INVENTION
The present invention monitors the amount of time that a LOB or other type of data file is stored in a temporary, public directory. The invention includes an interface module which is configured to store data files in the temporary directory. The data files are those requested by a requesting application such as a web browser. The interface module provides translation between the database search language and the web browser format language.
The interface module further generates or duplicates data file names corresponding to each data file. The data file names are sent to a clean module which is configured to receive the data file names. The data file names are placed in a data structure. The clean module includes a timing module for generating time stamps for each data file name. The time stamps reflect the time of receipt for each data file name and are stored in association with their respective data file names. The data file names may be stored in a time sequence.
The clean module further includes a delete module which reviews the time stamps to determine if a preestablished time delay has passed. Upon passage of the time delay, the delete module generates a delete command to remove the corresponding data file from the public directory. Only those data files processed by the interface module will be deleted.
Thus, it is an object of the invention to provide management of data files by deleting files after a reasonable amount of time has passed.
It is another object of the invention to automatically increase storage space and reduce opportunities for unauthorized viewing of data files.
It is yet another object of the invention to delete only those data files which were stored by the interface module, thereby reducing the likelihood of accidental deletions.
These and other objects, features, and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other more detailed and specific objects and features of the present invention are more fully disclosed in the following specification, with reference to the accompanying drawings, in which:
FIG. 1 is a schematic block diagram of a computer system suitable for implementing one embodiment of the invention;
FIG. 2 is a schematic block diagram of one embodiment of a system of the present invention;
FIG. 3 is a schematic block diagram of the clean module in the embodiment of FIG. 2 ; and
FIG. 4 is a flow diagram illustrating steps performed in one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of the invention is now described with reference to FIGS. 1-4 , where like reference numbers indicate identical or functionally similar elements. The components of the present invention, as generally described and illustrated in the Figures, may be implemented in a wide variety of configurations. Thus, the following more detailed description of the embodiments of the system and method of the present invention, as represented in the FIGS. 1-4 , is not intended to limit the scope of the invention, as claimed, but is merely representative of presently preferred embodiments of the invention.
Various components of the invention are described herein as “modules.” In one embodiment, the modules may be implemented as software, hardware, firmware, or any combination thereof. For example, as used herein, a module may include any type of computer instruction or computer executable code located within a memory device and/or transmitted as electronic signals over a system bus or network. An identified module may, for instance, have one or more physical or logical blocks of computer instructions, which may be organized as an object, procedure, function, or the like.
Nevertheless, the identified modules need not be located together, but may include disparate instructions stored in different locations, which together implement the described functionality of the module. Indeed, a module may have a single instruction, or many instructions, and may even be distributed over several different code segments, among different programs, and across several memory devices.
As used herein, the term executable code, or merely “executable,” is intended to include any type of computer instruction and computer executable code that may be located within a memory device and/or transmitted as electronic signals over a system bus or network. An identified module of executable code may, for instance, comprise one or more physical or logical blocks of computer instructions which may, for instance, be organized as an object, procedure, or function. Nevertheless, the executables of an identified module need not be located together, but may comprise disparate instructions stored in different locations which together comprise the module and achieve the purpose stated for the module. Indeed, an executable may be a single instruction, or many instructions, and may even be distributed over several different code segments, among different programs, and across several memory devices.
Similarly, operational data may be identified and illustrated herein within modules, and may be embodied in any suitable form and organized within any suitable type of data structure. The operational data may be collected as a single data set, or may be distributed over different locations including over different storage devices, and may at least partially exist merely as electronic signals on a system bus or network.
FIG. 1 is a schematic block diagram illustrating a computer system 10 in which a plurality of modules may be hosted on one or more computer workstations 12 in a network 14 . The network 14 may comprise a wide area network (WAN) or local area network (LAN) and may also comprise an interconnected system of networks, one particular example of which is the Internet.
A typical computer workstation 12 may include a logic device 16 and may be embodied as a central processing unit (CPU), microprocessor, a general purpose programmable device, application specific hardware, a state machine, or other processing machine. The logic device 16 may be operably connected to one or more memory devices 18 . The memory devices 18 are depicted as including a non-volatile storage device 20 , such as a hard disk drive, CD-ROM drive, tape drive, or any other suitable storage device. The memory devices 18 may further include a read-only memory (ROM) 22 , and a random access volatile memory (RAM) 24 . The RAM 24 may be used to store instructions by the logic device 16 during execution. The memory devices 18 may further include a virtual memory 26 which, in one embodiment, is a portion of the non-volatile storage 20 which is used to extend the RAM 24 .
Preferably, the computer workstation 12 operates under the control of an operating system (OS) 28, such as OS/2, WINDOWS NT, WINDOWS 98, UNIX, or the like. In one embodiment, the operating system 28 may be loaded from the storage 20 into the RAM 24 at the time the workstation 12 is booted.
The computer workstation 12 may also include one or more input devices 30 , such as a mouse or keyboard, for receiving inputs from a user. Similarly, one or more output devices 32 , such as a monitor or printer, may be provided within, or be accessible from, the workstation 12 .
A network interface 34 , such as an Ethernet card, may be provided for coupling the workstation 12 to other devices via the network 14 . Where the network 14 is remote from the computer workstation 12 , the network interface 30 may comprise a modem, and may connect to the network 14 through a local access line, such as a telephone line.
Within any given workstation 12 , a system bus 36 may operably interconnect the logic device 16 , the memory devices 18 , the input devices 30 , the output devices 32 , the network interface 34 , and one or more additional ports 38 , such as parallel ports and RS-232 serial ports.
The system bus 36 and a network backbone 40 may be regarded as data carriers. Accordingly, the system bus 36 and the network backbone 40 may be embodied in numerous configurations. For instance, the system bus 36 and the network backbone 40 may comprise wire and/or fiber optic lines, as well as “wireless” electromagnetic links using visible light, infrared, and radio frequencies.
In general, the network 14 may comprise a single local area network (LAN), a wide area network (WAN), several adjoining networks, an intranet, or as in the manner depicted, a system of interconnected networks such as the Internet 42 . The individual workstations 12 may communicate with each other over the backbone 40 and/or over the Internet 42 using various communication techniques. Thus, a communication link may exist, in general, between any of the stations 12 .
Different communication protocols, e.g., ISO/OSI, IPX, TCP/IP, may be used within the network 14 , but in the case of the Internet 42 , a single, layered communications protocol (TCP/IP) generally enables communications between the differing networks 14 and workstations 12 .
The workstations 12 may be coupled via the network 14 to application servers 44 , and/or other resources or peripherals 46 , such as printers, scanners, and facsimile machines. External networks may be coupled to the network 14 through a router 48 and/or through the Internet 42 .
Referring now to FIG. 2 , a temporary data file management system 200 of the present invention is shown. The system 200 preferably includes a plurality of modules containing executable code and operational data suitable for operation within the memory devices 18 of FIG. 1 . Of course, the memory devices 18 in which the modules of the present invention are located may also be distributed across both local and remote computer workstations 12 . Likewise, two or more illustrated modules may be integrated into a single module without departing from the scope of the invention.
The present invention may be used over the Internet 42 and in conjunction with a conventional web browser 202 . The web browser 202 interprets HTML documents and formats and defines web pages 204 . The web browser 202 may be at a remote workstation 12 and may be connected through the Internet 42 to a web server 206 . The web server 206 stores HTML documents and interacts with the web browser 202 for downloading and uploading the documents for generation of web pages 204 .
In operation, a user located at a remote site operates the web browser 202 to send a request. This request is sent across the Internet 42 to the web server 206 , where the request is interpreted by the web server 206 . Where a request is for data files stored in a database, the request must be interpreted into a SQL command. An SQL command request is sent to an interface module 208 which reads the request and formats it into a SQL command. Both the web server 206 and the interface module 208 may be resident on the server side.
The interface module 208 is configured to be compatible with HTML as well as SQL transactions and commands. In one embodiment, the interface module 208 may be Net.Data, but one of skill in the art will appreciate that other computer gateway interfaces capable of supporting and interfacing HTML formats and SQL commands may be used as well. The interface module 208 sends the request as a SQL command to a database system 210 . In one embodiment, the database system 210 system may be a relational database, but hierarchical and object oriented databases are also within the scope of the invention. In embodiments were databases other than relational databases are used, the interface module 208 is configured to be compatible with such databases in a supporting transaction and command language.
A database manager 212 , such as DB 2 manufactured by International Business Machines, receives the SQL command and searches in the database 210 to retrieve data files 214 that satisfy the request. Data files 214 may include any number of various files stored in a database 210 including text, values, characters, integers, and LOBs. Once the data files are retrieved, the database manager 212 passes the retrieved data files to the interface module 208 . The interface module 208 may directly pass relatively small data files 214 in an HTML format to the web browser 202 . This feature is performed by the Net.Data application and expedites retrieval of data files 214 and generation of the web page 204 . The web browser 202 then includes the small data files 214 in a generated web page 204 .
Alternatively, the interface module 208 may pass the small data files 214 to the web server 206 for inclusion in an HTML document. The web server 206 then transmits the data files 214 to the web browser 202 .
If the interface module 208 receives one or more LOBs 216 , the LOBs 216 are sent to a temporary directory 218 . This is because LOBs 216 are typically too large to pass directly to a web browser 202 . The temporary directory 218 is a public directory in that it is accessible by the web server 206 . In an HTML document generated by the web server 206 , a link is established to the appropriate LOB 216 in the temporary document 218 . The web server 206 uses the link to create the LOB 216 on the web page 204 as required. In this manner, the web browser 202 is able to display a web page 204 having relatively small data files 214 as well as LOBs 216 .
By way of example, a remote user may request a table from the database system 210 . The table may include data files 214 containing numerical values as well as a LOB 216 picture file, such as in a GIF or JPEG format. The table may be generated on the web page 204 with a row containing values and a LOB 216 picture. The system 200 would display the data files 214 parsed in appropriate columns by directly passing the values and storing the LOB 216 in a temporary directory 218 .
The interface module 208 is further configured to transmit the file names 220 of LOBs 216 to a clean module 222 . The file names 220 correspond to the name of the LOBs 216 . The interface module 208 need not wait until a browser session is closed before sending the file name 220 to the clean module 222 . In one embodiment, the interface module 208 temporarily stores the file names 220 in a buffer 224 . At the end of a transaction with the database system 210 , the file names 220 in the buffer 224 are sent to the clean module 222 . The interface module 208 may contact the clean module 222 through a port number and a socket configured to transfer data.
The clean module 222 assists in removing files and, in particular, LOBs 216 stored in the temporary directory 218 . The clean module 222 may be embodied as a daemon which is launched automatically on the web server 206 site and is further configured to run in the background. The clean module 222 has a timing module 226 configured to establish an entry time for each file name 220 . The clean module 222 further includes a delete module 228 configured to review each the entry time of each file name 220 and determine if sufficient time has passed to delete the corresponding LOB 216 . If sufficient time has passed, the delete module 228 sends a delete command 230 to an operating system 232 to delete the LOB 216 corresponding to the file name 220 . The operating system 232 receives the command 230 , accesses the temporary directory 218 , and deletes the appropriate LOB 216 .
Referring to FIG. 3 , a block diagram of the clean module 222 is shown. As previously discussed, the interface module 208 sends the file name 220 of the LOB 216 to the clean module 222 . The invention is contemplated for use with several interface modules 208 as may be required to support Internet access and use of the database system 210 . Thus, there may be several interface modules 208 sending file names 220 to a clean module 222 . A management system 200 may further incorporate a plurality of clean modules 222 as required to support the number of interface modules 208 . The interface module 208 loads the file name 220 into a data structure 300 within the clean module 222 such as a linked list 300 .
Once the file name 220 is placed in the linked list 300 , the timing module 226 generates and assigns a time stamp 302 to each file name 220 . This may be done individually for each incoming file name 220 or it may be done collectively as a buffer 224 containing file names 220 is received. The time stamp 302 is a reflection of the entry time of a file name 220 . A time stamp 302 is stored in association with each file name 220 .
The file names 220 may be stored in the linked list 300 in time sequence. As such, the delete module 228 periodically reviews the oldest file name 304 in the linked list 300 . The delete module 228 compares the time stamp 302 of the oldest file name 304 to the existing time to determine how much time has passed since entry of the file name 304 .
A time delay 229 , indicating a certain increment of time, is preestablished by a user or by the system 200 and stored in the clean module 222 . The time delay serves in determining the approximate time that must pass before a LOB 216 will be deleted. The time delay 229 may be adjusted by a user or by the system 200 as needed. The delete module 228 compares the time that has passed to the time delay 229 to determine if sufficient time has passed. The time delay 229 may be set to allow for a reasonable amount of time for a browsing session. This reduces the likelihood of a premature deletion of the LOB 216 . In some instances, the browsing session may exceed the time delay which would eliminate the LOB 216 from the web page 204 and require a reloading of the web page 204 . Nevertheless, the advantages gained in freeing storage in the temporary directory 218 and reduction in hacker risks outweighs the occasional inconvenience of reloading.
If sufficient time has passed, the delete module 228 generates and sends the delete command 230 to the operating system 232 . The delete module 228 further deletes the file name 304 and its corresponding time stamp 302 within the clean module 222 . The delete module 228 then reviews the next file name 220 in the linked list which will now be the oldest file name 304 if the file names 220 are stored in time sequence.
An advantage of the invention is that the clean module 222 only deletes LOBs 216 sent to the temporary directory 218 by the interface module 208 . Thus, other files in the temporary directory 218 not sent by the interface module 208 will are not deleted by intervention of the clean module 222 . This reduces the risk of accidental deletion by the clean module 222 .
Referring to FIG. 4 , a flow diagram 400 incorporates one embodiment of a method of use of the system 200 of FIG. 2 . In step 402 , the method begins. A requesting application, such as the web browser 202 requests 404 one or more data files 214 . The data files 214 are stored in the database system 210 and may include text, characters, integers, values, as well as LOBs 216 such as graphics, audio, video data files. The request may be sent over the Internet 42 to the interface module 208 which translates the request into a suitable search command such as SQL.
The database system 210 retrieves 406 data files 214 satisfying the request. The interface module 208 may directly pass relatively small data files 214 to the web browser 202 for incorporation into a web page 204 . LOBs 216 , on the other hand, are stored by the interface module 208 in the temporary directory 218 .
The interface module 208 generates 408 data file names 220 corresponding to LOBs 216 stored in the temporary directory 218 . The data file names 220 may be temporarily stored in a buffer 224 .
The interface module 208 sends 410 the file names 220 to the clean module 222 where the file names 220 are stored 410 in a data structure 300 .
The clean module 222 generates 412 a time stamp 302 for each file name 220 . The time stamp 302 reflects the approximate entry time of the file name 220 into the clean module 222 . The time stamp 302 is stored in association with each file name 220 .
The clean module 222 reviews 414 each time stamp 302 and determines how much time has passed since the corresponding file name 220 was stored in the data structure 302 . The storage time of a file name 220 is then compared to a preestablished time delay to determine if sufficient time has passed. If sufficient time has not yet passed, the clean module 222 continues to periodically review the time stamp 302 . If sufficient time has passed, the process continues to step 416 .
In one embodiment, the file names 220 may be stored in time sequence. In such an embodiment, the clean module 222 would first review the time stamp 302 of the oldest file name 220 .
The clean module 222 generates 416 a command 230 to delete the LOB 216 associated with corresponding data file name 220 . In step 418 , the method terminates.
The invention provides a system and method for increasing storage space in a public directory 218 by deleting LOBs 216 after a certain amount of time. Storage space may be quickly depleted in an Internet environment where numerous requests for LOBs 216 are constantly made. The invention ensures that the LOBs 216 will be available for a reasonable amount of time, after which time the LOBs 216 are efficiently deleted. Files which were not stored in the public directory 218 by the interface module 208 will not be deleted inadvertently. The invention operates automatically, that is, without user intervention, to keep storage to manageable levels. The invention may be readily adapted to existing software applications such as web browsers, web servers, database management systems, operating systems and other modules disclosed herein.
The present invention may be embodied in other specific forms without departing from its scope or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. 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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The invention provides management of requested data files, such as large object binary files (LOBs), to maximize storage space. An interface module provides translation between a requesting application and a database containing the data files. The interface module stores requested data files in a temporary directory which is accessible by the requesting application. The interface module further generates or duplicates data file names corresponding to each data file. The data file names are sent to a clean module where the data file names are placed in a data structure. The clean module includes a timing module which generates time stamps for each data file name. The time stamps reflect the time of receipt for each data file name and are stored in association with their respective data file names. The clean module further includes a delete module which reviews the time stamps to determine if a preestablished time delay has passed. Upon passage of the time delay, the delete module generates a delete command to remove the corresponding data file from the temporary directory.
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TECHNICAL FIELD
This invention relates to image projectors, and more particularly to a bowling alley score projector having a light source within a table like housing for projecting an image onto a remote screen.
BACKGROUND DISCLOSURE INFORMATION
Bowling alley score projectors commonly have double terminal quartz-halogen lamps as a light source. The quartz-halogen lamp fits in a light fixture that is bolted onto an interior frame within a score projector housing. The light fixture sockets include metal leaf springs that are biased against the terminal ends of the lamp. The leaf spring has a nodule to assure contact with an electrical contact recessed in a porcelain terminal end of the quartz-halogen lamp. A cooling fan within the housing blows air through the bracket assembly which has cooling fins to cool the lamp.
If the leaf spring does not securely contact the terminal ends of the lamp, electrical sparking may deteriorate the terminal ends of both the leaf spring and the terminal ends of the lamp. If deterioration occurs, the electrical circuit may be broken and the light bulb and the light fixture may have to be replaced. Besides the expense of the replacement parts, there is added expense for labor in replacing the parts. Furthermore, the score projector is inoperable until the parts are replaced.
A reliable and durable lamp fixture is needed for a bowling alley score projector that minimizes the necessity of replacing the lamp and the lamp fixture.
SUMMARY OF THE INVENTION
In accordance with the invention, the bowling alley score projector includes a writing surface and a transparent window section in the writing surface. A light source is mounted under the writing surface and a mirror directs the light up through the transparent section where it is redirected to a projection screen.
The score projector has an interior frame for mounting a light fixture. The light fixture includes a U-shaped bracket having two end sections and a central bight section. Two lamp holders are mounted on the end sections of the U-shaped bracket and oppose each other. Each lamp holder has a housing section containing a coil spring and a socket biased by the coil spring. The sockets are spring biased toward each other. A high intensity light source such as a quartz-halogen bulb is positioned between the sockets and secured to the sockets by the biasing force of the coil spring.
The ends of the bracket have cooling passageways therethrough for allowing the passage of cooling air. A fan or other means for causing a flow of air through the passageways is positioned in proximity to the interior frame to direct air flow through the frame, through the cooling passageways, and about the bracket, lamp holders, and light bulb.
In one embodiment, the bight section of the bracket has a spacer which spaces the major portion of the bracket away from the interior frame to form a gap therebetween. The gap allows air to flow against the backside of the bracket to further cool the bracket.
In broader terms, the invention relates to an image projection system having a frame with passage therethrough. A bracket is removeably secured to the frame. Two lamp holders are secured to the bracket opposing each other for receiving a high intensity light source. The light source has two terminal ends engaging the respective lamp holders. Each lamp holder has a housing section receiving a coil spring. The coil spring biases a socket into contact with a respective terminal end of the high intensity source. A blower is mounted in proximity to the passage through the frame for blowing air through the passage and directing the air about the bracket, the lamp holders, and the high intensity light source.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference will now be made to the accompanying drawings in which:
FIG. 1 is a schematic side elevational and partially segmented view of a bowling alley score projector utilizing one embodiment of the invention;
FIG. 2 is a perspective and partially broken view showing the interior frame shown in FIG. 1 and a lamp assembly according to the invention;
FIG. 3 is a side elevational view of the lamp assembly shown in FIGS. 1 and 2;
FIG. 4 is a plan view of the lamp assembly shown in FIG. 3; and
FIG. 5 is an end elevational view taken along the line V--V shown in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a bowling alley score projector has a lower housing 12 which mounts an interior frame 14. The interior frame mounts a lamp assembly 16. The lamp assembly 16 has its light directed downward through an opening 94 in frame 14. The light is reflected upward by a concave mirror 18 through a window section 20 in a table top 22 of the lower housing 12. The light is redirected to a screen 24 by an optical system 26 mounted within an upper housing 28 that is attached to the lower housing 12 by a stem 30.
Referring to FIGS. 2 and 3, lamp assembly 16 is attached to each laterally extending arm 32. The U-shaped bracket 34 is attached to the upper surface 36 of the frame 32. The U-shaped bracket 34 has a spacer block 38 secured thereto which spaces a bight section 40 of bracket 34 away from the wall 36 of the frame 32. The bracket 34 has end sections 42 downwardly extending from its bight section 42. A lamp holder 44 is secured to each end section 42. Each lamp holder 44 has a housing section 46 in a socket 48. A double terminal quartz-halogen light bulb 50 is received in the sockets 48. Each terminal portion 60 has a porcelain outer shell insulating an electrical contact in electrical contact with filament 90.
Referring to FIG. 4, each lamp holder 44 has a housing section 46 having a central bore 52 sized to receive a coil spring 54. The socket 48 has a flange 56 which abutts the end of coil spring 54. Consequently, the socket 48 is biased by the coil spring toward the center of the bracket 34. The socket 48 has a silver contact 58 which contacts the terminal portions 60 of bulb 50. The silver contact 58 is electrically connected to an asbestos wrapped silicone coated wire 62. The wire 62 passes through the bore 52 of housing 46 and an aperture 64 in end section 42.
Referring to FIG. 5, the housing 44 has an outer extending flange 66 having two apertures 68 therethrough. The apertures 68 are on radial opposite sides of the housing and are positioned to be aligned with two apertures 70 in the end 42, shown more clearly in FIG. 4. The apertures 70 and apertures 68 form an axis indicated as 72 which is canted with respect to a transverse axis 74 to form an angle indicated as θ. Canting of the axis 72 formed by the apertures 68 and 70 reduces the necessary width of end 42 in order to mount the housing 44.
Insertion of the light bulb 50 into the sockets 48 causes the sockets 48 to compress the coil springs such that the coil springs exert a reactive force onto the socket which in turn pushes the silver contact 58 into the terminal portion 60 of light bulb 50. It has been found that the force of coil spring 54 pressing the silver contact 58 into the terminal portion 60 of the light bulb 50 prevents electrical arcing and high heat generated by the electrical arcing. The elimination of arcing extends the life of the terminal 60 of the light bulb and the contact 58. The porcelain material of terminal 60 does not crack or otherwise deteriorate due to intense heat. In addition, filament 90 near terminal section 60 also sees extended life due to the lack of intense heat.
When the light bulb is actuated, a fan 76 positioned below the frame 14 is also actuated. Air from vent 92 is forced by the fan 76 to pass through an air passage 78 and through two branches 80 of arms 32. The air passes through the aperture 64 in each end 42 and also as shown in FIG. 3 through a gap 82 formed between the bight section 34 and the upper surface 36 of the extending arm 32. The air passes around the lamp holders 44 and the light bulb 50 to take away the heat generated by the light bulb 50.
The bracket 34 and spacer 38 are made from metal and act as a heatsink to draw away the initial heat generated by the light bulb 50. The gap 82 and the positioning of the bracket longitudinally within the passage 80 provide for the air flow to surround the bracket 34 from the lamp holders 44 and the light bulb 50 to draw away sufficient amount of heat to prevent overheating of the lamp assembly 16.
The lamp assembly 16 can be a direct substitute for present day lamp assembly which uses the leaf spring clips. The spacer block 38 of bracket 34 has threaded apertures 84 therethrough which are positioned to be aligned with the existing apertures 86 in the upper surface 36 of the arm 32. Bolts 88 extend through holes 86 and threadably engage the apertures 84 to hold the bracket 34 in place within the arm 32.
If per chance replacement of the bracket 34 or the light bulb 50 is necessary, easy access is provided by the axis panel 88 mounted on the upper surface 36 of the arm being pivoted to the upper position which is shown in FIG. 2. The light bulb 50 and the bracket 34 become exposed for easy access.
Incorporation of the above described lamp assembly 16 within a score projector reduces lamp burnout. The porcelain terminals 60 of the lamp 50 by being in pressured contact with the silver contact 58 of the socket 48 see no arcing and therefore no high heat is generated which may cause the porcelain terminals to crack or otherwise deteriorate. In addition, the filament 90 also sees increased life. The alignment of the apertures 64 in the direction of the air flow from the fan to the passages 80 allows air to pass therethrough and to constantly take away any excess heat buildup generated by the light bulb. In this fashion, a lamp assembly reduces the replacement and labor costs and provides for a more reliable score projector.
Variation and modifications of the present invention are possible without departing from its spirit and scope as defined by the appended claims.
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A lamp assembly (16) mounted to an interior frame (14) of a bowling alley score projector (10). The lamp assembly (16) includes a U-shaped bracket (34) having two end portions mounting two lamp holders (44). Lamp holders (44) have housings (46) receiving coil springs (54) which spring bias sockets (48). The sockets (48) are spring biased against terminals (60) of a dual terminal quartz-halogen light bulb (50). A center bight section (40) forming a U-shaped bracket is connected to a spacer (38) which is in turn removeably secured to an arm (32) of interior frame (14).
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BACKGROUND OF THE INVENTION
The invention relates to a pharmaceutical for the treatment of sleep disorders, which contains lower dosages of barbiturates in combination with cinnarizine and/or flunarizine.
Among the therapeutically employed hypnotics, barbiturates still hold a central position today. Among the disadvantages of their use is, among others, the need of a higher dosage, which, depending upon the barbiturate, requires single doses of 150 mg to about 650 mg. In the literature, different materials are known which can increase the effect of barbiturates. Thus, Dimercaprol (BAL) checks the decomposition of pentobarbital [J. Pharmacol. Exp. Therap. 109, 292 (1953)], also tocopherol increases the effect of barbiturates [Arch. Int. Pharmacodyn. Therap. 97, 473 (1954)]. In addition it is known that strong antihistamines (phenothiazines) and tranquilizers (Meprobamate), have a pontentiating or enhancing effect on barbiturates. Under the usual combinations of barbiturates with sedatives and other hypnotics, which are registered in the list of traded drugs in Germany, there are still few representatives of these two groups.
SUMMARY OF THE INVENTION
It has now been surprisingly found that cinnarizine and flunarizine have a potentiating or enhancing effect on the action of barbiturates and these combinations have new pharmacological properties. Cinnarizine (1-benzhydryl-4-trans-cinnamylpiperazine or 1-cinnamyl-4-diphenylmethylpiperazine) is known from German Pat. No. 1,086,235. Cinnarizine and also its difluorinated structural analog, flunarizine, have only weak antihistaminic properties and are used therapeutically as peripheral and cerebral vasodilators.
According to the invention there is provided a pharmaceutical characterized in that, besides the usual pharmaceutical adjuvants and carriers, it contains, as the active ingredient, a combination of
(a) one or more compounds from the group of barbiturates and their pharmaceutically acceptable salts and
(b) cinnarizine or flunarizine or a pharmaceutically acceptable salt of these compounds.
The pharmaceutical according to the invention is outstandingly suitable for the treatment of sleep disorders.
DETAILED DESCRIPTION
Typical representatives of the group of barbiturates are phenobarbital, cyclobarbital-calcium and/or hexobarbital.
Suitably the pharmaceuticals according to the invention contain components a(barbiturate) and b(cinnarizine or flunarizine) in a weight ratio of a:b from 100:1 to 5:1, preferably, from 50:1 to 10:1. Preferably the pharmaceuticals according to the invention are formulated for oral and rectal application. Each unit dose of the pharmaceutical according to the invention contains suitable 100-150 mg of the barbiturate component (a) and 5-15 mg cinnarizine (b 1 ) or 2-5 mg flunarizine (b 2 ).
In general, the weight ratio of barbiturate (a) to cinnarizine (b 1 ) is 30:1 to 5:1, preferably 20:1 to 10:1, and the weight ratio of barbiturate (a) to flunarizine (b 2 ) is 100:1 to 20:1, preferably 50:1 to 30:1.
The effect of cinnarizine and flunarizine on the prolongation of sleeping time was determined on male NMRJ mice modified according to "Screening Methods in Pharmacology", R. A. Turner, 1976, page 70. A typical representative from the group of barbiturates with long action (phenobarbital), with short to average action (cyclobarbital-calcium) as well as ultra short action (hexobarbital) as well as a combination of two barbiturates (cyclobarbital-calcium+hexobarbital) was applied orally in graduated doses. The dose required for a 30-minute sleeping period was calculated as the ED 50 . In further tests, the animals were given the respective ED 50 as the sleep inducing basic dose as well as cinnarizine or flunarizine in graduated dosages. For the combination, the ED 50 was calculated by probit analysis, whereby the respective dosages of cnnarizine or flunarizine were selected so that the onset of sleeping time was increased by 50%. The results of these tests are set forth in Tables 1 and 2.
In a further experiment, the influence of cinnarizine on barbiturates on the measured parameters of sleep duration, prolongation of sleeping time, ED 50 , as well as the onset of the effect and the optimum effect were tested. The results of this experiment are given in Table 3.
As a criterium for the onset of the effect, the beginning of the excitation stage was measured. For the optimum effect, the beginning of the sleep phase was tested every 10 minutes by the tail and corneal reflex (according to Irvin) according to the following designations:
______________________________________ 0 = normal reaction-1 = slightly lessened-2 = clearly lessened-3 = highly lessened Optimum effect-4 = complete lack of reaction______________________________________
The results of the sleep duration and the sleeping time prolongation in Table 3 confirm the results of the previous experiments (Table 2). A corresponding synergistic effect is confirmed for the onset of the effect as well as for the optimum effect. Obviously there is also a specific barbiturate effect. In the case of hexobarbital, cinnarizine shows the highest potency, whereas for cyclobarbital-calcium, flunarizine shows the highest potency.
The combination of both barbiturates requires, for cinnarizine as well as for flunarizine, higher dosages to obtain an ED 50 in comparison with the individual barbiturates. The onset of the effect in comparison with the control is not changed with the combination, as it is for the individual barbiturates. Here the marked effect of cyclobarbital-calcium is confirmed.
From the results in Tables 1 to 3, it is concluded that a mixture of cinnarizine or flunarizine with barbiturates produces a marked prolongation of the sleeping time, whereby, to obtain an equivalent effect, considerably lower dosages of the barbiturates are possible. It also produces a considerable improvement in the onset of the effect and of the optimum effect.
The pharmaceuticals according to the invention are dispensed rectally in the form of suppositories and rectal capsules and orally in the form of tablets, capsules or dragees with the use of conventional pharmaceutically acceptable aids as well as necessary carriers, lubricants and disintegrants.
EXAMPLES
______________________________________1. Hard Gelatin CapsulesCyclobarbital - Ca 100.0 mgFlunarizine 5.0 mgLactose 80.0 mgMagnesium Stearate 2.0 mgTalc 8.0 mgPolyvinylpyrrolidone 5.0 mgCorn Starch 30.0 mg2. TabletsHexobarbital 50.0 mgCyclobarbital - Ca 100.0 mgCinnarizine 15.0 mgHydroxypropylcellulose 15.0 mgMicrocrystalline cellulose 103.0 mgGelatine 5.5 mgStearic Acid 1.5 mgTalc 5.0 mg3. SuppositoriesHexobarbital 150.0 mgCinnarizine 10.0 mgSuppository Base 1890.0 mg______________________________________
TABLE 1______________________________________Determination of the oral ED.sub.50 ofthe barbiturates using 10 male NMRτ mice/group Dose Sleep Time ED.sub.50Barbiturate mg/kg Min. mg/kg______________________________________Phenobarbital 200 4.29 256 250 27.52 300 49.06 400 49.28Hexobarbital 250 3.03 710 500 16.52 750 32.53 1000 56.08Cyclobarbital-Ca 100 -- 239 200 14.01 250 34.38 300 90.sup.(1)Cyclobarbital-Ca + 150 8.64 225Hexobarbital 200 21.05(40 + 30) 250 41.09 400 >90.0.sup.(2)______________________________________ .sup.(1) 8 animals showed 90 min., 2 animals 60.5 and 53.3 min. .sup.(2) 2 animals had a sleep time of 67.60 and 66.90 min., the rest >90 min.
TABLE 2__________________________________________________________________________Determination of the sleeping time prolongation under the influence ofcinnarizine and flunarizine (ED.sub.50) 10 male NMRτ mice/group Cinnarizine Flunarizine Dose Dose Sleep Time ED.sub.50 Dose Sleep Time ED.sub.50Barbiturate mg/kg mg/kg Min. mg/kg mg/kg Min. mg/kg__________________________________________________________________________Phenobarbital 256 -- 22.34 256 1 25.78 3.57 256 5 32.85 256 10 43.55*Hexobarbital 710 -- 32.74 -- 38.78 710 0.5 35.37 0.75 1.0 40.44 2.94 710 0.75 43.93** 2.5 45.17 710 1.0 65.58** 5.0 94.51***Cyclobarbital-Ca 239 -- 27.45 -- 32.03 239 1.0 24.34 2.77 0.25 39.54 0.38 239 2.5 41.43* 1.0 62.67*** (0.29- 0.45) 239 5.0 49.99** 2.5 75.15***Cyclobarbital-CA + 225 -- 34.27 -- 33.07Hexobarbital 225 1.0 31.09 4.68 2.5 33.45 7.52(40 + 30) 225 2.5 37.92 10.0 56.49** (6.85- 8.30) 225 5.0 53.22* 15.0 65.12***__________________________________________________________________________ *p <0.05 **p <0.01 ***p <0.001
TABLE 3__________________________________________________________________________Sleeping Time, Onset of Effect and Optium Effect under the influence ofcinnarizine on 10 male NMRτ mice/group SleepBarbi- Dose Cinn- Time ED.sub.50.sup.(2) Onset p.a. Optimumturate mg/kg arizine Min. % mg/kg x Min. % Min. Reflex %.sup.(1) (2)__________________________________________________________________________Hexo- 710 --(C) 35.86 100.0 2.89 100.0 10-20 -1 100.0barbi- 710 0.50 40.66 113.4 0.77 2.49 86.2 10-30 -3 278.2-336.0tal 710 0.75 42.38 118.2 2.22 76.8 10-20 -3 263.2-203.0 710 1.00 76.14 212.3 1.59 55.0 10-30 -4 300.8-407.0Cyclo- 239 --(C) 24.64 100.0 4.27 100.0 10 0/-1 100.0barbital 239 1.0 26.21 106.4 3.52 2.19 51.3 10 -1 166.7calcium 239 2.5 31.08 126.1 (3.07- 2.31 54.1 10-30 -1 350.0 239 5.0 42.49 172.4 4.21) 2.54 59.5 10 -2 350.0Cyclo- 225 --(C) 35.01 100.0 1.15 100.0 10-20 -1/-2 100.0barbital 225 1.0 32.42 92.6 4.94 1.09 94.8 10-20 -2 156.3-183.3calcium + 225 2.5 38.65 110.4 (4.19- 1.18 102.6 10-20 -2 138.8-177.5Hexo- 225 5.0 54.82 156.6 6.49) 1.18 102.6 10-40 -2/-3 175.0-233.0barbital(40 + 30)__________________________________________________________________________ (1) % value calculated on each barbiturate without cinnarizine (C) (2) where there were strong differences among individuals the entire rang (min./max. confidence interval) is given
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At least one barbiturate or one of its pharmaceutically acceptable salts is combined with cinnarizine or flunarizine or one of their pharmaceutically acceptable salts to provide a hypnotic requiring lower dosages of barbiturates to produce the same effect as the barbiturate alone.
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BACKGROUND OF THE INVENTION
This invention relates to a window of the type in which the space between a pair of face-to-face panes is adapted to be selectively flooded with liquid in order to reduce the transmission of heat and light through the window. The liquid may be exhausted from the space when conditions are such that it is desirable for the window to transmit heat and light in a normal manner.
Windows of this general type are disclosed in Colleran U.S. Pat. No. 2,332,060; Solis U.S. Pat. No. 2,378,591 and Winn U.S. Pat. No. 2,439,553.
SUMMARY OF THE INVENTION
The general aim of the present invention is to provide an new and improved window of the above character in which a unique liquid supply manifold is located between the two panes and in which the liquid is supplied to an exhausted from the space between the panes in a novel manner in order to keep the pressure exerted on the panes substantially uniform over the entire area of each pane and thereby prevent the pressure from breaking the window.
A further object is to provide a liquid supply manifold which allows gas to escape from the space between the panes as liquid is introduced into the space, which reduces the formation of bubbles in the liquid within the space, and which enables the liquid to be exhausted from the space in such a manner as to leave the panes virtually clear in a short period of time.
The invention also resides in the provision of uniquely arranged supply and overflow reservoirs for the liquid and in the incorporation in the supply manifold of relatively simple and inexpensive gas outlet tubes which enable gas to escape from the space between the panes as the space is filled with liquid while preventing liquid from the overflow reservoir from re-entering the space when the latter is exhausted.
These and other objects and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a new and improved window incorporating the unique features of the present invention, the liquid supply system for the window being shown schematically.
FIG. 2 is a fragmentary front elevation of the window shown in FIG. 1.
FIG. 3 is a cross-section taken along the line 3--3 of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in the drawings for purposes of illustration, the invention is embodied in a window 10 which is adapted to be flooded with liquid, preferably a colored liquid, at selected times in order to reduce the transmission of heat and/or light through the window. The window comprises two panes 11 of clear glass or other transparent material disposed in face-to-face relation and spaced from one another by a distance of approximately 1/2 inch so that a space 13 for liquid is defined between the panes. Herein, a liquid-tight seal is established around the space by joining the edges of the panes to one another with expoxy cement 14 although many other suitable sealing means could be used in lieu of the cement.
In accordance with the present invention, a unique manifold 15 is located between the panes 11 and within the space 13 and is supplied with liquid in such a manner that the pressure exerted on the entire area of each pane is substantially uniform so as to reduce the danger of the panes breaking when liquid is introduced into or exhausted from the space. In addition, the manifold 15 virtually eliminates the formation of bubbles in the liquid and permits virtually all of the liquid to be quickly exhausted from the space 13.
More specifically, the manifold 15 is shaped as a generally rectangular loop and includes four tubular branches 16, 17, 18 and 19 (FIG. 2) made of rigid plastic tubing or other similar material having an outside diameter of approximately 1/2 inch and an inside diameter of approximately 3/8 inch. The branches 16 and 17 extend generally horizontally and are located adjacent the upper and lower margins, respectively, of the panes 11. The branches 18 and 19 are disposed in vertical positions adjacent the left and right side margins of the panes. Each side branch 18, 19 is joined at its upper end to the upper branch 16 and at is lower end to the lower branch 17 in such a manner that each side branch establishes liquid communication between the upper and lower branches. One end of the lower branch 17 communicates with a liquid supply line 20 while the corresponding end of the upper branch 16 communicates with an overflow line 21.
Inlet means are formed in the lower branch 17 to enable liquid supplied to that branch to flow into the space 13. Herein, the inlet means are in the form of a series of slots 23 (FIG. 2) which are spaced along the upper side of the lower branch and which open out of such upper side and into the space. The manifold 15 also is equipped with gas outlet means which enable air or other gas in the space 13 to be expelled therefrom as liquid is admitted into the space through the inlet slots 23. In carrying out the invention, the gas outlet means are in the form of small tubes 24 (FIG. 2) which are located adjacent the upper end portions of the side branches 18 and 19, there being one outlet tube for each side branch with each tube having an outside diameter of about 1/8 inch. Each tube 24 extends horizontally through and is cemented to the upper end portion of its respective side branch and is located with its inner end flush with the side branch and communicating with the space 13. Also, the lower sides of the upper branch 16 are recessed to accommodate the tubes and enable the interior of the tubes to communicate directly with the extreme upper end of the space 13.
For a purpose to be described subsequently, the outer end portion of each tube 24 is cut on a bevel and is inclined downwardly and inwardly as indicated at 25 in FIG. 2. Each tube spans the interior diameter of its respective side branch 18, 19 and thus the extreme outer end of the tube contacts the adjacent interior wall of the side branch.
Liquid is delivered to the manifold 15 from a supply reservoir or tank 30 (FIG. 1) which communicates with the supply line 20 leading to the lower branch 17 of the manifold. The reservoir initially contains a suitable liquid --such as denatured alcohol colored with blue or green vegetable dye-- which is delivered into the manifold 15 when the tank 30 is pressurized. To pressurize the tank, an air compressor 13 communicates with the tank by way of a solenoid-controlled valve 33, there being a second solenoid-controlled valve 34 associated with the tank and adapted to open and close an air vent 35 leading out of the upper end of the tank.
The compressor 31 also is capable of selectively pressurizing an overflow reservoir or tank 36 which communicates with the line 21 leading from the upper branch 16 of the manifold 15. When a solenoid-controlled valve 37 is opened, pressurized air is delivered from the compressor 31 to the overflow tank 36. Another solenoid-controlled valve 39 is located in an air vent 40 leading from the top of the overflow tank and is adapted to open and close the vent.
To explain the manner of flooding and exhausting the window 10, let it be assumed that all of the liquid is initially contained in the supply tank 30 and that it is desired to flood the space 13 in order to reduce the transmission of heat and/or light through the window. To effect such flooding, the valves 33 and 39 are opened and the valves 34 and 37 are closed. Thus, operation of the compressor 31 results in pressurization of the supply tank 30 so that the liquid therein is forced through the line 20 and into the manifold 15. Such liquid flows into the lower branch 17 and then part of the liquid enters the space 13 through the inlet slots 23. At the same time, liquid flows into the side branches 18 and 19 and subsequently enters the upper branch 16. The level of the liquid in the side branches rises at approximately the same rate as the level of the liquid in the space 13.
As the liquid enters into and gradually rises within the space 13, the air in the upper end of the space is expelled therefrom through the outlet tubes 24 and thence through the side branches 18 and 19 and the upper branch 16. With the valve 39 being open, such air ultimately is bled off to atmosphere through the vent line 40.
Because the outlet tubes 24 enable exhaustion of the air from the space 13 and because of the construction of the manifold 15, the pressure of the air in the space, the weight or pressure of the liquid and the external pressure exerted on the liquid are in virtual balance and thus the total pressure is substantially uniformly distributed over the entire area of each pane 11. Accordingly, the space 13 may be filled with liquid without danger of the pressure breaking the panes. Also, very little bubble formation occurs since any air within the liquid is vented to atmosphere through the outlet tubes 24.
When the space 13 is completely filled, any additional liquid which is supplied to the lower branch 17 simply flows through the side branches 18 and 19 and the upper branch 16 to the overflow tank 36. Thus, the side branches and the upper branch prevent the build up of excessive pressure within the space 13 and avoid the need for cutting off the flow of liquid at the precise time that the space is completely filled. After the space has been filled, the compressor 31 may be shut down and the valves 33 and 39 may be closed so as to prevent drainage of the liquid from the space.
When it is desired to exhaust the space 13, the valves 34 and 37 are opened. Thus, operation of the compressor 31 results in pressurization of the overflow tank 36 to force the liquid therein into the upper branch 16 of the manifold 15. The pressure is transmitted to the liquid in the space 13 and thus such liquid flows reversely through the inlet slots 23 by virtue of the applied pressure as well as by gravity. The liquid in the line 21 and the upper branch 16 of the manifold flows downwardly through the side branches 18 and 19 and, for the most part, none of such liquid enters the space 13. That is, the beveled outer ends 25 of the tubes 24 restrict the flow of liquid through the tubes and into the space 13 since the upper portions of the beveled ends tend to deflect the returning liquid downwardly around the tubes and into the lower portions of the side branches 18 and 19 rather than allowing the liquid to flow inwardly through the tubes and into the space. Accordingly, the surplus liquid in the overflow tank 36, the line 21 and the upper branch 16 is returned to the lower branch 17 by way of the side branches 18 and 19 and does not trickle downwardly within the space and along the inner sides of the panes 11. The space 13 can, therefore, be completely exhausted and the panes can be rendered free of liquid in a relatively short period of time.
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A space defined between two face-to-face panes of a window is adapted to be selectively flooded with a colored liquid in order to reduce the transmission of heat and/or light through the window. The window is characterized by the provision of a supply manifold located between the panes and by the manner of delivering liquid to the manifold and into the space to insure against unequal pressures and thereby eliminate the danger of the panes being broken.
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CROSS REFERENCE TO CO-PENDING APPLICATION
This application claims the benefit of the Sep. 30, 1998 filing date of provisional application Ser. No. 60/102,541 Sep. 30, 1998, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates, in general, to garden or landscaping ornamental structures and, more specifically, to gazing globes.
2. Description of the Art
So-called gazing globes have long been used as decorations in gardens and lawns. Such gazing globes are typically formed of a hollow, glass globe which has a small diameter and short length neck extending from the spherical portion of the globe. Gazing globes are provided in different colors, typically with a reflective, mirror finish.
Such globes typically rest and are supported on columns mounted on the ground or in small brackets attached to a wall or other vertical surface. A recess in the top surface of the columns and brackets receives the neck to stationarily position the gazing globe on the column or bracket.
It is also known to support gazing globes in a cylindrical sleeve or receiver which is mounted at one end of a support formed of one or more interconnected metal rods. In all such applications, the spherical portion of the gazing globe is disposed uppermost above the associated support column or collar so as to clearly view from all sides.
It would be desirable to provide a different type of gazing globe holder which provides a different aesthetic appearance, while still providing the necessary globe support function. It would also be desirable to provide a gazing globe holder which is capable of hanging a gazing globe from a support surface.
SUMMARY OF THE INVENTION
One aspect of the present invention is a holder for receiving a decorative gazing globe having a spherical body and a smaller diameter neck extending from the body. In one aspect, the holder includes a receiver which receives the neck of the gazing globe, and a member encircling at least a portion of the globe when the globe is mounted in the receiver. The receiver is joined to or carried on the member.
The receiver is preferably in the form of a hollow, cylindrical member. The encircling member is a tubular member which encircles, in one aspect, substantially all of the circumference of the gazing globe when the gazing globe is mounted in the receiver. In another aspect of the invention, the encircling member encircles less than the entire circumference of the gazing globe. In a specific aspect, the encircling member encircles substantially one-half of the circumference of the gazing globe.
The receiver member and the encircling member are preferably fixedly welded together. In one aspect, the encircling member has an arcuate shape. In another aspect, the encircling member has a polygonal shape. In yet another aspect, the encircling member is in the form of an annular disk having a central aperture through which the globe is disposed when mounted in the receiver.
In another aspect of the present invention, a hanger is carried on the receiver for hanging the gazing globe and the holder on a support. In one example, the hanger is in the form of a hook carried on the encircling member.
The receiver may also be mounted, in another aspect of the present invention, on an upright pedestal or stake for supporting the holder on a horizontal surface, such as the ground, a floor, etc.
In another aspect, the encircling member is in the form of at least two circumferentially spaced members each projecting from the receiver and engageable with the globe when the globe is mounted in the receiver. Each member has a first end affixed to the receiver and an opposed second end. The second end is freely moveable with respect to the first end and preferably disposed radially inwardly of the first end. Each member preferably extends non-planarly between the first and second ends. More specifically, each member preferably extends arcuately between the first and second ends.
The gazing globe holder of the present invention provides a unique ornamental or decorative appearance for a conventional gazing globe while providing support for the gazing globe on the ground or other support. The present holder uniquely enables a gazing globe to rotate under manual force or in the wind when the gazing globe holder carries a hanger connected to a support surface.
BRIEF DESCRIPTION OF THE DRAWING
The various features, advantages and other uses of the present invention will become more apparent by referring to the following detailed description and drawing in which:
FIG. 1 is an exploded, perspective view of one embodiment of a gazing globe holder according to the present invention
FIG. 2 is a front elevational view of the gazing globe holder shown in FIG. 1;
FIG. 3 is a perspective view of another embodiment of a gazing globe holder according to the present invention;
FIG. 4 is a front elevational view of yet another embodiment of a gazing globe holder according to the present invention;
FIG. 5 is a perspective view of yet another embodiment of a gazing globe holder according to the present invention;
FIG. 6 is a perspective view of yet another embodiment of the gazing globe holder according to the present invention; and
FIG. 7 is a perspective view of the gazing globe holder shown in FIG. 6 with a modified stand.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawing and to FIGS. 1-3, in particular, there is depicted a support or holder which is ideally suited for stationarily supporting a gazing globe 10 .
As is conventional, the gazing globe 10 has a spherical portion 12 with a generally cylindrical, tubular neck 14 projecting therefrom. The gazing globe 10 is typically formed of blown glass and has a hollow interior.
In a first embodiment of a gazing globe holder 16 according to the present invention, shown in FIGS. 1 and 2, the holder 16 includes a receiver 20 which functions to snugly receive the small diameter and short length neck 14 projecting from the spherical portion 12 of the globe 10 . Although the receiver 20 can take many different forms, by way of example only, the receiver 20 is in the form of a hollow, cylindrical body 22 having a first end 24 and an opposed second end 26 . The overall length of the body 22 is approximately the length of the neck 14 of a conventional gazing globe 10 .
However, it will be understood that since gazing globes 10 can be provided in different sizes with different diameter spherical portions 12 and different length and diameter necks 14 , the body 22 of the receiver 20 can also take many different forms or sizes so as to be snugly receive the neck 14 of one of many different sized gazing globes 10 .
Regardless of the size of the neck 14 of the globe 10 , the inner diameter of the body 22 of the receiver 20 will be approximately the same as the outer diameter of the neck 14 so as to securely receive and support the gazing globe 10 without substantial movement of the globe 10 in the body 22 .
According to the present invention, an encircling member 30 is provided which encircles at least a portion of the outer surface of the spherical portion 12 of the gazing globe 10 when the gazing globe 10 is securely mounted within the receiver 20 . The encircling member 30 may be formed of any material, such as metal, plastic, etc., with metal being preferred for long use under harsh exterior conditions.
In one aspect of the invention, the encircling member 30 is in the form of a ring 32 formed of a generally square cross section tube. It will be understood that rectangular, circular or other cross sectional shapes may also be used for the ring 32 . The ring 32 may be formed of a continuous member or as an elongated strip which is bent into a circle prior to having the ends of the strip joined together, such as by welding.
The ring 32 is preferably powder coated in any color. The color may match the color of the gazing globe 10 mounted in the receiver 20 or be of a contrasting color, such as black. In the case of a plastic material used to form the ring 32 , the selected color is blended with the plastic when molded, extruded, etc.
The ring 32 is fixedly secured to the body 22 of the receiver 20 by welding, mechanical fasteners or other suitable means. In one mounting arrangement shown in FIGS. 1 and 2, the second end 26 of the body 22 of the receiver 20 is mounted on the interior surface of the ring 32 and secured thereto by welding, fasteners, etc. Other mounting arrangements will be described hereafter in conjunction with alternate embodiments of the gazing globe holder of the present invention.
In the aspect of the invention shown in FIGS. 1 and 2, the ring member 32 completely encircles the spherical portion 12 of the globe 10 to provide a unique appearance for the gazing globe 10 . In addition, the ring 32 provides an additional feature in that it may be employed to hang the gazing globe 10 from a support, not shown.
As shown in FIGS. 1 and 2, a hanger 36 in the form of a hook, ring or other attachment is carried on the ring 32 , generally spaced 180° or directly opposite from the mounting position of the receiver body 22 . In one embodiment, the hook 36 has a closed end which extends from a stem mounted through an aperture in the ring 32 . One end of the stem 32 is bent or otherwise secured to the ring 32 to mount the hook 36 on the ring 32 . A connector member 38 , such as a string, wire, cable, etc., may be tied or fastened to the hook 36 to support the entire ring member 32 and the gazing globe 10 mounted therein from an external support, such as a tree, trellis, stand, etc.
In addition to encircling the spherical portion 12 of the gazing globe 10 , the ring 32 is also spaced from the exterior surface of the spherical portion 12 of the gazing globe 10 for aesthetic appearance purposes as well as to enable the gazing globe 10 to be inserted into and be removed from the receiver body 22 .
FIG. 3 depicts an alternate embodiment of a gazing globe holder 50 according to the present invention. In this aspect of the invention, the holder 50 includes the same receiver 20 described above and shown in FIGS. 1 and 2. The ring member 32 of the first embodiment is replaced by an arcuate or other shaped strip member 52 having opposed first and second ends 54 and 56 .
The strip member 52 , which is depicted by way of example only as having the same square cross sectional shape and curved radius configuration as the ring member 32 of the first embodiment of the holder 16 , will also be understood to be able to be formed with different cross sections and different shapes. The illustrated 180° arcuate shape for the strip member 52 is by way of example only. Other shapes for the strip member 52 will be described hereafter.
The first end 54 of the strip member 52 is fixedly connected to the receiver body 22 by welding, fasteners, etc. In one mounting arrangement, the first end 54 of the strip member 52 may underlie the entire diameter of the receiver body 22 , as shown in FIGS. 1 and 2.
However, in the aspect of the invention depicted in FIG. 3, the first end 54 of the strip member 52 may be fixedly secured by means of a mechanical fastener, welding, etc., to the side wall of the body 22 of the receiver 20 to integrally join the strip member 52 and the receiver 20 .
An aperture is formed in the second end 56 of the strip member 52 and receives a hook 58 . The hook 58 is connectible to a hanger, such as a string or cable 38 as in the first embodiment, to enable the strip member 52 to be hung from an external support, such as a tree, deck, trellis, stand, bracket or other hanger mounted on a wall of a building, home, etc., or in the ground.
The strip member 52 encircles only a portion of the gazing globe 10 mounted in the receiver 20 and is spaced from the exterior surface of the spherical portion 12 of the gazing globe 10 along the entire length of the strip member 52 .
In both of the first and second embodiments shown in FIGS. 1-3, since the ring member 32 and the strip member 52 are supported by means of a wire or cable 38 from an external support, the entire holder 30 or 50 may be rotatable about the interconnecting cable 38 .
This enables the gazing globe 10 to be rotated either by manual force or by the wind to provide a moving aesthetic appearance which has not been heretofore provided for gazing globes.
Referring now to FIG. 4, there is depicted yet another aspect of a holder 70 for the gazing globe 10 . FIG. 4 depicts two unique aspects of the present gazing globe holder. First, the holder 70 , in the embodiment shown in FIG. 4, has a polygonal shape, such as an exemplary triangular configuration, formed of planar or arcuate legs 72 , 74 , 76 and 78 which may be formed of a single continuous member bent into the desired triangular or other polygonal shape, or provided in a number of separate segments which are joined together, such as by welding, for example, into the polygonal shape.
It will be understood that the specific example of a triangular shape for the holder 70 illustrates the construction of the gazing globe holder of the present invention in any polygonal shape, as well as for other non-polygonal shapes, such as oval. Such polygonal or non-polygonal shapes as well as various design shapes, such as elliptical, oval, serpentine, or other irregular shapes apply equally to a continuous holder, such as holder 30 or to a partial encircling holder, such as holder 50 .
In the embodiment shown in FIG. 4, the legs 76 and 78 of the support 70 are spaced apart and secured by welding or fasteners to opposite portions of the side wall of the body 22 of the receiver 20 .
The embodiment shown in FIG. 4 also depicts the support 70 as being mounted on a stationary post 80 extending from a base 82 which can be mounted on the ground, floor or other generally horizontal surface. The post 80 could also be mounted directly in the ground without the need for the base 82 . A cross bar 84 is mounted interiorly within the body 22 of the receiver 20 generally adjacent to the second end 26 of the body 22 . The post 80 is connected to the cross bar 84 , such as by welding, for example.
It will be understood that the post 80 may take other configurations as conventional in gazing globe supports or to suit the particular aesthetic appearance of an artist.
Another embodiment of a gazing globe holder 90 is depicted in FIG. 5 . In this aspect of the invention, the holder 90 is depicted as being mounted on the post 80 which can be mounted directly in the ground or attached to the base or pedestal 82 as described above and shown in FIG. 4 .
The holder 90 includes a receiver 92 which is in the form of a decorative, cylindrical member, such as a tubular wire coil. A cross bar, not shown, may be mounted interiorly within the receiver 92 for connection to one end of the post 80 . Alternately, the receiver 92 may take on other forms, such as a smooth exterior tubular member of circular, polygonal or other shape. In this embodiment, by example only, the inner diameter of the receiver 92 is greater than the outer diameter of the neck of the gazing globe 10 .
A unique feature of the holder 90 is the formation of the encircling member as a plurality of support fingers, with three support fingers, each denoted by reference number 94 , being shown by example only. Each support finger 94 may be individually attached at one end to the receiver 92 , such as by welding, soldering, etc. Alternately, as shown in FIG. 5, each of the plurality of support fingers 94 is integrally formed or attached to an annular ring 96 which is fixedly mounted on one end of the receiver 92 , by welding, mechanical fasteners or the like. The ring 96 has an inner aperture through which the neck of the gazing globe 10 extends into the receiver 92 in a non-contacting arrangement. It should be noted that at least two and preferably three, four or even more support fingers 94 may be provided on the ring 96 .
The support fingers 94 have a flower petal-like shape with a first end connected to the ring 96 and the outer edges smoothly or sharply tapering to an opposed apex or tip 98 . As shown in FIG. 5, each of the support fingers 94 extends smoothly outward from the first end connected to the ring 96 such that the tip 98 of each support finger 94 extends radially outward beyond the outer diameter of the ring 96 .
The support fingers 94 are preferably formed of a resilient, spring-like material, such as a spring steel. This provides resiliency to each of the support fingers 94 .
In a normal relaxed state, the tips 98 of each of the support fingers 94 define an opening which has a diameter smaller than the outer diameter of the gazing globe 10 . However, the gazing globe 10 may be easily forced past the tips 98 of the support fingers 94 which urges the tips 98 of the support fingers 94 radially outward allowing the circumference of the gazing globe 10 to pass beyond the tips 98 into a cavity between the inner surfaces of the support fingers 94 . Due to the resiliency of the support fingers 94 , the tip ends 98 of the support fingers 94 follow the contour of the gazing globe 10 and move radially inward toward their normal, relaxed position to firmly support the gazing globe 10 in the holder 90 . In this supporting position, it can be seen in FIG. 5 that the tips 98 of the support fingers 94 engage the gazing globe 10 at a position above the equator of the gazing globe 10 .
Referring now to FIGS. 6 and 7, there is depicted yet another aspect of the present gazing globe holder denoted by reference number 100 . In this aspect, the holder 100 includes a receiver 20 as described previously for other embodiments of the present invention. A support 102 in the form of an elongated pole or stake is joined at one end to the receiver 20 , such as by welding, and projects therefrom for emplacement in the ground to support the receiver 20 above the ground. Alternately, the support 102 could be in the form of a stationary post 80 and base 82 as shown in FIG. 4 .
The holder 100 also includes a pair of arms 104 and 106 which are joined at one end to the receiver 20 , such as by welding, fasteners, etc., and project outwardly therefrom, generally in an arcuate shape by example only. The arms 104 and 106 may be formed of any suitable material, such as metal, plastic, etc., with metal being preferred due to the normal outdoor use of the gazing globe holder 100 , and are formed from a thin metal sheet in identical arcuate shapes having the same radius.
The arms 104 and 106 have different arcuate lengths by example only. The outer ends of each of the arms 104 and 106 are fixedly joined to a disk 108 having a central aperture 110 formed therein. The disk 108 is fixedly joined to the ends of each of the arms 104 and 106 by suitable fastening means, such as welding, rivets, or other mechanical fasteners. Due to the different arcuate length of the arms 104 and 106 , the disk 108 is disposed at an angle to horizontal when the holder 100 is mounted in the ground or otherwise supported on an underlying surface.
The central aperture 110 has a diameter to enable the gazing globe 10 to be freely passed therethrough into and out of engagement with the receiver 20 . However, an upper portion of the gazing globe 10 projects through the aperture 110 and the disk 108 when the gazing globe 10 is fully mounted in the receiver 20 , the gazing globe 10 and the disk 108 bear a decorative resemblance to the planet Saturn.
Although the disk 108 is depicted as having a solid form between inner and outer diametrical edges, it will be understood that the disk 108 may actually be in the form of multiple radially spaced disks interconnected to each other by thin ribs or strips.
FIG. 7 depicts a modified support 120 usable with the gazing globe holder 100 described above and shown in FIG. 6 . In this aspect of the invention, the support 120 is shown by example only in the form of a thin rod having multiple bends forming individual angular disposed segments between opposed ends to provide a decorative appearance for the support 120 . It will also be understood that the angular segmented shape of the support 120 may also be used with an underlying base 82 as shown in FIG. 4 .
Although different shaped encircling members as well as underlying support posts have been individually depicted in various aspects or embodiments of the present invention, it will be understood that the present invention contemplates the use of any of the encircling members with any of the support members in any combination to form a pleasing decorative appearance.
In summary, there has been disclosed a holder for a decorative gazing globe having a conventional spherical body and a small diameter neck extending from the body. The holder includes a receiver for receiving the neck of the globe. A member encircles at least a portion of the globe when the globe is mounted in the receiver. The receiver is fixed to the member.
The receiver preferably comprises a hollow cylindrical member having an inner diameter substantially the same as the outer diameter of the neck of a conventional gazing globe for securely receiving and supporting the gazing globe therein without movement.
The support member, which is disclosed in a plurality of embodiments, encircles at least a portion of or an entire circumference of the gazing globe when the gazing globe is mounted in the receiver.
A hanger is mounted on the support member for hanging the support member and the gazing globe mounted in the receiver on the support member to an external support. This enables the gazing globe and the support to rotate under manual force or by the wind to provide a moving, dynamic decoration. The support may also be stationarily mounted on a post mountable in the ground or to a base or pedestal.
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A holder for a circle gazing globe has a receiver for receiving the tubular neck of the gazing globe and a member affixed to the receiver and encircling at least a portion of the gazing globe when the gazing globe is mounted in the receiver. The encircling member takes a variety of forms. In one aspect, a hanger is carried on the encircling member for movably coupling the encircling member and the gazing globe to a fixed support surface. In another aspect, at least two fingers are resiliently coupled to the receiver and have at least one portion engageable with the gazing globe to releasably mount the gazing globe in the receiver.
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CLAIM OF PRIORITY
This application is a Continuation application claiming priority from Divisional application Ser. No. 13/933,388, filed on Jul. 2, 2013, which claims priority from U.S. patent application Ser. No. 12/335,505, filed on Dec. 15, 2008, now issued as U.S. Pat. No. 8,542,902, which claims priority from Provisional Application No. 61/014,427, entitled “D YNAMIC THREE-DIMENSIONAL OBJECT MAPPING FOR USER-DEFINED CONTROL DEVICE ”, filed on Dec. 17, 2007, which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
Description of the Related Art
The video game industry has seen many changes over the years. As computing power has expanded, developers of video games have likewise created game software that takes advantage of these increases in computing power. To this end, video game developers have been coding games that incorporate sophisticated operations and mathematics to produce a very realistic game experience.
Example gaming platforms, may be the Sony Playstation, Sony Playstation2 (PS2), and Sony Playstation3 (PS3), each of which is sold in the form of a game console. As is well known, the game console is designed to connect to a monitor (usually a television) and enable user interaction through handheld controllers. The game console is designed with specialized processing hardware, including a CPU, a graphics synthesizer for processing intensive graphics operations, a vector unit for performing geometry transformations, and other glue hardware, firmware, and software. The game console is further designed with an optical disc tray for receiving game compact discs for local play through the game console. Online gaming is also possible, where a user can interactively play against or with other users over the Internet.
As game complexity continues to intrigue players, game and hardware manufacturers have continued to innovate to enable additional interactivity and computer programs. The traditional way of interacting with a computer program or interactive game has remained relatively unchanged, even thought there have been great advances in processing power. For example, computer systems still require basic input objects, such a computer mouse, a keyboard, and possibly other specially manufactured objects/devices. In a similar manner, computer gaming consoles generally require some type of controller, to enable interaction with a game and/or console. All of these input objects, however, are specially manufactured with a predefined purpose and have special buttons, configurations and functionality that is predefined. Accordingly, traditional interfacing devices must be purchased, and used for the purpose defined by the manufacturer.
It is within this context that embodiments of the invention arise.
SUMMARY
In one embodiment, a computer-implemented method to interactively capture and utilize a three-dimensional object as a controlling device for a computer system is disclosed. One operation of the method is capturing depth data of the three-dimensional object. In another operation, the depth data of the three-dimensional object undergoes processing to create geometric defining parameters for the three-dimensional object. The method can also include defining correlations between particular actions performed with the three-dimensional object and particular actions to be performed by the computer system. The method also includes an operation to save the geometric defining parameters of the three-dimensional object to a recognized object database. In another operation, the correlations between particular actions performed with the three-dimensional object and particular actions to be performed by the computer system in response to recognizing the particular actions are also saved to the recognized object database.
In one embodiment, a system for initiating and using a three-dimensional object as a controlling device when interfacing with a computer system used for interactive video game play, is provided. The system includes an interface for receiving data from a capturing device of a three-dimensional space and storage coupled with computer system. The computer system provides data to a screen and receiving user input to obtain geometric parameters of the three-dimensional object and assign actions to be performed with the three-dimensional object when moved or placed in positions in front of the capture device during interactive video game play. The geometric parameters and the assigned actions being saved to a database on the storage for access during interactive video game play or future interactive sessions.
In another embodiment, a computer-implemented method is disclosed to interactively capture and utilize a three-dimensional object to be a controlling device for a computer system. The method includes an operation for identifying the three-dimensional object. To identify the three-dimensional object, there are operations for capturing depth data of the three-dimensional object and processing captured depth data of the three-dimensional object to create geometric defining parameters for the three-dimensional object. There are also operations for defining correlations between particular actions performed with the three-dimensional object and particular actions to be performed by the computer system. Additionally, there are also operations for saving the geometric defining parameters of the three-dimensional object and correlations between particular actions performed with the three-dimensional object and particular actions to be performed by the computer system to a recognized object database. The method also includes operations for presenting the three-dimensional object to a camera and moving the presented three-dimensional object in front of the camera so as to trigger one or more of the particular actions to be performed by the computer system.
In yet another embodiment, a system for using a three-dimensional object as a controlling device when interfacing with a computer system is disclosed. The system includes a camera interfaced with the computer system that is configured to capture data from a three-dimensional space. Also include in the system is storage that is linked to the computer system. The system can also include a display that can be coupled to the computer system. The display can be configured to display a plurality of graphical display screens to enable set-up of a capture session to obtain geometric parameters of an object. The capture session can also be used to assign actions to be performed with the object when moved in front of the camera during an interactive session. During the interactive session, the geometric parameters and the assigned actions can be saved to a database for access on the storage linked to the computer system. Wherein the assigned actions can be custom defined by a user for particular movements made by the user on the object when holding the object in front of the camera.
Other aspects and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, together with further advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings.
FIG. 1 illustrates a scene 100 with a user 101 manipulating a generic three-dimensional object 102 to interact with a computer system 108 in accordance with one embodiment of the present invention.
FIG. 2A is an exemplary flow chart illustrating various operation that can be performed to allow the computer system 108 to recognize the three-dimensional object 102 , in accordance with one embodiment of the present invention.
FIG. 2B is another exemplary flow chart illustrating a procedure to define and use a three-dimensional object to control a computer system, in accordance with one embodiment of the present invention.
FIGS. 3A-3G illustrate real-world and virtual-world views of various actions performed by users while holding the three-dimensional object 102 , in accordance with various embodiments of the present invention.
FIGS. 4A-4D are examples where various three-dimensional objects can be recognized and used to control a variety of virtual devices based on the configuration of the three-dimensional object and the software being executed by the computer system, in accordance with one embodiment of the present invention.
FIG. 5A and FIG. 5B illustrate movements of a three-dimensional object to perform pre-configured remote control operations, in accordance with one embodiment of the present invention.
FIGS. 6A-6D illustrate capturing a three-dimensional object in various states of deformation, in accordance with one embodiment of the present invention.
FIG. 7 is an exemplary flow chart illustrating operations to map geometric defining parameters of a three-dimensional object, in accordance with one embodiment of the present invention.
FIG. 8 is an exemplary flow chart illustrating one method to configure an object to control virtual elements or the graphical user interface of the computer system, in accordance with one embodiment of the present invention.
FIG. 9 is an exemplary flow chart illustrating operations to utilize an object that has been mapped and configured, in accordance with one embodiment of the present invention.
FIG. 10 schematically illustrates the overall system architecture of the Sony® Playstation 3® entertainment device, a computer system capable of utilizing dynamic three-dimensional object mapping to create user-defined controllers in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION
An invention is disclosed for capturing geometric identifying data for everyday objects and mapping controls to the everyday object to control a computer system. Broadly speaking, the computer system can be any type of system that takes input from a user, whether it be a general purpose computer (e.g., desktop, laptop, portable device, phone, etc.), or a special purpose computer like a game console. A camera capable of measuring depth data can be used to capture geometric data along with actions that can be correlated to controls for a variety of different programs. In one embodiment, a single camera is used, and in other embodiments, multiple cameras can be used to capture images from various locations or view perspectives. The correlated controls can be used to control aspects of a virtual object defined by a program executed by the computer system. The correlations between actions performed with the object and control of the virtual world element can be saved with the captured geometric identifying data of the object. Comparisons of real-time image data captured by the camera can be made to geometric identifying data that has been saved in order to recognize an object that is presented to the camera. Once recognized, the saved correlations can be loaded and the user can manipulate the object to control various aspects of a virtual object. Accordingly, the capturing sequences, methods and systems should be broadly understood to enable the capture of any real-world object, discern its geometric identifying data and enable mapping of various controls to the real-world object. Recognition of the object along with recognition of actions correlated to control of a program can improve user interaction with the computer system.
As used herein, a three-dimensional object should include any physical or material thing that can be touched, held, moved, captured in an image, captured in a video, compared to other things to discern its size or relative size, or identified based on height, width, length, or depth, and the like. A virtual-world object shall be broadly construed to include a computer generated image or images that can be displayed on a screen. The screen can represent the virtual-world object as a two or three dimensional thing and can be animated to move, be placed, be interacted with, or be modified based on user interactivity. The interactivity can include commands provided by the user, using a three-dimensional object or other interface devices such as keyboards, computer mice, touch screens, gaming controllers, motion sensors, or, acoustic or audible sounds and combinations thereof. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order not to unnecessarily obscure the present invention.
FIG. 1 illustrates a scene 100 with a user 101 manipulating a generic three-dimensional object 102 to interact with a computer system 108 in accordance with one embodiment of the present invention. The computer system 108 can output video to a display 106 . In some embodiments the display 106 can be a computer monitor while in other embodiments the display 106 can be a television. While not shown in the scene 100 , the computer system 108 can also output audio. Associated with the computer system 108 is a camera 104 . The camera 104 can capture images and video that can be processed by the computer system 108 . The computer system 108 is shown wirelessly communicating with the camera 104 , but wired connections can also be used.
The camera 104 can be configured to capture depth data, as shown by depth sensing lines 104 a . In some embodiments, the depth data from the camera 104 is transmitted to and processed by the computer system 108 . User input from a controller 110 is also transmitted to the computer system 108 . In various embodiments, the controller 110 transmits user input using wireless protocols such as, but not limited to, Bluetooth or WiFi. Thus, a controller with a wired connection to the computer system 108 can also be used. As will be discussed in greater detail below, a generic three-dimensional object 102 , recognized by the computer system 108 via images captured from the camera 104 can also be used to provide user input to the computer system 108 . The “U” shape of the three-dimensional object 102 should not be construed to be limiting, as the shape was chosen for illustrative clarity and simplicity. The term “three-dimensional object” is intended to describe any physical object capable of being held by a user. As such, the three-dimensional object 102 does not need to be specifically made to interface with the computer system 108 , but may have been a random object found in the home of user 101 .
FIG. 2A is an exemplary flow chart illustrating various operations that can be performed to allow the computer system 108 to recognize the three-dimensional object 102 , in accordance with one embodiment of the present invention. The flow chart is shown with exemplary images displayed to the user from the user's perspective. Operation 200 shows a user manipulating an exemplary graphical user interface to initiate an object capture procedure. A variety of user interfaces including various menus can be used to display and interact with the computer system. In other embodiments, audible commands, gestures, or user input into a controller or previously captured three-dimensional object can be recognized to initiate the capture process shown in operation 200 .
In operation 202 , the user presents the three-dimensional object 102 to the camera. For simplicity, the three-dimensional object 102 is shown as a blocky “U” shaped object. However, the three-dimensional object 102 can be any real-world object that can be manipulated by a person and perceived by the camera. Exemplary three-dimensional objects include items such as coffee mugs, drinking glasses, books, bottles, etc. Note that the previously discussed three-dimensional objects were intended to be exemplary and should not be construed as limiting.
In operation 204 , the user is prompted to rotate the three-dimensional object 102 in front of the camera. As shown in FIG. 2 , the user can be prompted to rotate the three-dimensional object 102 is different directions to allow the camera can capture views necessary to recognize the three-dimensional object 102 . When the user rotates the three-dimensional object 102 , the camera and computer system can capture and process geometric defining parameters associated with the three-dimensional object 102 . In another embodiment, more than a single camera can be used, when placed in various locations to allow image mapping from various angles of the space. In one embodiment, the computer system uses depth data from the camera to measure ratios between various geometric defining parameters on the three-dimensional object. Geometric defining parameters can include, but are not restricted to recognizable features of a three-dimensional object such as points, planes, transitional surfaces, fillets, accent lines, and the like. In such an embodiment, recognizing ratios between geometric defining parameters can allow the computer system to more readily recognize the three-dimensional object if the three-dimensional object is presented to the camera for recognition at a different distance than when it was captured. Operation 206 informs the user when sufficient views of the three-dimensional object 102 have been presented so the computer system can recognize the three-dimensional object 102 based on the defined geometric parameters.
In one embodiment, operation 206 displays a computer-generated model of the three-dimensional object 102 , as captured and modeled by the computer system. In another embodiment, operation 206 displays real-time video of the user holding the three-dimensional object 102 . Operation 206 allows a user to choose between saving the three-dimensional object 206 without configuration, or continue to configure the three-dimensional object 206 .
Continuing with FIG. 2A , Operation 208 is an exemplary view of a screen prompting the user to save the geometric parameters associated with the three-dimensional object 102 . Operation 208 is an exemplary screen where users can choose to save the geometric parameters of the three-dimensional object 102 or to cancel the save procedure. If a user chooses to configure the three-dimensional object, operation 210 allows a user to choose between pre-configured or custom configurations. In either case, configuring the three-dimensional object 102 allows a user to define correlations between particular actions performed with the three-dimensional object 102 and particular actions to be performed by the computer system. In one embodiment, the user can select a pre-configured setting that enables control the computer system user interface with user-performed actions with the three-dimensional object 102 . For example, the pre-configured setting can correlate user-performed actions with the three-dimensional object to navigation and selection of menus within a graphical user interface. In other embodiments, the user can custom configure the three-dimensional object to control aspects of a game being executed by the computer system, as will be discussed below.
FIG. 2B is another exemplary flow chart illustrating a procedure to define and use a three-dimensional object to control a computer system, in accordance with one embodiment of the present invention. The procedure beings with start operation 220 . In operation 222 , a user presents a three-dimensional object and depth data for the three-dimensional object is captured. As previously discussed, a single depth camera or multiple depth cameras can be used to capture depth data for the three-dimensional object. Operation 224 processing the captured depth data for the three-dimensional object to create geometric defining parameters. In one embodiment, the depth data can be used to create wire frame models of the three-dimensional object. In another embodiment, the depth data for the three-dimensional object can be processed to define particular features such as, but not limited to, length, height, and width.
Operation 226 is where a user can define correlation between actions performed with the three-dimensional object and specific actions that are to be performed by the computer. The actions performed with the three-dimensional object can include moving and manipulating the three-dimensional object in a manner than can be detected by the depth camera or other sensors associated with the computer system. The computer system can capture a sequence of images and depth data of a user performing actions with the three-dimensional object and determine a relative position of the three-dimensional object throughout the action. For example, in one embodiment, a user can wave the three-dimensional object in a single plane or wave the three-dimensional object across multiple planes. Similarly, in another embodiment a user can create complex or simple gestures in a real-world three-dimensional space while holding the three-dimensional object.
The user can associate or correlate particular real-world actions or gestures performed with the three-dimensional object to virtual world actions performed by the computer. Thus, when a user performs a particular gesture while holding the three-dimensional object, the computer system can perform a particular task or execute a particular instruction. In some embodiments, real-world actions performed with the three-dimensional object can be associated with particular virtual world motions such as swinging a virtual world golf club or tennis racquet. In other embodiments, real-world actions can be associated with user interface menu navigation.
Operation 228 saves the geometric defining parameters for the three-dimensional object along with the correlations between user actions with the three-dimensional object and virtual world actions performed by the computer to a database. Once saved in the database, the computer system can perform real-time analysis on depth data to recognize geometric defining parameters within the database if a user picks up the corresponding real-world three-dimensional object. Furthermore, the computer system can perform real-time analysis on user actions while holding the recognized three-dimensional object to recognize when a user performs an action correlating to a virtual world action or command for the computer system. The procedure is terminated with end operation 230 .
FIGS. 3A-3G illustrate real-world and virtual-world views of various actions performed by users while holding the three-dimensional object 102 , in accordance with various embodiments of the present invention. In the following examples, the three-dimensional object 102 has been configured to perform a particular function associated with various in-game actions. The following examples are exemplary and not intended to be limiting. Furthermore, it should be noted that a three-dimensional object could be recognized and configured to perform multiple functions for more for multiple different games.
FIG. 3A illustrates a how a three dimensional object 102 can be configured to be used like a baseball bat, in accordance with one embodiment of the present invention. In the real-world view, the user 101 a is shown holding the three-dimensional object 102 and swinging it like a baseball bat. Accordingly, as shown in the in-game view of FIG. 3A , an in game character 101 b , representative of the user 101 a , swings a virtual baseball bat 300 in response to the real-world swing of the three-dimensional object 102 . In one embodiment, the in game character 101 b is a computer-generated likeness of a real-world professional baseball player swinging a virtual baseball bat 300 in response to the user 101 a swinging the three-dimensional object 102 . In another embodiment, the in game character 101 b is a user created avatar integrated into a virtual baseball stadium. In other embodiments, the in game character 101 b can be a combination of computer generated real-world characters and user generated avatars swinging a virtual baseball bat 300 in response to the real-world swing of the three-dimensional object 102 .
FIG. 3B illustrates how different orientations of the three-dimensional object 102 can be configured to different actions of a virtual world light sword 302 a and 302 b , in accordance with one embodiment of the present invention. As illustrated in the real-world view, the user 101 is holding a three-dimensional object 102 a in a first orientation. In one embodiment, this first orientation 102 a is correlated to the virtual world light sword 302 a being turned “off”, as shown in the in-game view of FIG. 3B . Conversely, when the user 101 holds the three-dimensional object 102 b in a second orientation as shown in the real-world view, the virtual world light sword 302 b is shown in an “on” position, in the in-game view. Thus, when the user 101 is holding the three-dimensional as shown in orientation 102 b , the computer will display the in-game character with the light sword extended. Additionally, while held as three-dimensional object 102 b , in an “on” position, the camera and computer system can recognize movement of the three-dimensional object 102 b , and move the in-game light sword 302 b accordingly.
FIGS. 3C-3G illustrate other virtual-world objects that can be controlled using the three-dimensional object 102 , in accordance with other embodiments of the present invention. For example, in FIG. 3C , the three-dimensional object 102 can be used to control the swing of a virtual golf club 304 . Similarly, in FIG. 3D , a virtual tennis racquet 306 can be controlled by a user swinging the three-dimensional object 102 . In FIG. 3E , the three-dimensional object 102 can be used to allow a user to control a virtual bowling ball 308 . In FIG. 3F , the three-dimensional object 102 can be used in a virtual game of pool or billiards to control a virtual cue 310 . Another example of where the orientation of the three-dimensional object may need to be detected is found in FIG. 3G where the three-dimensional object 102 is used to control a virtual steering wheel 312 . Orientation of the three-dimensional object 102 can be used to determine when the virtual steering wheel 312 returns to a centered position resulting in the virtual car traveling in a substantially straight direction. Accordingly, orientation of a three-dimensional object 102 when held by a user can also be applied to control of other virtual world objects or even control of the computer system interface.
FIGS. 4A-4D are examples where various three-dimensional objects can be recognized and used to control a variety of virtual world devices based on the configuration of the three-dimensional object and the software being executed by the computer system, in accordance with one embodiment of the present invention. FIG. 4A shows a scene 400 with three-dimensional objects 102 , 402 , and 404 in front of a user 101 . In this example, three-dimensional objects 102 , 402 , and 404 have previously been captured by the computer system and can be recognized by the computer system when presented to the camera 104 .
In FIG. 4B , the user 100 picks up a three-dimensional object 102 and software being executed on the computer system determines if the three-dimensional object controls a baseball bat 406 , a steering wheel 408 , or a remote control 410 . In one embodiment, if the computer system is executing a baseball simulation program, the three-dimensional object 102 is recognized and rendered as a virtual world baseball bat 406 . Thus, the computer system can attempt to recognize batting swing motions performed by the user 100 with the three-dimensional object 102 . Similarly, if the computer system is executing software to simulate a tennis simulation, the user 100 can control a virtual world tennis racquet 408 based on the real-world movement of the three-dimensional object 102 . In another embodiment, movements and interactions with the three-dimensional object 102 can be configured and recognized functions from a remote control 410 . This can allow a user to perform motions with the three-dimensional object 102 that result in, but not limited to, increasing/decreasing volume, accessing a channel guide, and paging up/down within the channel guide.
In FIG. 4C , the user has picked up three-dimensional object 402 . The three-dimensional object 402 can be used as a remote control 410 . Alternatively, the three-dimensional object 402 can be used to control a virtual tennis racquet 412 , or a virtual bowling ball 414 . Similarly, in FIG. 4D , depending on the type of software being executed on the computer system, three-dimensional object 404 can be recognized as a virtual baseball bat 406 , a virtual golf club 416 or a remote control 410 . In some embodiments, where software executed on the computer system can recognize multiple virtual world counterparts associated with a three-dimensional object, the computer system can prompt the user to select which virtual world counterpart to control. In another embodiments, when a user picks up a three-dimensional object the computer system automatically recognizes the three-dimensional object as a user defined default virtual object. Thus, while executing the appropriate software, a user can configure the three-dimensional objects 102 , 402 and 404 to be associated respectively with the virtual baseball bat, the virtual bowling ball, and the virtual golf club. Thus, when object 102 is picked up, the on screen character is immediately shown holding a baseball bat. Likewise, when the user picks up three-dimensional object 402 , the on screen character is holding and has control of a virtual bowling ball. Similarly, the virtual golf club 416 is controlled by an on screen character when the user picks up three-dimensional object 404 . In another embodiment, the various three-dimensional objects 102 , 402 , 404 could be representative of different weapons that can be accessed by a character in a first-person shooter game. For example, object 102 can correspond to a knife, object 402 can correspond to a pistol, and object 404 can correspond to an assault rifle. Physically switching between real world three-dimensional objects can result in increase user interaction and enjoyment of the first person shooter game.
FIG. 5A and FIG. 5B illustrate movements or deformations of a three-dimensional object 102 to perform pre-configured remote control operations, in accordance with one embodiment of the present invention. After capturing and mapping both un-deformed and deformed geometric defining parameters of the three-dimensional object 102 to basic television functions, the computer system can recognize changes made to the three-dimensional object 102 to control television functions such as changing the channel or changing the volume. In the embodiment shown in FIG. 5A , rotating the three-dimensional object 102 around the Y-axis, can result in changing the channel up or down. Likewise, in the embodiment shown in FIG. 5B , rotating the three-dimensional object about the X-axis can change the volume up or down.
FIGS. 6A-6D illustrate capturing a three-dimensional object in various states of deformation, in accordance with one embodiment of the present invention. For example, the three-dimensional object can be twisted and bent to control various aspects of the software being executed on the computer system. In one embodiment, twisting the three-dimensional object from the original shape shown in FIG. 6A to the deformed shape in FIG. 6B can bring up a television schedule. Similarly, deforming the three-dimensional object as shown in FIG. 6C can be correlated to having the computer system display the next page of the television schedule. Conversely, deforming the three-dimensional object as shown in FIG. 6D can instruct the computer system to display the previous page of the television schedule.
The deformation and corresponding actions used in FIGS. 6A-6D are intended to be exemplary and should not be considered limiting. In other embodiments, three-dimensional mechanical objects can be captured in various states to control various aspects of virtual world machines, virtual world objects, or graphical user interfaces. For example, scissors or a stapler can be captured in both the open and closed position. In one embodiment, a virtual world character can be standing when the stapler or scissors are closed, and crouched when the stapler or scissors are open. Alternatively, opening and closing the stapler or scissors can make an in-game character jump.
FIG. 7 is an exemplary flow chart illustrating operations to map geometric defining parameters of a three-dimensional object for use to control a computer system, in accordance with one embodiment of the present invention. In operation 700 a user initiates the object capture system. In operation 702 , the user presents the object to the depth camera. The object can be any object discernable by the depth camera and the object does not need to be specifically configured to interface with the computer system. In operation 704 , the depth camera and computer system capture depth data from multiple viewing angles to define the object through geometric defining parameters. In some embodiments the geometric defining parameters can be associated with dimensions such as height, depth, and width. In other embodiments, ratios between particular features of the object can be used. In still other embodiments, a combination of dimensions and feature ratios can be used as geometric defining parameters.
In operation 706 , it is determined whether the object can be deformed or manipulated into a different or alternate form. In one embodiment, this operation can be as performed by prompting the user to indicate whether the object is deformable or capable of having an alternate configuration. In yet another embodiment, the computer system can include basic generic object shapes that can be recognized as deformable. For example, the computer system may be able to recognize a generic pair of scissors or a stapler. As such, when a user presents scissors or a stapler, the computer system can automatically prompt the user to capture depth data for the deformed or alternate configuration. Operation 708 captures depth data for the manipulated or deformed object. In some embodiments, Operation 708 may require the user to present the object in the alternate form to the depth camera from multiple viewing angles, similar to the viewing angles in operation 704 . Operation 710 saves all of the depth data associated with the object, including any alternate or manipulated form of the object.
FIG. 8 is an exemplary flow chart illustrating one method to configure an object to control virtual elements or the graphical user interface of the computer system, in accordance with one embodiment of the present invention. Operation 800 recalls saved depth data associated with an object. In some embodiments the recalled depth data is stored on local storage associated with the computer system such as a local hard drive or flash memory. In other embodiments, the depth data can be stored on a local network or in still further embodiments, on remote storage accessible via the internet. Operation 802 associates movement of the object with actions performed by the computer system. In other embodiments, operation 802 can associate actions performed with the object such as waving, shaking, or deforming the object with actions performed by the computer system. Operation 804 saves the associated movements and actions with the depth data associated with the object. The associated movements and actions can be saved to a local storage element such as a hard drive or other non-volatile memory. Alternatively, the associated movements and actions can be uploaded to network storage via the internet and publicly shared among friends.
FIG. 9 is an exemplary flow chart illustrating operations to utilize an object that has been mapped and configured, in accordance with one embodiment of the present invention. In operation 900 a user presents an object to the depth camera for recognition. In operation 902 , the computer system performs real-time analysis of the depth camera data and recognizes the object from stored geometric parameters. Operation 902 also loads any associated movements and actions that are stored with the depth data associated with the object. In operation 904 , the camera and computer system perform real-time image processing of the user manipulating and moving the object and perform the desired actions when actions with the object are recognized. It is possible for a user to have multiple objects mapped and configured and the computer system is capable of recognizing and switching between configurations as different objects are presented to the depth camera. Furthermore, a single object can have multiple configurations and upon recognition, a default configuration is loaded. In one embodiment, the user can selectively load an alternate configuration. In other embodiments, the user is asked to confirm loading the default configuration when multiple configurations for one object are present.
FIG. 10 schematically illustrates the overall system architecture of the Sony® Playstation 3® entertainment device, a computer system capable of utilizing dynamic three-dimensional object mapping to create user-defined controllers in accordance with one embodiment of the present invention. A system unit 1000 is provided, with various peripheral devices connectable to the system unit 1000 . The system unit 1000 comprises: a Cell processor 1028 ; a Rambus® dynamic random access memory (XDRAM) unit 1026 ; a Reality Synthesizer graphics unit 1030 with a dedicated video random access memory (VRAM) unit 1032 ; and an I/O bridge 1034 . The system unit 1000 also comprises a Blu Ray® Disk BD-ROM® optical disk reader 1040 for reading from a disk 1040 a and a removable slot-in hard disk drive (HDD) 1036 , accessible through the I/O bridge 1034 . Optionally the system unit 1000 also comprises a memory card reader 1038 for reading compact flash memory cards, Memory Stick® memory cards and the like, which is similarly accessible through the I/O bridge 1034 .
The I/O bridge 1034 also connects to six Universal Serial Bus (USB) 2 . 0 ports 1024 ; a gigabit Ethernet port 1022 ; an IEEE 802.11b/g wireless network (Wi-Fi) port 1020 ; and a Bluetooth® wireless link port 1018 capable of supporting of up to seven Bluetooth connections.
In operation the I/O bridge 1034 handles all wireless, USB and Ethernet data, including data from one or more game controllers 1002 . For example when a user is playing a game, the I/O bridge 1034 receives data from the game controller 1002 via a Bluetooth link and directs it to the Cell processor 1028 , which updates the current state of the game accordingly.
The wireless, USB and Ethernet ports also provide connectivity for other peripheral devices in addition to game controllers 1002 , such as: a remote control 1004 ; a keyboard 1006 ; a mouse 1008 ; a portable entertainment device 1010 such as a Sony Playstation Portable® entertainment device; a video camera such as an EyeToy® video camera 1012 ; and a microphone headset 1014 . Such peripheral devices may therefore in principle be connected to the system unit 1000 wirelessly; for example the portable entertainment device 1010 may communicate via a Wi-Fi ad-hoc connection, whilst the microphone headset 1014 may communicate via a Bluetooth link.
The provision of these interfaces means that the Playstation 3 device is also potentially compatible with other peripheral devices such as digital video recorders (DVRs), set-top boxes, digital cameras, portable media players, Voice over IP telephones, mobile telephones, printers and scanners.
In addition, a legacy memory card reader 1016 may be connected to the system unit via a USB port 1024 , enabling the reading of memory cards 1048 of the kind used by the Playstation® or Playstation 2® devices.
In the present embodiment, the game controller 1002 is operable to communicate wirelessly with the system unit 1000 via the Bluetooth link. However, the game controller 1002 can instead be connected to a USB port, thereby also providing power by which to charge the battery of the game controller 1002 . In addition to one or more analog joysticks and conventional control buttons, the game controller is sensitive to motion in six degrees of freedom, corresponding to translation and rotation in each axis. Consequently gestures and movements by the user of the game controller may be translated as inputs to a game in addition to or instead of conventional button or joystick commands. Optionally, other wirelessly enabled peripheral devices such as the Playstation Portable device may be used as a controller. In the case of the Playstation Portable device, additional game or control information (for example, control instructions or number of lives) may be provided on the screen of the device. Other alternative or supplementary control devices may also be used, such as a dance mat (not shown), a light gun (not shown), a steering wheel and pedals (not shown) or bespoke controllers, such as a single or several large buttons for a rapid-response quiz game (also not shown).
The remote control 1004 is also operable to communicate wirelessly with the system unit 1000 via a Bluetooth link. The remote control 1004 comprises controls suitable for the operation of the Blu Ray Disk BD-ROM reader 1040 and for the navigation of disk content.
The Blu Ray Disk BD-ROM reader 1040 is operable to read CD-ROMs compatible with the Playstation and PlayStation 2 devices, in addition to conventional pre-recorded and recordable CDs, and so-called Super Audio CDs. The reader 1040 is also operable to read DVD-ROMs compatible with the Playstation 2 and PlayStation 3 devices, in addition to conventional pre-recorded and recordable DVDs. The reader 1040 is further operable to read BD-ROMs compatible with the Playstation 3 device, as well as conventional pre-recorded and recordable Blu-Ray Disks.
The system unit 1000 is operable to supply audio and video, either generated or decoded by the Playstation 3 device via the Reality Synthesizer graphics unit 1030 , through audio and video connectors to a display and sound output device 1042 such as a monitor or television set having a display 1044 and one or more loudspeakers 1046 . The audio connectors 1050 may include conventional analogue and digital outputs whilst the video connectors 1052 may variously include component video, S-video, composite video and one or more High Definition Multimedia Interface (HDMI) outputs. Consequently, video output may be in formats such as PAL or NTSC, or in 720p, 1080i or 1080p high definition.
Audio processing (generation, decoding and so on) is performed by the Cell processor 1028 . The Playstation 3 device's operating system supports Dolby® 5.1 surround sound, Dolby® Theatre Surround (DTS), and the decoding of 7.1 surround sound from Blu-Ray® disks.
In the present embodiment, the video camera 1012 comprises a single charge coupled device (CCD), an LED indicator, and hardware-based real-time data compression and encoding apparatus so that compressed video data may be transmitted in an appropriate format such as an intra-image based MPEG (motion picture expert group) standard for decoding by the system unit 1000 . The camera LED indicator is arranged to illuminate in response to appropriate control data from the system unit 1000 , for example to signify adverse lighting conditions. Embodiments of the video camera 1012 may variously connect to the system unit 1000 via a USB, Bluetooth or Wi-Fi communication port. Embodiments of the video camera may include one or more associated microphones that are also capable of transmitting audio data. In embodiments of the video camera, the CCD may have a resolution suitable for high-definition video capture. In use, images captured by the video camera may for example be incorporated within a game or interpreted as game control inputs.
In general, in order for successful data communication to occur with a peripheral device such as a video camera or remote control via one of the communication ports of the system unit 1000 , an appropriate piece of software such as a device driver should be provided. Device driver technology is well-known and will not be described in detail here, except to say that the skilled man will be aware that a device driver or similar software interface may be required in the present embodiment described.
Embodiments may include capturing depth data to better identify the real-world user and to direct activity of an avatar or scene. The object can be something the person is holding or can also be the person's hand. In this description, the terms “depth camera” and “three-dimensional camera” refer to any camera that is capable of obtaining distance or depth information as well as two-dimensional pixel information. For example, a depth camera can utilize controlled infrared lighting to obtain distance information. Another exemplary depth camera can be a stereo camera pair, which triangulates distance information using two standard cameras. Similarly, the term “depth sensing device” refers to any type of device that is capable of obtaining distance information as well as two-dimensional pixel information.
Recent advances in three-dimensional imagery have opened the door for increased possibilities in real-time interactive computer animation. In particular, new “depth cameras” provide the ability to capture and map the third-dimension in addition to normal two-dimensional video imagery. With the new depth data, embodiments of the present invention allow the placement of computer-generated objects in various positions within a video scene in real-time, including behind other objects.
Moreover, embodiments of the present invention provide real-time interactive gaming experiences for users. For example, users can interact with various computer-generated objects in real-time. Furthermore, video scenes can be altered in real-time to enhance the user's game experience. For example, computer generated costumes can be inserted over the user's clothing, and computer generated light sources can be utilized to project virtual shadows within a video scene. Hence, using the embodiments of the present invention and a depth camera, users can experience an interactive game environment within their own living room. Similar to normal cameras, a depth camera captures two-dimensional data for a plurality of pixels that comprise the video image. These values are color values for the pixels, generally red, green, and blue (RGB) values for each pixel. In this manner, objects captured by the camera appear as two-dimension objects on a monitor.
Embodiments of the present invention also contemplate distributed image processing configurations. For example, the invention is not limited to the captured image and display image processing taking place in one or even two locations, such as in the CPU or in the CPU and one other element. For example, the input image processing can just as readily take place in an associated CPU, processor or device that can perform processing; essentially all of image processing can be distributed throughout the interconnected system. Thus, the present invention is not limited to any specific image processing hardware circuitry and/or software. The embodiments described herein are also not limited to any specific combination of general hardware circuitry and/or software, nor to any particular source for the instructions executed by processing components.
With the above embodiments in mind, it should be understood that the invention may employ various computer-implemented operations involving data stored in computer systems. These operations include operations requiring physical manipulation of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. Further, the manipulations performed are often referred to in terms, such as producing, identifying, determining, or comparing.
The above-described invention may be practiced with other computer system configurations including hand-held devices, microprocessor systems, microprocessor-based or programmable consumer electronics, minicomputers, mainframe computers and the like. The invention may also be practiced in distributing computing environments where tasks are performed by remote processing devices that are linked through a communications network.
The invention can also be embodied as computer readable code on a computer readable medium. The computer readable medium is any data storage device that can store data that can be thereafter read by a computer system, including an electromagnetic wave carrier. Examples of the computer readable medium include hard drives, network attached storage (NAS), read-only memory, random-access memory, CD-ROMs, CD-Rs, CD-RWs, magnetic tapes, and other optical and non-optical data storage devices. The computer readable medium can also be distributed over a network coupled computer system so that the computer readable code is stored and executed in a distributed fashion.
Although the foregoing invention has been described in some detail for purposes of clarity of understanding, it will be apparent that certain changes and modifications may be practiced within the scope of the appended claims. Accordingly, the present embodiments are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope and equivalents of the appended claims.
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A system for initiating and using a three-dimensional object as a controlling device when interfacing with a computer system used for interactive video game play is provided. One example system includes an interface for receiving data from a capturing device of a three-dimensional space and storage coupled with computer system. The computer system provides data to a screen and receiving user input to obtain geometric parameters of the three-dimensional object and assign actions to be performed with the three-dimensional object when moved or placed in positions in front of the capture device during interactive video game play. The geometric parameters and the assigned actions being saved to a database on the storage for access during interactive video game play or future interactive sessions.
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FIELD OF THE INVENTION
The present application relates generally to an improved method of synthesizing naphthalocyanines. It has been developed primarily to reduce the cost of existing naphthalocyanine syntheses and to facilitate large-scale preparations of these compounds.
CROSS REFERENCE TO OTHER RELATED APPLICATIONS
The following applications have been filed by the Applicant simultaneously with this application:
IRB023US IRB024US
The disclosures of these co-pending applications are incorporated herein by reference. The above applications have been identified by their filing docket number, which will be substituted with the corresponding application number, once assigned.
The following patents or patent applications filed by the applicant or assignee of the present invention are hereby incorporated by cross-reference.
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10/291,524
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6,850,931
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10/685,523
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11/739,032
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6,957,921
6,457,883
10/743,671
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10/983,029
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6,428,155
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09/722,141
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09/693,514
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6,980,704
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6,797,895
7,015,901
10/782,894
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60,911,260
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BACKGROUND OF THE INVENTION
We have described previously the use of naphthalocyanines as IR-absorbing dyes. Naphthalocyanines, and particularly gallium naphthalocyanines, have low absorption in the visible range and intense absorption in the near-IR region (750-810 nm). Accordingly, naphthalocyanines are attractive compounds for use in invisible inks. The Applicant's U.S. Pat. Nos. 7,148,345 and 7,122,076 (the contents of which are herein incorporated by reference) describe in detail the use of naphthalocyanine dyes in the formulation of inks suitable for printing invisible (or barely visible) coded data onto a substrate. Detection of the coded data by an optical sensing device can be used to invoke a response in a remote computer system. Hence, the substrate is interactive by virtue of the coded data printed hereon.
The Applicant's netpage and Hyperlabel® systems, which makes use of interactive substrates printed with coded data, are described extensively in the cross-referenced patents and patent applications above (the contents of which are herein incorporated by reference).
In the anticipation of widespread adoption of netpage and Hyperlabel® technologies, there exists a considerable need to develop efficient syntheses of dyes suitable for use in inks for printing coded data. As foreshadowed above, naphthalocyanines and especially gallium naphthalocyanines are excellent candidates for such dyes and, as a consequence, there is a growing need to synthesize naphthalocyanines efficiently and in high yield on a large scale.
Naphthalocyanines are challenging compounds to synthesize on a large scale. In U.S. Pat. Nos. 7,148,345 and 7,122,076, we described an efficient route to naphthalocyanines via macrocyclization of naphthalene-2,3-dicarbonitrile. Scheme 1 shows a route to the sulfonated gallium naphthalocyanine 1 from naphthalene-2,3-dicarbonitrile 2, as described in U.S. Pat. No. 7,148,345.
However, a problem with this route to naphthalocyanines is that the starting material 2 is expensive. Furthermore, naphthalene-2,3-dicarbonitrile 2 is prepared from two expensive building blocks: tetrabromo-o-xylene 3 and fumaronitrile 4, neither of which can be readily prepared in multi-kilogram quantities.
Accordingly, if naphthalocyanines are to be used in large-scale applications, there is a need to improve on existing syntheses.
SUMMARY OF THE INVENTION
In a first aspect, there is provided a method of preparing a naphthalocyanine comprising the steps of:
(i) providing a tetrahydronaphthalic anhydride; (ii) converting said tetrahydronaphthalic anhydride to a benzisoindolenine; and (iii) macrocyclizing said benzisoindolenine to form a naphthalocyanine.
Optionally, the tetrahydronaphthalic anhydride is of formula (I):
wherein:
R 1 , R 2 , R 3 and R 4 are each independently selected from hydrogen, hydroxyl, C 1-20 alkyl, C 1-20 alkoxy, amino, C 1-20 alkylamino, di(C 1-20 alkyl)amino, halogen, cyano, thiol, C 1-20 alkylthio, nitro, C 1-20 alkylcarboxy, C 1-20 alkylcarbonyl, C 1-20 alkoxycarbonyl, C 1-20 alkylcarbonyloxy, C 1-20 alkylcarbonylamino, C 5-20 aryl, C 5-20 arylalkyl, C 5-20 arylalkoxy, C 5-20 heteroaryl, C 5-20 heteroaryloxy, C 5-20 heteroarylalkoxy or C 5-20 heteroarylalkyl.
Optionally, R 1 , R 2 , R 3 and R 4 are all hydrogen.
Optionally, step (ii) comprises a one-pot conversion from the tetrahydronaphthalic anhydride to a benzisoindolenine salt. This one-pot conversion facilitates synthesis of naphthalocyanines via the route described above and greatly improves yields and scalability.
Optionally, the benzisoindolenine salt is a nitrate salt although other salts (e.g. benzene sulfonate salt) are of course within the scope of the present invention.
Optionally, the one-pot conversion is effected by heating with a reagent mixture comprising ammonium nitrate.
Optionally, the reagent mixture comprises at least 2 equivalents of ammonium nitrate with respect to the tetrahydronaphthalic anhydride.
Optionally, the reagent mixture comprises urea.
Optionally, the reagent mixture comprises at least one further ammonium salt.
Optionally, the further ammonium salt is selected from: ammonium sulfate and ammonium benzenesulfonate
Optionally, the reagent mixture comprises a catalytic amount of ammonium molybdate.
Optionally, the heating is within a temperature range of 150 to 200° C.
The reaction may be performed in the presence of or in the absence of a solvent. Optionally, heating is in the presence of an aromatic solvent. Examples of suitable solvents are nitrobenzene, biphenyl, diphenyl ether, mesitylene, anisole, phenetole, dichlorobenzene, trichlorobenzene and mixtures thereof.
Optionally, the benzisoindolenine is liberated from the benzisoindolenine salt using a base. Sodium methoxide is an example of a suitable base although the skilled person ill be readily aware of other suitable bases.
Optionally, the benzisoindolenine is of formula (II):
wherein:
R 1 , R 2 , R 3 and R 4 are each independently selected from hydrogen, hydroxyl, C 1-20 alkyl, C 1-20 alkoxy, amino, C 1-20 alkylamino, di(C 1-20 alkyl)amino, halogen, cyano, thiol, C 1-20 alkylthio, nitro, C 1-20 alkylcarboxy, C 1-20 alkylcarbonyl, C 1-20 alkoxycarbonyl, C 1-20 alkylcarbonyloxy, C 1-20 alkylcarbonylamino, C 5-20 aryl, C 5-20 arylalkyl, C 5-20 aryloxy, C 5-20 arylalkoxy, C 5-20 heteroaryl, C 5-20 heteroaryloxy, C 5-20 heteroarylalkoxy or C 5-20 heteroarylalkyl.
Optionally, the naphthalocyanine is of formula (III):
wherein:
R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11 , R 12 , R 13 , R 14 , R 15 and R 16 are each independently selected from hydrogen, hydroxyl, C 1-20 alkyl, C 1-20 alkoxy, amino, C 1-20 alkylamino, di(C 1-20 alkyl)amino, halogen, cyano, thiol, C 1-20 alkylthio, nitro, C 1-20 alkylcarboxy, C 1-20 alkylcarbonyl, C 1-20 alkoxycarbonyl, C 1-20 alkylcarbonyloxy, C 1-20 alkylcarbonylamino, C 5-20 aryl, C 5-20 arylalkyl, C 5-20 aryloxy, C 5-20 arylalkoxy, C 5-20 heteroaryl, C 5-20 heteroaryloxy, C 5-20 heteroarylalkoxy or C 5-20 heteroarylalkyl;
M is absent or selected from Si(A 1 )(A 2 ), Ge(A 1 )(A 2 ), Ga(A 1 ), Mg, Al(A 1 ), TiO, Ti(A 1 )(A 2 ), ZrO, Zr(A 1 )(A 2 ), VO, V(A 1 )(A 2 ), Mn, Mn(A 1 ), Fe, Fe(A 1 ), Co, Ni, Cu, Zn, Sn, Sn(A 1 )(A 2 ), Pb, Pb(A 1 )(A 2 ), Pd and Pt;
A 1 and A 2 are axial ligands, which may be the same or different, and are selected from —OH, halogen or —OR q ;
R q is selected from C 1-16 alkyl, C 5-20 aryl, C 5-20 arylalkyl, C 1-20 alkylcarbonyl, C 1-20 alkoxy carbonyl or Si(R x )(R y )(R z ); and
R x , R y and R z may be the same or different and are selected from C 1-20 alkyl, C 5-20 aryl, C 5-20 arylalkyl, C 1-20 alkoxy, C 5-20 aryloxy or C 5-20 arylalkoxy;
Optionally, R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11 , R 12 , R 13 , R 14 , R 15 and R 16 are all hydrogen.
Optionally, M is Ga(A 1 ), such as Ga(OCH 2 CH 2 OCH 2 CH 2 OCH 2 CH 2 OMe); that is where R q is CH 2 CH 2 OCH 2 CH 2 OCH 2 CH 2 OMe. For the avoidance of doubt, ethers such as CH 2 CH 2 OCH 2 CH 2 OCH 2 CH 2 OMe fall within definition of alkyl groups as specified hereinbelow. Gallium compounds are preferred since they have excellent lightfastness, strong, absorption in the hear-IR region, and are virtually invisible to the human eye when printed on a page.
Optionally, step (iii) comprises heating the benzisoindolenine in the presence of a metal compound, such as AlCl 3 or corresponding metal alkoxide. The reaction may be performed in the absence of or in the presence of a suitable solvent, such as toluene, nitrobenzene etc. When a metal alkoxide is used, the reaction may be catalyzed with a suitable base, such as sodium methoxide. Alcohols, such as triethylene glycol monomethyl ether or glycol may also be present to assist with naphthalocyanine formation. These alcohols may end up as the axial ligand of the naphthalocyanine or they may be cleaved from the metal under the reaction conditions. The skilled person will readily be able to optimize the conditions for naphthalocyanine formation from the benzisoindolenine.
Optionally, the method further comprises the step of suffocating said naphthalocyanine. Sulfonate groups are useful for solubilizing the naphthalocyanines in ink formulations, as described in our earlier U.S. Pat. Nos. 7,148,345 and 7,122,076.
In a second aspect, there is provided a method of effecting a one-pot conversion of a tetrahydronaphthalic anhydride to a benzisoindolenine salt, said method comprising heating said tetrahydronaphthalic anhydride with a reagent mixture comprising ammonium nitrate.
This transformation advantageously obviates a separate dehydrogenation step to form the naphthalene ring system. The ammonium nitrate performs the dual functions of oxidation (dehydrogenation) and isoindolenine formation.
The isoindolenine salts generated according to the second aspect may be used in the syntheses of naphthalocyanines. Hence, this key reaction provides a significant improvement in routes to naphthalocyanines.
In general, optional features of this second aspect mirror the optional features described above in respect of the first aspect.
In a third aspect, there is provided a method of preparing a sultine of formula (V) from a dihalogeno compound of formula (IV)
the method comprising reacting the dihalogeno compound (IV) with a hydroxymethanesulfinate salt in a DMSO solvent so as to prepare the sultine (V);
wherein:
R 1 , R 2 , R 3 and R 4 are each independently selected from hydrogen, hydroxyl, C 1-20 alkyl, C 1-20 alkoxy, amino, C 1-20 alkylamino, di(C 1-20 alkyl)amino, halogen, cyano, thiol, C 1-20 alkylthio, nitro, C 1-20 alkylcarboxy, C 1-20 alkylcarbonyl, C 1-20 alkoxycarbonyl, C 1-20 alkylcarbonyloxy, C 1-20 alkylcarbonylamino, C 5-20 aryl, C 5-20 arylalkyl, C 5-20 aryloxy, C 5-20 arylalkoxy, C 5-20 heteroaryl, C 5-20 heteroaryloxy, C 5-20 heteroarylalkoxy or C 5-20 heteroarylalkyl; and
X is Cl, Br or I.
The method according to the third aspect surprisingly minimizes polymeric by-products and improves yields, when compared to literature methods for this reaction employing DMF as the solvent. These advantages are amplified when the reaction is performed on a large scale (e.g. at least 0.3 molar, at least 0.4 molar or at least 0.5 molar scale).
Optionally, NaI is used to catalyze the coupling reactions when X is Cl or Br.
Optionally, a metal carbonate base (e.g. Na 2 CO 3 , K 2 CO 3 , Cs 2 CO 3 etc) is present.
Optionally, the hydroxymethanesulfinate salt is sodium hydroxymethanesulfinate (Rongalite™).
Optionally, R 1 , R 2 , R 3 and R 4 are hydrogen.
Optionally, the method comprises the further step of reacting the sultine (V) with an olefin at elevated temperature (e.g. about 80° C.) to generate a Diels-Alder adduct.
Optionally, the olefin is maleic anhydride and said Diels-Alder adduct is a tetrahydronaphthalic anhydride.
Optionally, the tetrahydronaphthalic anhydride is used as a precursor for naphthalocyanine synthesis, as described herein.
Optionally, the naphthalocyanine synthesis proceeds via conversion of tetrahydronaphthalic anhydride to benzisoindolenine, as described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in detail with reference to the following drawings, in which:
FIG. 1 is a 1 H NMR spectrum of the crude sultine 10 in d 6 -DMSO;
FIG. 2 is a 1 H NMR spectrum of the anhydride 8 in d 6 -DMSO;
FIG. 3 is a 1 H NMR spectrum of the crude benzisoindolenine salt 12 in d 6 -DMSO;
FIG. 4 is an expansion of the aromatic region of the 1 H NMR spectrum shown in FIG. 3 ;
FIG. 5 is a 1 H NMR spectrum of the benzisoindolenine 7 in d 6 -DMSO.
FIG. 6 is an expansion of the aromatic region of the 1 H NMR spectrum shown in FIG. 5 ; and
FIG. 7 is a UV-VIS spectrum of naphthalocyanatogallium methoxytriethyleneoxide in NMP.
DETAILED DESCRIPTION
As an alternative to dicarbonitriles, the general class of phthalocyanines is known to be prepared from isoindolenines. In U.S. Pat. No. 7,148,345, we proposed the benzisoindolenine 5 as a possible precursor to naphthalocyanines.
However, efficient syntheses of the benzisoindolenine 5 were unknown in the literature, and it was hitherto understood that dicarbonitriles, such as naphthalene-2,3-dicarbonitrile 2, were the only viable route to naphthalocyanines.
Nevertheless, with the potentially prohibitive cost of naphthalene-2,3-dicarbonitrile 2, the present inventors sought to explore a new route to the benzisoindolenine 5, as outlined in Scheme 2.
Tetrahydronaphthalic anhydride 6 was an attractive starting point, because this is a known Diels-Alder adduct which may be synthesized via the route shown in Scheme 3.
Referring to Scheme 2, it was hoped that the conversion of naphthalic anhydride 7 to the benzisoindolenine 5 would proceed analogously to the known conversion of phthalic anhydride to the isoindolenine 8, as described in WO98/31667.
However, a number of problems remained with the route outlined in Scheme 2. Firstly, the dehydrogenation of tetrahydronaphthalic anhydride 6 typically requires high temperature catalysis. Under these conditions, tetrahydronaphthalic anhydride 6 readily sublimes resulting in very poor yields. Secondly, the preparation of tetrahydronaphthalic anhydride 6 on a large scale was not known. Whilst a number of small-scale routes to this compound were known in the literature, these generally suffered either from poor yields or scalability problems.
The use of sultines as diene precursors is well known and 1,4-dihydro-2,3-benzoxathiin-3-oxide 10 has been used in a synthesis of 6 on a small scale (Hoey, M. D.; Dittmer, D. A. J. Org. Chem. 1991, 56, 1947-1948). As shown in Scheme 4, this route commences with the relatively inexpensive dichloro-o-xylene 11, but the feasibility of scaling up this reaction sequence is limited by the formation of undesirable polymeric by-products in the sultine-forming step. The formation of these by-products makes reproducible production of 6 in high purity and high yield difficult.
Nevertheless, the route outlined in Scheme 4 is potentially attractive from a cost standpoint, since dichloro-o-xylene 11 and maleic anhydride are both inexpensive materials.
Whilst the reaction sequence shown in Schemes 4 and 2 present significant synthetic challenges, the present inventors have surprisingly found that, using modified reaction conditions, the benzisoindolenine 5 can be generated on a large scale and in high yield. Hence, the present invention enables the production of naphthalocyanines from inexpensive starting materials, and represents a significant cost improvement over known syntheses, which start from naphthalene-2,3-dicarbonitrile 2.
Referring to Scheme 5, there is shown a route to the benzisoindolenine 5, which incorporates two synthetic improvements in accordance with the present invention.
Unexpectedly, it was found that by using DMSO as the reaction solvent in the conversion of 11 into 10, the reaction rate and selectivity for the formation of sultine 10 increases significantly. This is in contrast to known conditions (Hoey, M. D.; Dittmer, D. A. J. Org. Chem. 1991, 56, 1947-1948) employing DMF as the solvent, where the formation of undesirable polymeric side-products is a major problem, especially on a large scale. Accordingly, the present invention provides a significant improvement in the synthesis of tetrahydronaphthalic anhydride 6.
The present invention also provides a significant improvement in the conversion of tetrahydronaphthalic anhydride 6 to the benzisoindolenine 5. Surprisingly, it was found that the ammonium nitrate used for this step readily effects oxidation of the saturated ring system as well as converting the anhydride to the isoindolenine. Conversion to a tetrahydroisoindolenine was expected to proceed smoothly, in accordance with the isoindolenine similar systems described in WO98/31667. However, concomitant dehydrogenation under these reaction conditions advantageously provided a direct one-pot route from the tetrahydronaphthalic anhydride 6 to the benzisoindolenine salt 12. This avoids problematic and low-yielding dehydrogenation of the tetrahydronaphthalic anhydride 6 in a separate step. Subsequent treatment of the salt 12 with a suitable base, such as sodium methoxide, liberates the benzisoindolenine 5. As a result of these improvements, the entire reaction sequence from 11 to 5 is very conveniently carried out, and employs inexpensive starting materials and reagents (Scheme 5).
The benzisoindolenine 5 may be converted into any required naphthalocyanine using known conditions. For example, the preparation of a gallium naphthalocyanine from benzisoindolenine 5 is exemplified herein. Subsequent manipulation of the naphthalocyanine macrocycle may also be performed in accordance with known protocols. For example, sulfonation may be performed using oleum, as described in U.S. Pat. Nos. 7,148,345 and 7,122,076.
Hitherto, the use of tetrahydronaphthalic anhydride 6 as a building block for naphthalocyanine synthesis had not previously been reported. However, it has now been shown that tetrahydronaphthalic anhydride 6 is a viable intermediate in the synthesis of these important compounds. Moreover, it is understood by the present inventors that the route shown in Scheme 5 represents the most cost-effective synthesis of benzisoindolenines 5.
The term “aryl” is used herein to refer to an aromatic group, such as phenyl, naphthyl or triptycenyl. C 6-12 aryl, for example, refers to an aromatic group having from 6 to 12 carbon atoms, excluding any substituents. The term “arylene”, of course, refers to divalent groups corresponding to the monovalent aryl groups described above. Any reference to aryl implicitly includes arylene, where appropriate.
The term “heteroaryl” refers to an aryl group, where 1, 2, 3 or 4 carbon atoms are replaced by a heteroatom selected from N, O or S. Examples of heteroaryl (or heteroaromatic) groups include pyridyl, benzimidazolyl, indazolyl, quinolinyl, isoquinolinyl, indolinyl, isoindolinyl, indolyl, isoindolyl, furanyl, thiophenyl, pyrrolyl, thiazolyl, imidazolyl, oxazolyl, isoxazolyl, pyrazolyl, isoxazolonyl, piperazinyl, primidinyl, piperidinyl, morpholinyl, pyrrolidinyl, isothiazolyl, triazolyl, oxadiazolyl, thiadiazolyl, pyridyl, pyrimidinyl, benzopyrimidinyl, benzotriazole, quinoxalinyl, pyridazyl, coumarinyl etc. The term “heteroarylene”, of course, refers to divalent groups corresponding to the monovalent heteroaryl groups described above. Any reference to heteroaryl implicitly includes heteroarylene, where appropriate.
Unless specifically stated otherwise, aryl and heteroaryl groups may be optionally substituted with 1, 2, 3, 4 or 5 of the substituents described below.
Where reference is made to optionally substituted groups (e.g. in connection with aryl groups or heteroaryl groups), the optional substituent(s) are independently selected from C 1-8 alkyl, C 1-8 alkoxy, —(OCH 2 CH 2 ) d OR d (wherein d is an integer from 2 to 5000 and R d is H, C 1-8 alkyl or C(O)C 1-8 alkyl), cyano, halogen, amino, hydroxyl, thiol, —SR v , —NR N R v , nitro, phenyl, phenoxy, —CO 2 R v , —C(O)R v , —OCOR v , —SO 2 R v , —OSO 2 R v , —SO 2 OR v , —NHC(O)R v , —CONR N R v , —CONR N R v , —SO 2 NR N R v , wherein R N and R v are independently selected from hydrogen, C 1-20 alkyl, phenyl or phenyl-C 1-8 alkyl (e.g. benzyl). Where, for example, a group contains more than one substituent, different substituents can have different R N or R v groups.
The term “alkyl” is used herein to refer to alkyl groups in both straight and branched forms. Unless stated otherwise, the alkyl group may be interrupted with 1, 2, 3 or 4 heteroatoms selected from O, NH or S. Unless stated otherwise, the alkyl group may also be interrupted with 1, 2 or 3 double and/or triple bonds. However, the term “alkyl” usually refers to alkyl groups having double or triple bond interruptions. Where “alkenyl” groups are specifically mentioned, this is not intended to be construed as a limitation on the definition of “alkyl” above.
Where reference is made to, for example, C 1-20 alkyl, it is meant the alkyl group may contain any number of carbon atoms between 1 and 20. Unless specifically stated otherwise, any reference to “alkyl” means C 1-20 alkyl, preferably C 1-12 alkyl or C 1-6 alkyl.
The term “alkyl” also includes cycloalkyl groups. As used herein, the term “cycloalkyl” includes cycloalkyl, polycycloalkyl, and cycloalkenyl groups, as well as combinations of these with linear alkyl groups, such as cycloalkylalkyl groups. The cycloalkyl group may be interrupted with 1, 2 or 3 heteroatoms selected from O, N or S. However, the term “cycloalkyl” usually refers to cycloalkyl groups having no heteroatom interruptions. Examples of cycloalkyl groups include cyclopentyl, cyclohexyl, cyclohexenyl, cyclohexylmethyl and adamantyl groups.
The term “arylalkyl” refers to groups such as benzyl, phenylethyl and naphthylmethyl.
The term “halogen” or “halo” is used herein to refer to any of fluorine, chlorine, bromine and iodine. Usually, however halogen refers to chlorine or fluorine substituents.
Where reference is made herein to “a naphthalocyanine”, “a benzisoindolenine”, “a tetrahydronaphthalic anhydride” etc, this is understood to be a reference to the general class of compounds embodied by these generic names, and is not intended to refer to any one specific compound. References to specific compounds are accompanied with a reference numeral.
Chiral compounds described herein have not been given stereo-descriptors. However, when compounds may exist in stereoisomeric forms, then all possible stereoisomers and mixtures thereof are included (e.g. enantiomers, diastereomers and all combinations including racemic mixtures etc.).
Likewise, when compounds may exist in a number of regioisomeric or tautomeric forms, then all possible regioisomers, tautomers and mixtures thereof are included.
For the avoidance of doubt, the term “a” (or “an”), in phrases such as “comprising a”, means “at least one” and not “one and only one”. Where the term “at least one” is specifically used, this should not be construed as having a limitation on the definition of “a”.
Throughout the specification, the term “comprising”, or variations such as “comprise” or “comprises”, should be construed as including a stated element, integer or step, but not excluding any other element, integer or step.
The invention will now be described with reference to the following drawings and examples. However, it will of course be appreciated that this invention may be embodied in may other forms without departing from the scope of the invention, as defined in the accompanying claims.
Example 1
1,4-dihydro-2,3-benzoxathiin-3-oxide 10
Sodium hydroxymethanesulfinate (Rongalite™) (180 g; 1.17 mol) was suspended in DMSO (400 mL) and left to stir for 10 min. before dicholoro-o-xylene (102.5 g; 0.59 mol), potassium carbonate (121.4 g; 0.88 mol) and sodium iodide (1.1 g; 7 mmol) were added consecutively. More DMSO (112 mL) was used to rinse residual materials into the reaction mixture before the whole was allowed to stir at room temperature. The initial endothermic reaction became mildly exothermic after around 1 h causing the internal temperature to rise to ca. 32-33° C. The reaction as followed by TLC (ethyl acetate/hexane, 50:50) and found to be complete after 3 h. The reaction mixture was diluted with methanol/ethyl acetate (20:80; 400 mL) and the solids were filtered off, and washed with more methanol/ethyl acetate (20:80; 100 mL, 2×50 mL). The filtrate was transferred to a separating funnel and brine (1 L) was added. This caused more sodium chloride from the product mixture to precipitate out. The addition of water (200 mL) redissolved the sodium chloride. The mixture was shaken and the organic layer was separated and then the aqueous layer was extracted further with methanol/ethyl acetate (20:80; 200 mL, 150 mL, 250 mL). The combined extracts were dried (Na 2 SO 4 ) and rotary evaporated (bath 37-38° C.). More solvent was removed under high vacuum to give the sultine 10 as a pale orange liquid (126 g) that was found by 1 H NMR spectroscopy to be relatively free of by-product but containing residual DMSO and ethyl acetate ( FIG. 1 ).
Example 2
Tetrahydronaphthalic anhydride 6
The crude sultine from about (126 g) was diluted in trifluorotoluene (100 mL) and then added to a preheated (bath 80° C.) suspension of maleic anhydride (86 g; 0.88 mol) in trifluorotoluene (450 mL). The residual sultine was washed with more trifluorotoluene into the reaction mixture and then the final volume was made up to 970 mL. The reaction mixture was heated at 80° C. for 15 h, more maleic anhydride (28.7 g; 0.29 mol) was added and then heating was continued for a further 8 h until TLC showed that the sultine had been consumed. While still at 80° C., the solvent was removed by evaporation with a water aspirator and then the residual solvent was removed under high vacuum. The moist solid was triturated with methanol (200 mL) and filtered off, washing with more methanol (3×100 mL). The tetrahydronaphthalic anhydride 6 was obtained as a fine white crystalline solid (75.4 g; 64% from 10) after drying under high vacuum at 60-70° C. for 4 h.
Example 3
The sultine was prepared from dichloro-o-xylene (31.9 g; 0.182 mol), as described in Example 2, and then reacted with maleic anhydride (26.8 g; 0.273 mol) in toluene (300 mL total volume) as described above. This afforded the tetrahydronaphthalic anhydride 6 as a white crystalline solid (23.5 g; 64%).
Example 4
1-amino-3-iminobenz[f]isoindolenine nitrate salt 12
Urea (467 g; 7.78 mol) was added to a mechanically stirred mixture of ammonium sulfate (38.6 g; 0.29 mol), ammonium molybdate (1.8 g) and nitrobenzene (75 mL). The whole was heated with a heating mantle to ca. 130° C. (internal temperature) for 1 h causing the urea to melt. At this point the anhydride 6 (98.4 g; 0.49 mol) was added all at once as a solid. After 15 min ammonium nitrate (126.4 g; 1.58 mol) was added with stirring (internal temperature 140° C.) accompanied by substantial gas evolution. The reaction temperature was increased to 170-175° C. over 45 min and held there for 2 h 20 min. The viscous brown mixture was allowed to cool to ca. 100° C. and then methanol (400 mL) was slowly introduced while stirring. The resulting suspension was poured on a sintered glass funnel, using more methanol (100 mL) to rinse out the reaction flask. After removing most of the methanol by gravity filtration, the brown solid was sucked dry and then washed with more methanol (3×220 mL, 50 mL), air-dried overnight and dried under high vacuum in a warm water bath for 1.5 h. The benzisoindolenine salt 12 was obtained as a fine brown powder (154.6 g) and was found by NMR analysis to contain urea (5.43 ppm) and other salts (6.80 ppm). This material was used directly in the next step without further purification.
Example 5
1-amino-3-iminobenz[f]isoindolenine 7
The crude nitrate salt 12 (154.6 g) was suspended in acetone (400 mL) with cooling in an ice/water bath to 0° C. Sodium methoxide (25% in methanol; 284 ml; 1.3 mol) was added slowly drop wise via a dropping funnel at such a rate as to maintain an internal temperature of 0-5° C. Upon completion of the addition, the reaction mixture was poured into cold water (2×2 L) in two 2 L conical flasks. The mixtures were then filtered on sintered glass funnels and the solids were washed thoroughly with water (250 mL; 200 mL for each funnel). The fine brown solids were air-dried over 2 days and then further dried under high vacuum to give the benzisoindolenine 5 as a fine brown powder (69.1 g; 73%).
Example 6
Naphthalocyanatogallium methoxytriethyleneoxide
Gallium chloride (15.7 g; 0.089 mol) was dissolved in anhydrous toluene (230 mL) in a 3-neck flask (1 L) equipped with a mechanical stirrer, heating mantle, thermometer, and distillation outlet. The resulting solution was cooled in an ice/water bath to 10° C. and then sodium methoxide in methanol (25%; 63 mL) was added slowly with stirring such that the internal temperature was maintained below 25° C. thereby affording a white precipitate. The mixture was then treated with triethylene glycol monomethyl ether (TEGMME; 190 mL) and then the whole was heated to distill off all the methanol and toluene (3 h). The mixture was then cooled to 90-100° C. (internal temperature) by removing the heating mantle and then the benzisoindolenines 5 from the previous step (69.0 g; 0.35 mol) was added all at once as a solid with the last traces being washed into the reaction vessel with diethyl ether (30 mL). The reaction mixture was then placed in the preheated heating mantle such that an internal temperature of 170° C. was established after 20 min. Stirring was then continued at 175-180° C. for a further 3 h during which time a dark green/brown colour appeared and the evolution of ammonia took place. The reaction mixture was allowed to cool to ca. 100° C. before diluting with DMF (100 mL) and filtering through a sintered glass funnel under gravity overnight. The moist filter cake was sucked dry and washed consecutively with DMF (80 mL), acetone (2×100 mL), water (2×100 mL), DMF (50 mL), acetone (2×50 mL; 100 mL) and diethyl ether (100 mL) with suction. After brief air drying, the product was dried under high vacuum at 60-70° C. to constant weight. Naphthalocyanatogallium methoxytriethyleneoxide was obtained as a microcrystalline dark blue/green solid (60.7 g; 76%; λ max (NMP) 771 ( FIG. 7 ).
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A method of preparing a sultine of formula (V) from a dihalogeno compound of formula (IV) is provided.
The method comprises reacting the dihalogeno compound (IV) with a hydroxymethanesulfinate salt in a DMSO solvent,
wherein:
R 1 , R 2 , R 3 and R 4 are each independently selected from hydrogen, hydroxyl, C 1-20 alkyl, C 1-20 alkoxy, amino, C 1-20 alkylamino, di(C 1-20 alkyl)amino, halogen, cyano, thiol, C 1-20 alkylthio, nitro, C 1-20 alkylcarboxy, C 1-20 alkylcarbonyl, C 1-20 alkoxycarbonyl, C 1-20 alkylcarbonyloxy, C 1-20 alkylcarbonylamino, C 5-20 aryl, C 5-20 arylalkyl, C 5-20 arylalkoxy, C 5-20 heteroaryl, C 5-20 heteroaryloxy, C 5-20 heteroarylalkoxy or C 5-20 heteroarylalkyl; and
X is Cl, Br or I.
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BACKGROUND OF THE INVENTION
This invention is directed to suspended ceilings and more particularly to suspended ceilings constructed of wood.
With the increase in home remodeling, industries supplying the tools and materials for the home remodeler have grown dramatically. In the past, most suspended ceilings utilized metal cross beams and required numerous supports to hold the ceiling in place. If the remodeler desires a wooden suspended ceiling, a carpenter must be hired to build each individual support system for the ceiling.
Examples of the present wood beam ceiling structures are the Kern patent, U.S. Pat. No. 4,454,700 issued June 19, 1984 and the Pearson patent, U.S. Pat. No. 4,367,616 issued Jan. 11, 1983.
The Kern patent requires assembly of the main beam which is then attached to similarly assembled cross beams. The cross beam is attached to the main beam using specifically designed metal clips. The entire structure is then attached to a wall piece by these same metal clips. The Pearson patent similarly utilizes a series of metal clips to attach the cross beams to the main beam and to attach the entire assembly to the wall pieces. Although aesthetically attractive, these ceilings are too complicated for many home remodelers. The use of metal brackets and braces also increase the weight of the assembly and necessitates the use of additional supports.
SUMMARY OF THE INVENTION
An object of this invention is to provide the home remodeler with an inexpensive suspended ceiling which is easy to assemble and install.
Another object of this invention is to construct a suspended ceiling assembly that is easily manufactured and required little modification to be installed in the home or office.
A feature of this suspended ceiling assembly is the use of single piece main beams and cross beams. The main beams may be constructed in various lengths and have ends cut at an angle to allow simple fastening of one main beam piece to the other. The sides of the main beam contain outward extensions which provide the support necessary for the cross beams and ceiling tiles. The ends of the cross beams are grooved to form an interlocking fit with the side extensions of the main beam. This interlocking fit may be further strengthened by fastening wood blocks to the intersection of the cross beam with the main beam.
This beam assembly is then attached to a series of wall mounted supports. The wall supports consist of a vertical support member and an upper horizontal member. The horizontal member extends outwardly from the wall to provide a support base for the beam assembly. The main beam extends to fit flush with the wall and rests on the top of the vertical member. The horizontal members are grooved to interlock with the side extensions. Wood blocks may also be used to provide additional support for the suspended ceiling.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view of the suspended ceiling assembly.
FIG. 2 is an enlarged section view taken along lines 2--2 of FIG. 1.
FIG. 3 is an enlarged section view taken along line 3--3 of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
One form of this invention is illustrated by the drawings and is described herein. The suspended ceiling is constructed primarily of wood and is described generally as 10. The suspended ceiling 10 includes a main beam 11 and cross beams 12. The beam assembly is supported against the wall 13 by vertical wall supports 14 which are fastened to the wall 13 along the entire perimeter of the room.
The main beam 11 is generally rectangular when seen in cross section. The lower section of the main beam 11 has horizontally projecting extensions 15 which extend approximately 1/4 inch from the main section. The top of the horizontal extension 15 is flat and serves to support the cross beams 12 and ceiling tiles 26. The lower surface of the horizontal extensions 15 angle inwardly towards the main section of the beam 11 and provide and aesthetically pleasing surface. The ends 16 of the mean beam are cut at 45 degree angles to provide easy mating of the pieces. These main beam ends 16 may be fastened together using any commonly available fastening means, such as glue, nails or screws.
The cross beams 12 are constructed of wood and contain horizontally projecting side extensions 17 of the same dimension as those present on the main beam 11 and provide support for the ceiling tiles 26. The ends 18 of the cross beam 12 are grooved to create an interlocking fit with the corresponding horizontal extensions 15 of the main beam 11. The top of the cross beam 12 may be fastened to a wood block 19 which is then fastened to the top section of the main beam 11. The addition of these wood blocks 19 provides added stability to the suspended ceiling assembly 10.
A vertical wall support 14 is attached to the wall and provides the primary means of support for the entire suspended ceiling 10. Horizontal wall members 20 are attached to the flat top surface 21 of the vertical wall support 14. One side 22 of these horizontal wall members 20 is flat and fits flush with the wall 13. The other side 23 of the horizontal wall member 20 extends horizontally in the same configuration as the projecting horizontal extensions 15 of the main beam 11 and the side extensions 17 of the cross beams 12 to provide support for the ceiling tiles 26. The ends 24 of the horizontal wall member 20 are grooved to frictionally surround the horizontal extensions 15 of the main beam 11 near the end of the main beam 11 which is adjacent to the wall 13, in the same manner as is shown in FIG. 2. As illustrated in FIG. 1, the ends of the cross beams 12 and the end of the main beam 11 which is adjacent to wall 13, are nearly flush with the wall 13 and the respective extensions, 15 and 17, of the cross beams 12 and the main beam 11, frictionally fit within the grooved ends 24 of the horizontal wall members 20. As shown in FIG. 1, elongated wood blocks 25 may be used to provide added support to the suspended ceiling assembly 10.
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A suspended ceiling constructed of wood having main beams and cross beams arranged to receive and support ceiling tiles. Each beam having horizontally projecting side extensions with the ends of the cross beams being grooved to frictionally fit on the side extensions of the main beam.
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CROSS-REFERENCE TO RELATED APPLICATION(S)
This application is a continuation of U.S. patent application Ser. No. 09/393,464, filed Sep. 10, 1999 for “Fire-Fighting System Having Improved Flow” by David R. Bissen, William F. Burch, and Lawrence P. Schmidt.
BACKGROUND OF THE INVENTION
The present invention relates to an improved device for use in fighting fires. More particularly, it relates to an improved device for conveying a quenching agent from the fire-fighting vehicle to an advantageous application point.
To effectively contain and extinguish fires, it is necessary to accurately direct the flow of a quenching agent such that it makes contact with the source of the fire. This task is often made difficult by the inaccessibility of the fire's source caused by intervening obstacles or the heat radiating from the fire itself. Also, the fire is often not located near a quenching agent supply, and the quenching agent must be conveyed a substantial distance from its supply to the source of the fire. Prior art systems often employed either a telescoping boom or a water cannon to deliver quenching agent from a distant location. An exemplary device, employing a telescoping boom, is disclosed in U.S. patent application Ser. No. 4,875,526, issued Oct. 24, 1989 to Latino, et al. entitled “ROUGH TERRAIN, LARGE WATER VOLUME, TRACK DRIVEN FIRE-FIGHTING APPARATUS AND METHOD.” The prior art devices suffer from a lack of accuracy and dispensing range. The prior art devices also are incapable of conveying large flow rates of quenching agent.
There is a need in the art for a fire-fighting vehicle having the ability to pinpoint the position of the quenching agent dispensing point from a remote location. Also, there is a need in the art for a fire-fighting vehicle capable of conveying large volumetric flow rates of quenching agent.
BRIEF SUMMARY OF THE INVENTION
The present invention is an improved fire-fighting vehicle having an articulable boom for accurate positioning of a nozzle near a fire source. The improved fire-fighting vehicle includes a vehicle chassis for rotatably supporting a plurality of boom sections. It further includes a conveying pipeline having an inside diameter of approximately six inches or greater and allowing a quenching agent throughput of at least 3,000 gallons per minute. The improved fire-fighting vehicle also includes a nozzle connected to a distal end of the conveying pipeline at a distal end of the outermost boom section.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a fire-fighting vehicle in accordance with the present invention.
FIG. 2 is an exploded perspective view of an inlet pipeline according to the present invention.
FIG. 3A is a perspective view of a first boom section according to the present invention.
FIG. 3B is an exploded perspective view of a first pipeline section according to the present invention.
FIG. 4A is a perspective view of a second boom section according to the present invention.
FIG. 4B is an exploded perspective view of a second pipeline section according to the present invention.
FIG. 5A is a perspective view of a third boom section according to the present invention.
FIG. 5B is an exploded perspective view of a third pipeline section according to the present invention.
DETAILED DESCRIPTION
FIG. 1 shows a perspective view of a fire-fighting system 10 according to the present invention. The fire-fighting system 10 includes a truck 12 , a boom 14 , a conveying pipeline 16 , and a nozzle 18 . The truck 12 acts as a support or a base for the boom 14 . The boom 14 supports and articulates the conveying pipeline 16 . The truck 12 provides the ability for the fire-fighting system 10 to be mobile and transported to a location near the vicinity of the fire. The boom 14 and the conveying pipeline 16 function to allow the dispensing point of a quenching agent (not shown) to be located near the fire source. The quenching agent is dispensed through the nozzle 18 , which is mounted at the outermost end of the boom 14 . Although the preferred embodiment, as shown in FIG. 1, shows the fire-fighting system 10 having a boom 14 and conveying pipeline 16 mounted on the truck 12 , in other embodiments the boom 14 and conveying pipeline 16 may be mounted on a stationary support. Also, in some embodiments a monitor (not shown) may be placed between the outermost end of the boom 14 and the nozzle 18 to adjust the spray direction of the nozzle 18 .
The truck 12 includes a chassis 20 , outriggers 22 , a tank 24 , a pump 26 , three hose connectors 27 a , 27 b , 27 c , and a boom base 28 . The chassis 20 of the truck 12 provides the main structural support for supporting the boom 14 and the conveying pipeline 16 . The outriggers 22 extend laterally from the chassis 20 and impose a downward force on the surrounding ground. The outriggers 22 function to stabilize the truck 12 and prevent it from tipping during deployment of the boom 14 and conveying pipeline 16 . The tank 24 holds a supply of the quenching agent used to suppress or quench the fire. The quenching agent is commonly water or a fire retardant chemical foam.
The quenching agent may also be supplied by a source external to the truck 12 . In this case, the quenching agent is supplied to the pump 26 from an external source (not shown) by connecting hoses between the external source and the hose connectors 27 a , 27 b , 27 c . The hose connectors 27 a , 27 b , 27 c then couple to an eight inch manifold pipeline (not shown), which connects to the pump 26 . The pump 26 acts to move quenching agent through the conveying pipeline 16 and out the nozzle 18 . The base 28 provides a surface for mounting the boom 14 . The boom 14 includes a turret 30 , a first boom section 32 a second boom section 34 , a third boom section 36 , a first actuator assembly 38 , a second actuator assembly 40 , and a third actuator assembly 42 .
In a preferred embodiment, the truck 12 includes a tank 24 for storing about 850 gallons of fire retardant chemical foam, and the water is provided by an external source. The tank is constructed from fiberglass using resins selected to be compatible with the fire retardant chemical foam. In a preferred embodiment, the truck does not include a tank for storing water. In a preferred embodiment the quenching agent is a mixture of approximately two to six percent by volume of fire retardant chemical foam in water. The foam is injected into the water supply using methods generally known to those of skill in the fire fighting devices art.
The turret 30 of the boom 14 is mounted to the base 28 of the truck 12 . The turret 30 allows rotatable motion, about a vertical axis, of the boom 14 with respect to the truck 12 . As shown in FIG. 1, a proximal end of the first boom section 32 is pivotally coupled to the turret 30 . A distal end of the first boom section 32 is pivotally connected to a proximal end of the second boom section 34 . A distal end of the second boom section 34 is pivotally connected to a proximal end of the third boom section 36 . Although the preferred embodiment shown in FIG. 1 includes three boom sections, the boom 14 could include any number of boom sections.
As shown in FIG. 1, the first actuator assembly 38 is connected between the turret 30 and the first boom section 32 . The first actuator assembly 38 extends or retracts to control the angular position of the first boom section 32 with respect to the truck 12 . The second actuator assembly 40 is coupled between the first boom section 32 and the second boom section 34 and controls the angular position of the second boom section 34 with respect to the first boom section 32 . The third actuator assembly 42 is coupled between the second boom section 34 and the third boom section 36 and controls the angular position of the third boom section 36 with respect to the second boom section 34 . An operator of the fire-fighting system 10 can control the position of the distal end of the third boom section 36 by controlling the positions of the turret 30 , the first actuator assembly 38 , the second actuator assembly 40 , and the third actuator assembly 42 . The position of the distal end of the third boom section 36 , where the nozzle 18 is located, determines the dispensing point of the quenching agent.
The conveying pipeline 16 , as shown moving from left to right in FIG. 1, includes a feed pipe section 44 , a first pipe section 46 , a second pipe section 48 , a third pipe section 50 , a first pipeline joint 52 , a second pipeline joint 54 , and a third pipeline joint 56 . The first pipe section 46 is pivotally coupled to the feed pipe section 44 by the first pipeline joint 52 . The second pipe section 48 if pivotally coupled to the first pipe section 46 by the second pipeline joint 54 . The third pipe section 50 is pivotally coupled to the second pipe section 48 by the third pipeline joint 56 . A distal end of the third pipe section 50 is coupled to the nozzle 18 . The various pipe sections 46 , 48 , 50 are rigidly coupled to the respective boom sections 32 , 34 , 36 . During motion of the boom 14 by an operator, the pipeline joints 52 , 54 , 56 allow the pipe sections 46 , 48 , 50 to pivot along with the boom sections 32 , 34 , 36 . The pipeline joints 52 , 54 , 56 allow pivotal motion while maintaining a liquid seal such that the quenching agent does not leak out of the conveying pipeline 16 .
The fire-fighting system 10 of the present invention allows an operator to manipulate the actuators and strategically position the nozzle 18 for maximum fire-fighting efficacy. The fire-fighting system 10 of the present invention also teaches a solid-walled pipeline having a large diameter that allows large quenching agent flow rates. The boom sections 32 , 34 , 36 are generally constructed from a high-strength steel giving them the necessary strength and durability to operate in the vicinity of a fire and the pipe sections 46 , 48 , 50 are generally constructed from aluminum to minimize the weight that the boom sections 32 , 34 , 36 must support.
FIG. 2 is an exploded perspective view of the feed pipe section 44 . The feed pipe section 44 carries the quenching agent from the tank 24 to a proximal end of the first pipe section 46 . As shown in FIG. 2, moving from a proximal end (the end near the tank 24 holding the quenching agent) to a distal end, the feed pipe section 44 includes a pipe 60 , a rigid coupling 62 , a sealing ring 64 , a pipe elbow 66 , a fixed coupling 68 , a sealing ring 70 , a horizontal pipe 72 , a sealing ring 74 , a swivel coupling 76 , a pipe elbow 78 , a sealing ring 80 , a swivel coupling 82 , a pipe 84 , a swivel coupling 86 , and a sealing ring 88 . The feed pipe 44 is configured such that it allows rotation of the turret 30 about a vertical axis and pivotal motion of the first pipe section 46 without compromising the integrity of the feed pipe section 44 . In other words, the feed pipe section 44 must maintain a seal such that it will completely contain the quenching agent. The components of the feed pipe section 44 which allow these movements are the swivel couplings 86 , 82 , and 76 . The swivel couplings 82 and 86 are mounted to the pipe 84 which is disposed in a horizontal plane generally parallel to the ground on which the truck 12 is supported. The swivel couplings 82 and 86 allow pivotal motion of the first pipe section 46 with respect to the feed pipe section 44 . The pipe elbow 78 turns the feed pipe section 44 ninety degrees such that the feed pipe section 44 runs toward the bottom of the truck 12 . The vertical pipe 72 runs through the center of the turret 30 and is disposed concentric thereto. The swivel coupling 76 allows the feed pipe section 44 to maintain integrity during rotation of the turret 30 . The remaining components of the feed pipe section 44 are fixed and connect to the tank 24 or other quenching agent source.
FIGS. 3A and 3B show perspective views of the first boom section 32 and the first pipe section 46 , respectively. The first pipe section 46 , which is supported by the first boom section 32 , carries quenching agent from the distal end of the feed pipe section 44 to the proximal end of the second pipe section 48 . The first boom section 32 , shown in FIG. 3A, and the first pipe section 46 , shown in FIG. 3B, are illustrated with the proximal end on the left side of the figures. In other words, the quenching agent would move through the first pipe section 46 from the left side to the right side of FIG. 3 B.
As shown in FIG. 3A, moving from left to right, the first boom section 32 includes a proximal coupling 92 , three pipe supports 94 a , 94 b , 94 c , a boom body 96 , and a distal coupling 98 . The proximal coupling 92 of the first boom section 32 couples to the turret 30 on the truck 12 . The boom body 96 provides the main structural support for the first boom section 32 . The pipe supports 94 a , 94 b , 94 c are welded to the boom body 96 and support the first pipe section 46 . The distal coupling 98 , shown at the far left in FIG. 3A, connects to a proximal end of the second boom section 34 . Both the proximal coupling 92 and the distal coupling 98 allow pivotal rotation of the first boom section 32 with respect to the adjacent boom sections.
As shown in FIG. 3B, moving from left to right, the first pipe section 46 includes a pipe elbow 100 , a rigid coupling 102 , a sealing ring 104 , a pipe 106 , a rigid coupling 108 , a sealing ring 110 , a pipe elbow 112 , a rigid coupling 114 , a sealing ring 116 , a pipe elbow 118 , a swivel coupling 120 , and a sealing ring 122 . The first pipe section 46 is configured such that it allows for pivotal motion of the second pipe section 48 without compromising the integrity of the conveying pipeline 16 . In other words, the first pipe section 46 and the second pipe section 48 must maintain a seal such that they completely contain the quenching agent. The component of the first pipe section 46 that allows pivotal motion of the second pipe section 48 is the swivel coupling 120 . The pipe elbow 100 , shown on the left side of FIG. 3B, pivotally couples to the pipe 84 of the feed pipe section 44 using the swivel coupling 86 . The remainder of the recited components of the first pipe section 46 are then coupled together in an end-to-end manner and attached to the pipe supports 94 a , 94 b , 94 c of the first boom section 32 .
FIGS. 4A and 4B show perspective views of the second boom section 34 and the second pipe section 48 , respectively. The second pipe section 48 , which is supported by the second boom section 34 , carries the quenching agent from the distal end of the first pipe section 46 to a proximal end of the third pipe section 50 . Like FIGS. 3A and 3B, FIGS. 4A and 4B are illustrated such that the proximal end is on the left side and the distal end is on the right side of the figure.
As shown in FIG. 4A, the second boom section 34 includes a proximal coupling 126 , pipe supports 128 a , 128 b , 128 c , a boom body 130 , and a distal coupling 132 . The proximal coupling 126 of the second boom section 34 is pivotally coupled to the distal coupling 98 of the first boom section 32 such that the second boom section 34 may pivot with respect to the first boom section 32 . The pipe supports 128 a , 128 b , 128 c are mounted to the boom body 130 , which applies the main structural support of the second boom section 34 . The distal coupling 132 is pivotally coupled to a proximal end of the third boom section 36 .
The second pipe section 48 , as shown from left to right in FIG. 4B, includes a pipe elbow 134 , a sealing ring 136 , a rigid coupling 138 , a pipe elbow 140 , a rigid coupling 142 , a sealing ring 144 , a pipe 146 , a rigid coupling 148 , a sealing ring 150 , and a pipe elbow 152 . These components are rigidly connected together in an end-to-end manner and function to convey quenching agent from a proximal end of the second pipe section 48 to a distal end of the second pipe section 48 . The pipe elbow 134 , shown on the far left side in FIG. 4B, is pivotally coupled to the pipe elbow 118 of the first pipe section 46 by the swivel coupling 120 . The second pipe section 48 is therefore capable of pivotal motion with respect to the first pipe section 46 without disturbing the integrity of the pipe line 16 . The various components of the second pipe section 48 are fixed to the pipe supports 128 a , 128 b , 128 c of the second boom section 34 . The second pipe section 48 conveys quenching agent from the distal end of the first pipe section 46 to the proximal end of the third pipe section 40 .
FIGS. 5A and 5B show perspective views of the third boom section 36 in the third pipe section 50 , respectively. The third boom section 36 and the third pipe section 50 are shown if FIGS. 5A and 5B with a proximal end on the left side and a distal end on the right side of the figures.
As shown if FIG. 5A, the third boom section 36 includes a proximal coupling 156 , pipe supports 158 a , 158 b , 158 c , 158 d , a boom body 160 , and a distal end 162 . The proximal coupling 156 pivotally couples to the distal coupling 132 of the second boom section 34 such that the third boom section 36 may pivot with respect to the second boom section 34 in the same general plane. The pipe supports 158 a , 158 b , 158 c , 158 d are coupled to the boom body 160 and act to support the third pipe section 50 . The distal end 162 of the third boom section 36 supports the nozzle 18 .
The third pipe section 50 , as shown from left to right in FIG. 5B, includes a sealing ring 164 , a swivel coupling 166 , a pipe 168 , a rigid coupling 170 , a sealing ring 172 , a pipe elbow 174 , a rigid coupling 176 , a sealing ring 178 , a pipe 180 , a reducer 182 , and a flange 184 . The third pipe section 50 is configured such that it allows pivotal motion of the third boom section 36 and the third pipe section 50 with respect to the second boom section 34 and the second pipe section 48 . The third pipe section 50 must maintain a sealed coupling to the second pipe section 48 during pivotal movement of the third boom section 36 with respect to the second boom section 34 . The component of the third pipe section 50 that allows this pivotal motion is the swivel coupling 166 . The pipe 168 of the third pipe section 50 is pivotally coupled to the pipe elbow 152 of the second pipe section 48 by the swivel coupling 166 . The swivel coupling 166 of the third pipe section 50 allows the pivotal motion of the third pipe section 50 with respect to the second pipe section 48 . The pipe elbow 174 turns the third pipe section 50 ninety degrees such that the pipe 180 runs generally parallel to the third boom section 36 . More specifically, the pipe 180 of the third pipe section 50 gradually approaches a center line of the boom body 160 of the third boom section 36 as it traverses from left to right in FIGS. 5A and 5B. In other words, the distal end of the third pipe section 50 is closer to the center line of the third boom section 36 than is the proximal end.
As shown at the right side of FIG. 5B, the reducer 182 and the flange 184 are coupled to a distal end of the pipe 180 . The flange 184 is coupled to the nozzle 18 . The various components of the third pipe section 50 function to convey quenching agent from a distal end of the second pipe section 48 to a distal end of the third pipe section 50 . The quenching agent then flows out through the flange 184 and into the nozzle 18 , which is the ultimate dispensing point for the quenching agent.
During operation, an operator may manipulate the quenching agent dispensing point by changing the positions of the boom section, 32 , 34 , 36 with respect to one another and by rotating the entire boom 14 with respect to the truck 12 using the turret 30 . An operator may thereby position the quenching agent dispensing point in a position having the greatest fire combating efficacy. The device of the present invention allows the quenching agent to be dispensed at a point near the source of the fire without endangering equipment or fire fighting professionals.
Once the operator has properly positioned the boom 14 , the pump 26 may be activated to convey quenching agent from the tank 24 (or other source) through the feed pipe section 44 to a proximal end of the first pipe section 46 , through the first pipe section 46 to a proximal end of the second pipe section 48 , through the second pipe section 48 to a proximal end of the third pipe section 50 , and through the third pipe section 50 to the nozzle 18 . The solid, articulable, conveying pipeline 16 also allows for maximum quenching agent flow rates.
The conveying pipeline 16 may have any overall length that is desirable and allows for the necessary quenching agent flow rates. In preferred embodiments, the conveying pipeline 16 has a length of 85 feet, 110 feet, or 130 feet. Also, should be apparent to one of ordinary skill in the art that shorter or longer booms could also be used with present invention. The conveying pipeline 16 design of the present invention will adequately pump quenching agent through pipe of these overall lengths.
In a preferred embodiment, the present invention utilizes a conveying pipeline 16 having an six or eight inch inside diameter. The motive force is generated using a single-stage centrifugal pump constructed from cast iron (pump body), stainless steel (impeller shaft), and bronze (impellers, clearance rings, and fittings). The pump 26 of the preferred embodiment is capable of generating a flow rate of 3000 gallons per minute at a pump discharge pressure of 150 pounds per square inch, a flow rate of 2100 gallons per minute at a pump discharge pressure of 200 pounds per square inch and a flow rate of 1500 gallons per minute at a pump discharge pressure of 250 pounds per square inch. To generate the above flow rates, the pump requires 470 horsepower input from the engine of the truck 12 . Typically, the engine of the truck 12 can provide about 500 horsepower.
The conveying pipeline 16 of the fire-fighting system 10 of the present invention can support flow rates in excess of 3000 gallons per minute when the pump 26 can provide such flow rates. The pump 26 can provide a flow rate of 4,000 gallons per minute at 110 pounds per square inch pump discharge pressure when the quenching agent source is charged or pressurized to 10 pounds per square inch (e.g., a fire hydrant). This configuration allows the device of the present invention to generate a quenching agent volumetric flow rate of approximately 5,000 gallons per minute when the quenching agent source is sufficiently charged. The quenching agent flow rate, which may be modeled as laminar flow through a pipe, may be calculated using the following equation for ideal flow: Q = π ( Δ p - p g Δ ) D 4 128 µ l
where Q is the volumetric flow rate, Δp is the change in pressure between a pipe inlet and a pipe exit, ρ is the fluid density, D is the diameter of the pipe, μ is the fluid viscosity, and 1 is the length of the pipe. The above equation cannot be used to accurately calculate flow rates for the fire-fighting system 10 of the present invention for at least two reasons. The fire-fighting system 10 , which generates flow rates up to 5,000 gallons per minute, is operating at a Reynolds number well in excess of 4000, and thus the flow of quenching agent is turbulent, not laminar. Also, the conveying pipeline 16 of the fire-fighting system 10 is not an ideal pipe. Pressure losses occur in the pipeline 16 due to frictional forces, bends in the pipeline 16 , and irregularities at the pipe joints.
The above equation, however, does accurately show the general effect of adjustments to one of the parameters on volumetric flow rate. As is apparent from this equation, the volumetric flow rate is strongly dependent on the diameter of the pipe. For example, an increase in the diameter of the pipe by a factor of two will result in an increase in the flow rate by a factor of sixteen (two to the power of four). It is apparent, therefore, that a system, such as that of the present invention, having an increased diameter pipe will greatly improve the overall quenching agent volumetric flow rate.
As described herein, the preferred embodiment uses a pipeline having an inside diameter of at least six inches and preferably eight inches. It should be understood, however, that the teachings of the present invention would apply equally as well to a device using larger than eight inch pipeline. Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
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An improved fire-fighting device designed to allow variable positioning of a quenching agent dispensing point. The fire-fighting device also allows high quenching agent flow rates. The device uses an articulable boom arrangement and solid pipeline to achieve these advantages.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to shoe machines, and more particularly to shoe bottom roughing machines having dust extraction features.
2. Prior Art
In the manufacture of shoes in which an outsole is cemented directly to the margin of an upper, it is necessary to perform a roughing operation. The roughing operation is necessary to produce a smooth, continuous sole attaching surface by removal of pleats, bulges or irregularities from the overlasted margin. Roughing of the grain side of the margin is also necessary to permit the cement to adhere securely thereto.
Usually in a roughing machine as referred to above, a dust extraction means is provided comprising, for each tool, a hood member within which a tool can be accommodated. The tool has an operating surface portion thereof exposed. Furthermore, the tool supporting means is usually so arranged as to enable a tool or tools supported thereby to follow the heightwise contour of the bottom of a shoe being operated upon, each tool being mounted for movement heightwise of the shoe support as relative movement takes place between the shoe support and the tool supporting means. In such a machine, it is preferable to maintain each hood member in a most effective condition, wherein each hood is mounted for movement heightwise of the shoe support together with each tool.
Usually, each tool is mounted for pivotal movement about a horizontal axis. Such axis may extend generally parallel, to the axis about which the tool can be mounted for rotation, or may alternatively extend generally normally to such axis. In such a case, the hood member for each tool may also be mounted on the axis about which the tool support is mounted for pivotal movement. Where, however, the bottom of a high-heeled shoe is being operated upon, that is a shoe with a pronounced heightwise contour, it can be seen that by pivoting both the hood member and the tool support about the same axis, the hood member is likely, as the tool is being moved upwardly, to be raised to a greater extent in the region thereof away from the pivot, with a result that it may be moved out of its most effective condition in relation to the operating surface portion of the tool.
It is an object of the present invention, to provide a shoe bottom roughing machine which will, especially when operating on the bottoms of high-heeled shoes, as the tool operates "uphill" and "downhill" progressively along marginal portions of the shoe bottom, ensure that adequate clearance is achieved between the hood member associated with each tool and the shoe bottom.
It is a further object of the present invention to provide an improved apparatus suitable for use in performing a roughing operation on marginal portions of shoe bottoms, in which apparatus an effective dust extraction means can be provided.
BRIEF SUMMARY OF THE INVENTION
The present invention comprises a portion of a machine for performing a roughing operation on marginal portions of shoe bottoms. The machine includes a shoe support for supporting a last carrying a shoe, tool supporting means for supporting a rotary roughing tool, and means for effecting relative movement between the shoe support and the tool supporting means. A tool supported by the tool supporting means is caused to operate progressively along a marginal portion of the bottom of a shoe supported by the shoe support. The tool supporting means comprises a tool support mounted on a carrier for pivotal movement relative thereto, about an axis extending parallel, or substantially parallel, to the axis about which a rotatable tool can be mounted. A tool supported by the tool support can be moved heightwise of the shoe support. The machine further comprises a dust extraction hood member within which the rotary tool can be accommodated. The hood member is supported by the tool support, for pivotal movement relative thereto, at a first point spaced from the axis about which said tool support can be pivoted, and is further supported by a lever member, one end of which is pivotally secured to the hood member at a second point, the other end of the lever being pivotally mounted on a portion of the carrier. The distance between said first and second points is the same, or substantially the same, as the distance between said axis and the pivotal mounting of the lever member. Also the distance between the first point and said axis is the same, or substantially the same, as the distance between the second point and said pivotal mounting.
It will thus be appreciated that, with the hood member mounted by a parallel linkage arrangement, the movement of the hood member as the tool is moved heightwise, can take place without its angle of inclination to the shoe bottom being varied. In this manner, the disadvantage of mounting the hood member for pivotal movement about the axis about which the tool support pivots, is overcome.
To maintain the hood member in the same relationship with the operating surface portion of the tool during heightwise movement of the latter, the first point is preferably arranged to be coincident with the axis of rotation of the tool. Operating on the bottoms of high-heeled shoes, however, where clearance between the hood member and the shoe bottom may otherwise give rise to problems, an advantage is to be gained by so arranging the hood member, that the tool, as it progresses "uphill" in effect withdraws into the hood member. The upward movement of the tool is at a greater rate than the corresponding upward movement of the hood member, so that, as the tool moves away from the portions of the shoe bottom where maximum clearance is required, the hood member shrouds a greater area of the tool. An apparatus in which a dust extraction means in accordance with the present invention can be incorporated is described in our co-pending patent application of Messrs. Tutt and Willbond entitled Low Inertia Shoe Machine Tool Support. Where the hood member is used with drive means as above described, including an endless drive member, said hood member may incorporate also a guard for such drive member.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and advantages of the present invention will become more apparent when viewed in conjunction with the following drawings, in which:
FIG. 1 is a fragmentary end view of a machine constructed according to the principles of the present invention, showing dust extraction means thereof; and
FIG. 2 is a plan view of parts of the apparatus shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The machine comprising the present invention is generally similar, except as hereinafter described, to the apparatus described in the aforementioned co-pending patent application, which is herein incorporated by reference. The machine comprises a frame (not shown) on which a shoe support 32, for supporting, bottom uppermost, a last 24 having an insole 25, located on its bottom, and an upper 26 mounted thereon, having its upper margin 27 secured to the periphery of the insole 25, to be operated upon. The last 24 is mounted for sliding movement along a rectilinear path. The machine also includes tool supporting means for supporting two radial wire brushes 38 (one only shown in the drawings), the brushes being arranged in the path of movement of a shoe supported by the shoe support, one at either side of such path.
The tool supporting means comprises an arrangement of two carrier arms 58 (only one being shown), one arranged at either side of the path of movement of the shoe support. Each carrier arm 58 is mounted for pivotal movement, about a vertical axis, under the control of sensing means (not shown) which cooperates with a template (not shown) mounted for movement together with the shoe support.
Each carrier arm 58 supports a drive shaft 608 which constitutes part of the drive means. Each drive shaft 608 is disposed in bearings carried in brackets (not shown). A motor (not shown) is mounted on each arm 58 and provides rotation of the shaft 608 by means of a belt-and-pulley connection. Each shaft 608 also supports, for limited pivotal movement thereon, a support member 616, which constitutes part of a tool support of the apparatus. Each support member 616 has an inwardly extending arm portion 618 which carries a stub shaft 620 for a toothed drive pulley 622. The stub shaft 620 also supports a brush mounting for the brush 38. The toothed drive pulley 622 is connected by means of a toothed endless belt 624 with a further toothed drive pulley 626 carried on the drive shaft 608. Thus, rotation of each motor causes rotation of the brushes 38.
The operation of the brush 38 upon marginal portions of a shoe bottom, effects an inward wiping action on such marginal portions 27. The rotation of each shaft 608 tends to urge its support member 616 attached thereto to rotate so as to lift the arm portion 618. This upward tendency is countered by the distribution of the weight of the support member 616 and also by the weight of the brush 38 supported thereby.
A stop surface 628 is provided on a work portion 630 of a bracket 604 carried on each arm 58 for determining the lowermost position of the support member 616, and thus of the brush 38 supported thereby, in relation to the arm 58. The stop surface 628 cooperates with a corresponding stop surface 632 provided on the underside of the support member 616.
Various piston and cylinder arrangements are provided, acting between a support member 638 secured to the arm 58 and the support member 616. A first piston and cylinder arrangement 634 when pressurized, urges the support member 616, and thus the brush 38 supported thereby, downwardly. A second, damping, piston and cylinder arrangement 644, acts to damp upward movement of the brush 38. A third piston and cylinder arrangement 662 when pressurized, lifts the tool support, and thus the brush supported thereby, out of operative engagement with the shoe bottom.
The apparatus also comprises, for each tool, dust extraction means comprising a hood 676' having an outlet 678'. The outlet 678' is connected by means of a flexible hose 684' to a hollow boss 682' carried on an extension 686' of the bracket 604. This extension has an aperture formed therein and is aligned with the hollow boss 682', to which a flexible tube 690 can also be connected by which the dust extraction means can be connected to a suction source.
A pin 750, which pivotally supports the hood 676', is carried by the arm portion 618 of the support member 616. A further pivotal connection is made, above the first pin 750, by means of a second pivot pin 752, which is carried at one end of a lever 754. The lever 754 carries a third pivot pin 756 at its other end. The third pivot pin 756 can be clampled captive in an arcuate slot 758 formed in an upstanding support plate 760. The support plate 760 is carried by the extension 686' of the bracket 604. The support plate 760 is provided with an arrangement of two side reinforcing support plates 762.
The center of curvature of the arcuate slot 758 lies coincident with the axis of the shaft 608. Furthermore, the distance between the axis of the shaft 608 and the pin 756 is the same, or substantially the same, as the distance between the first pin 750 (constituting a first pivot point) and the second pin 752 (constituting a second pivot point). Thus, adjustment of the third pin 756 in the arcuate slot 758 will not affect this relationship. Similarly, the distance between the second and third pins 752, 756 is the same, or substantially the same, as the distance between the first pin 750 and the axis of the shaft 608. The hood 676', therefor, is supported by a parallel linkage arrangement.
The first pin 750 lies in a plane in which the axis of the drive shaft 608 and the axis of the stub shaft 620 also lie, the first pin being intermediate said two axes. As the support member 616 is caused to pivot about the axis of the shaft 608, the tool will move upwardly proportionately more quickly than the hood 676', the ratio between the two movements depending upon the position of the pin 750. The initial position of the hood in relation to a shoe bottom is determined by the position of the pin 756 in the arctuate slot 758, The hood 676' can thus be initially positioned appropriately to the shoe bottom to be operated upon, and as the tool 38 follows the heightwise contour of the shoe bottom, the position of the hood will vary in relation to the operating surface portion of the tool, the arrangement being such that the higher the tool moves, the more it will be retracted within the hood 676'.
The hood 676' which is made of sheet metal, is generally shaped to shroud the rotary roughing tool 38. It is provided with a "door" 764 which pivots about the second pin 752, a spring catch 766 being provided for holding the door in position. Furthermore, a flap 768 of flexible material, e.g. leather, is provided which depends from the wall of the hood member remote from the first pivot pin 750. Since the brush 38 effects an inward wiping action on the shoe bottom, and thus rotates in the direction of the arrow shown in FIG. 1, the flap member 768 is effective to catch any particles of dust which are thrown in a low tangential path from the operating surface of the brush at the point of contact with the shoe bottom thereof. Furthermore, because the material is flexible, no damage will be done by the flap 768 engaging with the bottom of the shoe.
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A dust extraction hood is mounted for pivotal movement with its associated tool on an automatic shoe bottom roughing machine. A parallel linkage is arranged to permit the hood to be spaced equidistantly from the shoe bottom throughout the operation of the machine, or in a way in which the tool becomes retracted into the hood during upward movement thereof. The retraction can be so arranged where maximum clearance is required, that the tool can protrude from the hood, and as the clearance requirements decrease, the hood member can shroud a greater area of the operating surface of the tool.
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BACKGROUND OF THE INVENTION
This invention relates to a novel heat exchanger or quench cooler for quenching the effluent from a hydrocarbon cracking furnace. More particularly, the invention relates to the coupling between the cracking furnace tubes and the tubes of the quench cooler or transferline exchanger.
In the production of light olefins (ethylene, propylene, butadiene and butylenes) and associated aromatics (benzene, toluene, ethylbenzene, xylenes and styrene) by the thermal cracking of hydrocarbon feedstocks in the presence of steam, the cracking reactions are stopped by rapidly cooling or quenching the cracking furnace effluent. The quenching time is measured in milliseconds and has the purpose of "freezing" the furnace outlet composition at its momentary value to prevent degradation of the olefin yield through continuing secondary reactions. A number of different quench cooler designs are available in the marketplace depending upon the quantity of cracked gas to be cooled, the fouling tendencies of the furnace effluent and the pressure/temperature conditions of the steam to be generated. These designs range from conventional fixed tubesheet shell and tube heat exchangers to double pipe designs.
It is well known that for any given cracking furnace operating conditions, the yield of olefins can be maximized and quencher fouling minimized by decreasing the temperature of the gas leaving the cracking furnace as rapidly as possible. This requires that the quench cooler be positioned as close as possible to the cracking furnace outlet, that the volume of the inlet section of the quench cooler be minimized and that the surface to volume ratio in the cooling section be maximized. The latter requirement implies that a multiplicity of small quencher tubes are more favorable than a single large diameter arrangement.
One prior art type of quench cooler known as the SHG transferline exchanger (Schmidt'sche Heissdampf - Gesellschaft mbH) uses a multiplicity of double tube arrangements in parallel wherein each quench tube is surrounded by a concentric outer tube which carries the water-steam mixture. The annuli between the inner and outer tubes are supplied with boiler water through horizontal, oval-shaped headers. In this regard, see German Patentschrift DE 2551195. Another prior art patent which uses this double tube arrangement with an oval header for the outside tubes is U.S. Pat. No. 4,457,364. This patent discloses a distributor having an inlet for the gas from the furnace and two or three diverging branches forming a wye or tri-piece for the transition between the furnace and the quench cooler. As indicated, this transition where cooling has not yet begun can be critical in minimizing continued reaction and undesirable coke deposits. In this U.S. Pat. No. 4,457,364, the cross sectional area for flow through the connector is substantially uniform to achieve substantially constant gas velocity throughout the distributor. The distributor may also be divergent in cross sectional area up to the point where the ratio of the sum of the cross sectional areas of the branches to the cross sectional area of the inlet is 2:1.
SUMMARY OF THE INVENTION
The inlet section or connector for a quench cooler between the furnace outlet and the inlets to the quench cooler tubes splits the flow into a plurality of branches and is designed to reduce the inlet section residence time to a minimum. In order to uniformly distribute the gas to a plurality of in-line arranged quench tubes, the flow passages are configured to first efficiently decelerate the gas leaving the furnace and then re-accelerate the gas to the quencher cooling tube velocity. More specifically, a conical diverging diffuser section in the connector decelerates the gases and then a tapered and branched converging section re-accelerates the gases as they are fed into the quench cooler tubes. The cross sectional transitions are smooth with monotonic area change in the flow direction (aerodynamic) so that dynamic pressure is recovered, dead spaces, i.e. zones of flow separation, are avoided and the pressure loss is minimal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side elevation view of a quench cooler partially in cross-section incorporating the present invention.
FIG. 2 is a cross-sectional view of the quench cooler of FIG. 1 taken along line 2--2.
FIG. 3 is a perspective view of the connection of the tubes to and through the oval header.
FIG. 4 is an end view of a portion of the quench cooler of FIG. 1 in cross-section.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the quench cooler 10 comprises a plurality of double tube heat exchange elements 12 which in turn comprise the inner tubes 14 which carry the cracking furnace effluent gas surrounded by the outer tubes 16. The annulus between the two tubes carries the coolant water/steam mixture. The lower ends of the tubes 14 and 16 are connected to the oval headers 18 while the upper ends are connected to the oval headers 20.
The connection of the tubes to the oval headers is shown in detail in FIG. 3. The inner tubes 14 pass completely through the headers while the outer tubes 16 terminate at the header and are open to the inside of the header. Cooling water, which is supplied to the lower headers 18 via the coolant inlet connections 22 and 24, as shown in FIG. 1, flows through the lower headers, into the annular space between the tubes and upwardly emptying into the upper headers 20. The coolant, which is now a heated steam/water mixture, flows out from the headers 20 through the outlet connections 26 and 28. The cooled gas which is flowing up through the pipes 14, empties into the upper outlet chamber 30 and is discharged through the outlet 32.
Although other arrangements can be employed, the present invention is illustrated using a 16-tube arrangement which is best seen in FIG. 2. This figure shows the two oval headers 18 with eight tube combinations connected to each header. Two water inlet connections on each oval header are also shown at 22, 22a, 24 and 24a. The two headers 18 are joined to each other and joined to the surrounding plate 34 such as by welding. Around the periphery of the plate 34 is a flange 36 which is for the purpose of mounting the inlet connector to be described hereinafter. The upper oval headers 20 are similarly mounted including a flange 38 for attaching the flange 40 on the upper outlet chamber 30.
The quench cooler of the present invention can be applied most advantageously with cracking furnaces (not illustrated) employing a relatively large number of low capacity cracking coils. For example, such a furnace might have twenty four coils each 12 meters (40 feet) in height with each coil formed from four 5 cm (2 in.) internal diameter tubes feeding into a single 10 cm (4 in.) internal diameter outlet tube. The effluent from four such coils can be quenched in a single quench cooler of the present invention. The illustrated embodiment of the invention feeds the effluent from each furnace coil and outlet tube (four furnace inlet tubes) into four quencher tubes. The quench cooler has sixteen quencher tubes so it can handle four furnace coils (sixteen furnace inlet tubes).
The inlet chamber 42 at the lower end of the quench cooler comprises a container or tub 44 which forms the pressure boundary. A flange 46 around the edge of the inlet chamber container is attached by bolts 48 to the flange 36. The container is filled with a high temperature refractory material 50 which has the uniquely shaped internal gas passages 52, 54, 56 and 58 of the present invention formed therein. These gas passages are formed by properly placed cores which are then removed after the refractory has set. For example, the cores may be dissolved or burned out of the refractory. Alternately, the gas passages can be formed of a cast or formed metal such as a high nickel chrome alloy, as illustrated at 53 in FIG. 4. In that case, the refractory is merely poured around the formed passages.
In the illustrated embodiment of the present invention, each of the gas passages 52, 54, 56 and 58 is furcated or branched into four branches 60, 62, 64 and 66. Each branch connects to a single quench tube 14. Each gas passage comprises a first diverging conical diffuser portion 68 followed by a converging portion 70 which includes the branches. The conical diverging portion 68 can be seen in the two views shown in FIGS. 1 and 4. The converging portion is not as easily recognized since that portion begins with a divergence in one plane (FIG. 1) to spread out to the branches but with a convergance in the other plane (FIG. 4). The net effect of this combination of a divergence in one plane and a convergence in the other plane is a smooth or monotonic convergance of the flow area. Discontinuities are avoided which would create eddies and coking. Therefore, the gases are first decelerated in the conical diffuser and then re-accelerated back up to the quencher tube velocity. The smooth re-acceleration serves to avoid flow separation thereby minimizing coke formation in dead zones while providing a uniform flow distribution to the individual quencher tubes. As a specific example, the inside diameter of each inlet tube may be 10.16 cm (4 in.) and the inside diameter of the outlet of the diffuser may be 15.24 cm (6 in.) for a ratio of flow area of 2.25. The 15.24 cm (6 in.) maximum diameter then converges down to four (4) tubes of 5.7 cm (2.25 in.) for a ratio of flow area of 0.56.
Since the flow is re-accelerated without dead zones, coke deposition at the entrance to each tube is minimized. Even if coke is deposited in the tubes, deviation from uniform flow distribution is significantly reduced. This is the advantage of using an aerodynamically efficient diverging/converging passage instead of either a conventional transfer line exchanger inlet or a constant area or diverging bifurcation as shown in U.S. Pat. No. 4,457,364. In the latter case, flow separation in the wye or tri-piece and maldistribution to the transfer line exchanger tubes are likely. The result of applying the diverging/converging passage of the present invention is uniform distribution, reduced coking tendencies and consequently improved yields and increased run length.
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A quench cooler or transferline heat exchanger for quenching the effluent from a hydrocracking furnace has an inlet coupling between the cracking furnace tubes and the tubes of the quench cooler which splits the flow into a plurality of branches. The flow passages are configured to initially decelerate and then re-accelerate the gas. This involves a conical diverging diffuser section and then a tapered and branched converging section. The cross sectional transitions are smooth to avoid dead spaces and minimize pressure loss.
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BACKGROUND OF INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a drip portable cup.
[0003] 2. Description of Related Art
[0004] There are about three ways to make coffee at home, instant, drip and cooking. The present invention improves the device for drip coffee. The drip coffee is an option between coffee machine and instant coffee. The ground coffee is put in the funnel-shaped filter paper, the boiling water is poured in the filter paper to obtain thick, pure and fragrant coffee.
[0005] The device for traditional drip coffee is “coffee making stand”, which has the defects of large volume and restricted occasion, so the usage degree of freedom is low. Therefore, it is impossible to drink coffee at any time in work, open air or travel.
[0006] In addition, there is a “structure of drip cup”, which is small and portable, but it has the following problems: the components are assembled by chucking, if the binding site is not tight or steady enough, it is likely to leak and to be disassembled when it is shaken by external force or tilted.
[0007] Thus, to overcome the aforementioned problems of the prior art, it would be an advancement in the art to provide an improved structure that can significantly improve the efficacy.
SUMMARY OF THE INVENTION
[0008] the present invention is a drip portable cup, the portable cup comprising: a cup container having the first thread on top outer wall; a drip container disposed at a top of the cup container and comprising a funnel-shaped bottom wall, a casing wall surrounding the bottom wall, a connection wall extending downwards from the bottom edge of the casing wall, a plurality of flanges surrounded at a bottom surface of the bottom wall a ring groove arranged between the flange and the casing wall, a drip part disposed in a center of the bottom wall for dripping water, a second thread surrounded in the top outer wall of the casing wall, and a third thread arranged in the inner wall of the connection wall corresponding to the first thread and screwed on the first thread, so that the drip container can be screwed on the cup container;
[0009] a cover body at the top of the drip container, and the bottom inner wall of the cover body corresponds to the second thread, surrounded with the fourth thread which can be screwed on the second thread, so that the cover body can be screwed on the drip container; and a filter container disposed between the drip container and the cup container; the top edge of the filter container is clamped in the ring groove of the drip container; the top outer wall of the filter container is surrounded with a bearing rib which can be gripped by the inner wall of the cup container; a fitter screen at the bottom of the filter container.
[0010] wherein the drip part comprises a projection in the center of the bottom wall; a ring wall around the projection; a water holding space between the ring wall and the projection; a projecting part on the top of the projection; a water inlet through the center of the projecting part for dripping the water from the water holding space ( 263 ) into the filter container; and a through hole with narrow top and wide bottom which is connected to the bottom of the water inlet.
[0011] Wherein the top of the cover body has a concave annular groove, there is a drainage hole in the front of the annular groove, and there is a close over in the annular groove which can pivot to open or close the drainage hole.
[0012] Wherein the fourth thread of the cover body can be screwed on the first thread of the cup container, so that the cover body can be screwed on the cup container.
[0013] Wherein a seizing part on the inner wall of the bottom edge of the filter container, the filter screen comprises a silica gel cover gripping the seizing part and a screen at the bottom of the silica gel cover.
[0014] The function and effect of the present invention are described below:
1: the drip part is combined with the filter container, when the water drips from the drip part to the pulverized coffee in the filter container continuously, the pulverized coffee absorbs the water and swells, when it is saturated, it drips through the filter screen at the bottom of the filter container into the cup container for the user to drink, so as to implement dripping. 2: the cover body can be loosened and removed from the drip container, combined with the cup container for thermal insulation and cold insulation. Therefore, the present invention can be combined into different forms. 3: the user can take the portable cup with him when traveling or working outdoors, and he can make coffee at any time without coffee machine, it is very convenient. 4: the cup container, drip container and cover body are screwed, so the tightness and firmness are better than traditional cup, avoiding water leak and structural disassembly when it is shaken by external force or tilted. In addition, it is convenient to be assembled and disassembled. To clean the portable cup, the structures are loosened disassembled one by one, and cleaned one by one, so as to avoid leaving stains on the portable cup. 5: the filter container is set between the drip container and the cup container, so the drip container and the cup container are loosened and disassembled before the filter container is taken out and cleaned.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 : Three-dimensional schematic of the present invention.
[0021] FIG. 2 : Exploded schematic of the present invention.
[0022] FIG. 3 : P-P schematic section of the present invention.
[0023] FIG. 4 : schematic section of Part A of FIG. 3 .
[0024] FIG. 5 : schematic section of Part B of FIG. 3 .
[0025] FIG. 6 : schematic section of Part C of FIG. 3 .
[0026] FIG. 7 : schematic implementation of the present invention.
[0027] FIG. 8, 9 : schematic implementation of the present invention changed into thermal insulation and cold insulation cups.
[0028] FIG. 10 : schematic section of another implementation form of the filter container of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] FIGS. 1 ˜ 7 disclose a drip portable cup ( 100 ), including a cup container ( 1 ), the top outer wall has the first thread ( 11 ); a drip container ( 2 ), at the top of the cup container ( 1 ), and the drip container ( 2 ) comprises a funnel-shaped bottom wall ( 21 ), a casing wall ( 22 ) surrounding the bottom wall ( 21 ), and a connection wall ( 23 ) extending downwards from the bottom edge of the casing wall ( 22 ), there is a flange ( 24 ) surrounding the bottom surface of the bottom wall ( 21 ), there is a ring groove ( 25 ) between the flange ( 24 ) and the casing wall ( 22 ), and there is a drip part ( 26 ) in the center of the bottom wall ( 21 ) for dripping water, there is a second thread ( 27 ) surrounding the top outer wall of the casing wall ( 22 ), the inner wall of the connection wall ( 23 ) corresponds to the first thread ( 11 ), surrounded with a third thread ( 28 ) which can be screwed on the first thread ( 11 ), so that the drip container ( 2 ) can be screwed on the cup container ( 1 ); a cover body ( 3 ), at the top of the drip container ( 2 ), and the bottom inner wall of the cover body ( 3 ) corresponds to the second thread ( 27 ), surrounded with a fourth thread ( 31 ) which can be screwed on the second thread ( 27 ), so that the cover body ( 3 ) can be screwed on the drip container ( 2 ); and a filter container ( 4 ), located between the drip container ( 2 ) and the cup container ( 1 ), and the top edge of the filter container ( 4 ) is chucked in the ring groove ( 25 ) of the drip container ( 2 ), and the top outer wall of the filter container ( 4 ) is surrounded with a bearing rib ( 41 ) which can be gripped by the inner wall of the cup container ( 1 ), there is a filter screen ( 42 ) at the bottom of the filter container ( 4 ).
[0030] Said cup container ( 1 ) is screwed on the lower part of the drip container ( 2 ). The filter container ( 4 ) is located between the drip container ( 2 ) and the cup container ( 1 ). The cover body ( 3 ) is screwed on the upper part of drip container ( 2 ), and there is a drip part ( 26 ) in the drip container ( 2 ). Therefore, when the water is poured in the drip container ( 2 ), the water in the drip container ( 2 ) drips through the drip part ( 26 ) slowly into the pulverized coffee in the filter container ( 4 ). The pulverized coffee absorbs the water and swells, when it is saturated, it drips through the filter screen ( 42 ) at the bottom of the drip container ( 4 ) into the cup container ( 1 ), so as to implement dripping. The user loosens the cup container ( 1 ) from the bottom of the filter container ( 4 ) to drink coffee, it is very convenient.
[0031] Secondly, said cup container ( 1 ), drip container ( 2 ) and cover body ( 3 ) are assembled by threaded connection, so the tightness and firmness of the portable cup ( 100 ) are better than chucking of previous techniques, so as to avoid leak and structural disassembly when the cup is shaken by external force or tilted. In addition, it is convenient to be assembled and disassembled, the cup container ( 1 ), drip container ( 2 ) and cover body ( 3 ) can be loosened one by one, and then the structures are cleaned one by one to avoid stains.
[0032] In addition, the filter container ( 4 ) is located between drip container ( 2 ) and cup container ( 1 ), the filter container ( 4 ) can be removed and cleaned after the drip container ( 2 ) and cup container ( 1 ) are loosened and disassembled.
[0033] Said drip part ( 26 ) comprises a projection ( 261 ) in the center of the bottom wall ( 21 ); a ring wall ( 262 ) around the projection ( 261 ); a water holding space ( 263 ) between the ring wall ( 262 ) and the projection ( 261 ); a projecting part ( 264 ) on the top of the projection ( 261 ); a water inlet ( 265 ) through the center of the projecting part ( 264 ) for dripping the water from the water holding space ( 263 ) into the filter container ( 4 ); and a through hole ( 266 ) with narrow top and wide bottom which is connected to the bottom of the water inlet ( 265 ).
[0034] The water holding space ( 263 ) cooperates with the water in et ( 265 ) to control the flow and velocity of the water dripping from the drip container ( 2 ), to adjust the correct concentration mixing ratio of pulverized coffee and water effectively, so as to extract the most uniform coffee to enhance the coffee taste and quality.
[0035] As shown in FIGS. 8 and 9 , the fourth thread part ( 31 ) of said cover body ( 3 ) can be screwed on the first thread ( 11 ) of the cup container ( 1 ), so that the cover body ( 3 ) can be screwed on the cup container ( 1 ). Therefore, the cover body ( 3 ) can be loosened and removed from the drip container ( 2 ), and combined with the cup container ( 1 ). When there is some coffee left in the cup container ( 1 ), the cup container ( 1 ) can be sealed with the cover body ( 3 ) for thermal insulation and cold insulation, and the coffee will not overflow the cup container ( 1 ) when it is tilted.
[0036] Secondly, there is a concave annular groove ( 32 ) in the top of said cover body ( 3 ). There is a drainage hole ( 33 ) in the front of the annular groove ( 32 ), and there is a close over ( 34 ) in the annular groove ( 32 ) which can pivot to open or close the drainage hole ( 33 ). Therefore, when the user wants to drink the coffee in the cup container ( 1 ), the close over ( 34 ) is turned to expose the drainage hole ( 33 ). On the contrary, when the user does not drink the coffee, he turns the close over ( 34 ) to close the drainage hole ( 33 ). It is very convenient.
[0037] As shown in FIG. 10 , there is a seizing part ( 43 ) in the inner wall of bottom edge of said filter container ( 4 ), the filter screen ( 42 ) comprises a silica gel cover ( 421 ) gripping the seizing part ( 43 ) and a screen ( 422 ) at the bottom of the silica gel cover ( 421 ). Therefore, the filter screen ( 42 ) and the seizing part ( 43 ) are combined by chucking, it is more convenient to clean and change the filter screen ( 42 ).
[0038] Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.
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A drip portable cup comprises a cup container, a drip container, a cover body and a filter container. The cup container is screwed on the lower part of the drip container, the filter container is located between the drip container and cup container, the cover body is screwed on the upper part of drip container, and there is a drip part in the drip container. Therefore, the drip part and filter container filter the coffee, and the cup container holds the coffee dripped from the filter container, so that the user can enjoy coffee everywhere at any time.
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BACKGROUND OF THE INVENTION
This invention pertains to semi-automatic cartridge reloading machines which are particularly suited for persons who desire to reload their own firearms ammunition. Machines of this class are well known to those skilled in the art. For example such machines are described in U.S. Pat. No. 2,031,850 issued to C. R. Peterson, U.S. Pat. No. 3,058,387 issued to M. G. Hoyer, U.S. Pat. No. 3,097,560 issued to L. E. Ponsness, et al., U.S. Pat. No. 3,157,086 issued to T. G. Bachhuber, U.S. Pat. No. 3,483,792 issued to Charles F. Williams, U.S. Pat. No. 3,771,411 issued to Jan Vanden Hazel, U.S. Pat. No. 4,020,737 issued to Charles R. Ranson, and U.S. Pat. No. 4,031,804 issued to Richard C. Boschi. The machines of such inventions relate to shell reloaders which perform from one to multiple reloading operations, some of which position a plurality of shells sequentially in a plurality of operations and some of which perform a number of different reloading operations carried out simultaneously on separate shells including; removal of spent primers, introduction of new primers, powder loading, the reloading of bullets, and other operations. Some reloaders have a rotatable support which simultaneously position a plurality of shells open end up in different operating stations. Tools or dies on some machines are positioned above the open end up shells at various stations and are effected by moving the shell support either manually or in some cases automatically to each of the stations with some mechanism provided to bring the tools or dies into operating engagement with the shells.
Normally such machines are equiped with an operating lever or power drive system to provide movement of the tools or dies and the shot shell support. When levers are employed the lever is typically pivoted forward toward the operator to move the support upwardly toward the tools or dies and is pivoted rearwardly away from the operator to move the shot shell support downwardly away from the tools or dies.
In most cases the draw back of a lever-type reloader apparatus has been that the shot shell support must be manually rotated to position the shot shells at subsequent operating stations. In reloader apparatus that is equiped with mechanisms for automatically rotating the shot shell support such mechanisms usually include a cam and cam follower drive mechanism which is inefficient, complex and expensive to fabricate. In addition, such automatic rotating mechanisms still require the use of some manual intervention in performing operations at various stations of the reloading operation.
Other mechanisms drivingly engage the shot shells rather than the support but such mechanisms are undesirable not only because of failure to rotate the support properly if the support is not fully loaded with shot shells but also because of the damage the shell can sustain if the reloader jams and the operator applies excessive force to the operating lever.
Shell reloader machines known in the art while providing for some automatic features do not provide for a fully automatic loading function at all stations of the operation. Such machines require some manual intervention at the various stations of the operation. Further such machines do not provide for loading of both pistol and rifle cartridges with the same machine. In addition, many of the known shell reloading machines are of such design that require a spring as a material part of the machine and further do not provide for a satisfactory centering mechanism for centering the shells which enter the various tools and dies at each stage of the operation causing shell jamming or crushing and further requires the manual guiding of the shell casings by hand to avoid such problems.
SUMMARY OF THE INVENTION
The present invention relates to a semi-automatic cartridge reloading machine which overcomes the foregoing and other drawbacks of the prior art and provides a novel and improved semi-automatic cartridge reloading machine.
In accordance with one feature of the present invention a semi-automatic cartridge reloading machine of the type including a lower travelling platen with a rotatable support for sequentially positioning a plurality of cartridges in each of a series of operating stations and including an upper stationary platen with a plurality of tools or dies depending or extending downwardly and spaced circumferentially about the upper stationary platen and centered over the rotatable support defining a plurality of operating stations is provided with a mechanism for automatically rotating the support to re-position the cartridges in subsequent operating stations at the completion of each reloading step or operation, automatically centering cartridges and removing spent primers from cartridges, automatically belling and admitting powder into cartridges, automatically introducing and inserting new primers into cartridges, automatically introducing and inserting bullets into cartridges, and automatically crimping and seating bullets into cartridges simultaneously and in conjunction with the raising and lowering of the lower travelling platen. All of the mechanisms are synchronized so that cartridges may be operated on and reloaded from start to finish without the necessity of manual intervention.
Another feature of the present invention is the improvement of an indexing drive mechansim which operates simultaneously with and in conjunction with the raising and lowering of the lower travelling platen and is engageable with the indexing table and shell holder plate for rotating the indexing table and shell holder plate to position shell casings received in the indexing table and shell holder plate sequentially in each of the operating stations comprising in combination:
a. A clevis secured to the base structure;
b. A bar pivotedly secured to and extending upwardly, vertically from the clevis;
c. A bar slot formed in the upper end portion of the bar to accept a crank pin;
d. A crank pin which travels upwardly and downwardly in the bar slot simultaneously and in conjunction with raising or lowering the lower travelling platen by the positioning mechanism;
e. A curvilinear shaped crank extending axially from and secured to the crank pin at one end which rotates in one direction as the crank pin contacts the top or bottom of the bar slot and having a pinion pin secured and extending axially at the other end;
f. A housing extending radially from the circumference of the lower travelling platen which journals and supports the pinion pin and pinion;
g. A pinion comprised of a plurality of gear teeth positioned within the housing and journalling and secured to the pinion pin which rotates correspondingly with the rotation of the crank and engages a rack;
h. A rack comprised of a plurality of corresponding gear teeth formed in the underside of one end of an indexing ram which travels in a horizontal plane across the pinion as the pinion is rotated and correspondingly slides the indexing ram into and out of the lower travelling platen;
i. An indexing ram with a rack formed in the underside of one end of a pawl pivotedly secured at the other end which slides into and out of the lower travelling platen on rotation of the pinion;
j. A ram slot formed in the top surface of the lower travelling platen to accept the indexing ram and extending from the circumference to the center portion of the top surface of the lower travelling platen;
k. A pawl pivotedly secured to the end of the indexing ram which drivingly engages and rotates a ratchet secured to and extending axially from an indexing table center pin;
l. A ratchet secured to and extending axially from an indexing table center pin and recessed into a recess hole formed in the top surface at the center portion of the lower travelling platen;
m. A recess hole formed in the top surface at the center portion of the lower travelling platen to accept the ratchet and indexing table center pin;
n. An indexing table center pin positioned vertically within a recess hole secured to a ratchet and secured to the indexing table and shell holder plate to rotate the indexing table and shell holder plate to move and position shell casings between adjacent operating stations as the ratchet is engaged by the pawl on each cycle of operation;
o. A pawl return spring positioned within a spring hole formed in the pawl end of the indexing ram and biased against and between the pawl and an adjusting means set in the indexing ram to return the pawl to rest position after each cycle of operation;
p. A spring hole formed in the pawl end of the indexing ram to accept the pawl return spring;
q. An adusting means set in the pawl end of the indexing ram to adjust the pawl return spring;
r. A pawl stop screw disposed at and extending into a stop screw hole formed in the pawl end of the indexing ram which engages the pawl and may be adjusted in and out of the indexing ram to correct for wear to the pawl or ratchet;
s. A stop screw hole formed in the pawl end of the indexing ram to accept the pawl stop screw;
t. A key slot formed through the center portion of the indexing ram to slide across a register key correspondingly disposed in the ram slot which enters the key slot on each cycle of operation to assure stop lock action of the rotation of the indexing table and shell holder plate;
u. A register key disposed in the ram slot biased vertically, upwardly against the indexing ram by a register key spring and positioned to enter the key slot formed in the indexing ram on each cycle of operation;
v. A register key spring secured to the underside of the indexing ram to bias the register key vertically, upwardly against the underside of the indexing ram.
This eliminates the necessity of a cam and cam follower mechanism, is easier to service, is inexpensive to fabricate and is a mechanism with greater simplicity than mechanisms of machines of prior art.
In addition, another feature of the present invention is the improvement of a primer seating mechanism and tool which operates simultaneously with and in conjunction with the indexing drive mechanism and the raising and lowering of the lower travelling platen and engages and inserts a new primer into the shell casings received in the indexing and shell holder plate comprising in combination:
a. A clevis secured to the base structure;
b. A bar pivotedly secured to and extending upwardly, vertically from the clevis;
c. A bar slot formed in the upper end portion of the bar to accept a crank pin;
d. A crank pin which travels upwardly and downwardly in the bar slot simultaneously and in conjunction with raising or lowering the lower travelling platen by the positioning mechanism;
e. A curvilinear shaped crank extending axially from and secured to the crank pin at one end which rotates in one direction as the crank pin contacts the top or bottom of the bar slot and having a pinion pin secured and extending axially at the other end;
f. A housing extending radially from the circumference of the lower travelling platen which journals and supports the pinion pin and pinion;
g. A pinion comprised of a plurality of gear teeth positioned within the housing and journalling and secured to the pinion pin which rotates correspondingly with the rotation of the crank and engages a rack;
h. A rack comprised of a plurality of corresponding gear teeth formed in the underside of one end of an indexing ram which travels in a horizontal plane across the pinion as the pinion is rotated and correspondingly slides the indexing ram into and out of the lower travelling platen;
i. An indexing ram with a rack formed in the underside of one end of a pawl pivotedly secured at the other end which slides into and out of the lower travelling platen on rotation of the pinion;
j. A ram slot formed in the top surface of the lower travelling platen to accept the indexing ram and extending from the circumference to the center portion of the top surface of the lower travelling platen;
k. A primer ram slot formed in the top surface of the lower tavelling platen to accept a reversible primer positioner and extending from the circumference of the lower travelling platen parallel with and directly aside the ram slot to a position above and aligned with and in the same vertical axis as the primer seating tool positioned at one station of the operation;
l. A reversible primer positioner secured directly aside the indexing ram by slot and key to slide coextensively with the indexing ram into and out of the primer ram slot as the indexing ram slides into and out of the ram slot and disposed with different sized openings at each end to accept various sizes of shell casing primers and further disposed to be removed and turned end over end, thus reversed, and repositioned in the primer ram slot for operation of the machine with different sized primers.
m. A slot and key disposed between the indexing ram and reversible primer positioner to secure the reversible primer positioner to the indexing ram.
n. A primer dispenser base secured to the top surface of the housing and disposed with a dispenser hole formed vertically through the primer dispenser base centered above and vertically aligned with the primer ram slot to allow shell casing primers to drop one at a time by gravitation from the primer dispenser positioned above the primer dispenser base into the primer ram slot and to position the primers in one end opening of the reversible primer positioner so that the primers are delivered to the primer seating tool as the reversible primer positioner slides the primers along the primer ram slot;
o. A dispenser hole formed vertically through the primer dispenser base to accept and position shell casing primers from the primer dispenser positioned vertically above the primer dispenser into the primer ram slot;
p. A primer dispenser positioned vertically, upwardly above and recessed into the primer dispenser base and disposed with a plurality of tubes formed vertically through the primer dispenser to accept various sizes of shell casing primers vertically stacked within the tubes and further disposed so that the primer dispenser may be repositioned in the primer dispenser base to vertically align one tube at a time with the dispenser hole to drop one primer at a time through the dispenser hole into the primer ram slot at each cycle of the operation and further to allow the primer dispenser to be repositioned with another tube vertically aligned with the dispenser hole as the preceding tube is emptied;
q. A guide hole formed vertically into the lower travelling platen at the inner portion of the primer ram slot positioned in vertical alignment with a shell rim slot formed in the shell holder plate at one station of the operation to accept a primer delivered by the reversible primer positioner for insertion and seating in a shell casing;
r. A cup formed into the lower travelling platen vertically aligned with and below the guide hole to accept and center an anvil which moves vertically upwardly and downwardly within the cup and centers and engages the spherical face of a new shell casing primer positioned in the guide hole and forces the primer into a shell casing positioned in a shell rim slot formed in the shell holder plate at one station of the operation;
s. A plunger extending axially vertically downwardly from the anvil and below the lower travelling platen and retained within the lower travelling platen by a housing secured to the underside of the lower travelling platen disposed to engage with a second anvil extending vertically from the base of the machine;
t. A housing extending vertically downwardly from the lower travelling platen to retain the plunger within the lower travelling platen to allow the plunger to move upwardly and downwardly within the lower travelling platen to engage both anvils;
u. A spring journalling the anvil within the housing biased against the plunger to force the plunger downwardly to a ready position at the end of each cycle of operation;
v. A second anvil secured and extending vertically, upwardly from an anvil block secured to the base of the machine and vertically aligned below the plunger to engage the plunger simultaneously and in conjunction with the lowering of the lower travelling platen by the positioning mechanism and forcing the plunger upwardly to seat a new shell casing primer;
w. An anvil block secured to the base of the machine and disposed with a second anvil extending vertically, upwardly to engage the plunger.
Another feature of the present invention is the improvement of a sizing and primer extractor tool which operates simultaneously with and in conjunction with the raising and lowering of the lower travelling platen to center the shell casings received in the indexing table and shell holder plate and removes spent primers from the shells received in the indexing table and shell holder plate comprising in combination:
a. A plunger depending vertically, downwardly from the stationary upper platen at one operating station of the machine secured by means at one end to the stationary upper platen and disposed at the other end with a shell centering sleeve which journals the plunger and slides vertically upwardly and downwardly on the plunger and engages and centers a shell casing positioned in the shell rim slot of the operating station simultaneously and in conjunction with the raising of the lower travelling platen by the positioning mechanism.
b. A retainer secured to the plunger extending axially from the plunger and recessed into the end of the shell centering sleeve;
c. An extracting pin extending axially from and secured to the retainer to force spent primers out of shell casing engaged by the extracting pin;
d. A spring journalling the middle portion of the plunger biasing the shell centering sleeve against the retainer to return the shell center sleeve to ready position at the end of each cycle of operation;
In addition, another feature of the present invention is the improvement of a belling and powder admit tool mechanism which operates simultaneously with and in conjunction with the raising and lowering of the lower travelling platen to admit powder into the shell casings received in the indexing table and shell holder plate comprising in combination:
a. A drive bar boss secured to and extending radially from the circumference of the lower travelling platen;
b. A crank pin secured to and extending radially from the drive bar boss;
c. A drive bar extending vertically, upwardly pivotedly connected at one end to a powder measure means and disposed with a slot formed in the other end to accept the crank pin which travels upwardly and downwardly in the slot simultaneously and in conjunction with the raising and lowering of the lower travelling platen by the positioning mechanism;
d. A slot formed in one end of the drive bar to accept the crank pin which engages the top of the slot to actuate the powder measure means and deliver powder to shell casings positioned in the shell rim slot at the belling and powder admit tool station of the operation;
e. A powder measure means pivotedly secured to the drive bar and secured by means to the stationary upper platen at one operating station of the machine.
Another feature of the present invention is the improvement of a bullet feet mechanism which operates simultaneously with and in conjunction with the raising and lowering of the lower travelling platen to introduce and insert bullets into the shell casings received in the indexing table and shell holder plate comprising in combination:
a. A ram drive boss secured to and extending radially from the lower travelling platen;
b. A plurality of columns secured to the ram drive boss at one end by adjustable securing means and extending vertically, upwardly and secured by means to a cam follower block at the other end;
c. An adjustable cam block journalling the middle portion of the plurality of columns to provide for adjustment up or down to accomodate various size shell casings being acted on by the machine;
d. A cam follower block secured to the upper end portion of the plurality of columns which travels upwardly and downwardly simultaneously and in conjunction with the raising and lowering of the lower travelling platen by the positioning mechanism and engages and drives a crank pin correspondingly upwardly or downwardly;
e. A housing secured to and extending radially from the stationary upper platen which journals and secures a pinion comprised of a plurality of gear teeth secured by a horizontally extending pinion pin;
f. A pinion comprised of a plurality of gear teeth journalled by the housing and secured by a pinion pin which extends axially through the pinion;
g. A pinion pin extending axially through the pinion and secured to the housing;
h. A drive crank of curvilinear shape extending radially from and secured to the pinion pin is disposed with the crank pin previously described extending radially, horizontally away from the drive crank to provide for rotation of the pinion pin and pinion as the crank pin travels upwardly or downwardly;
i. A rack comprised of a plurality of corresponding gear teeth is formed in the underside of one end of a bullet ram to engage and slide in a horizontal plane across the pinion and into and out of the stationary upper platen as the pinion is rotated;
j. A bullet ram disposed with a rack in the underside of one end to engage the pinion and a circular hole formed vertically through the other end to accept bullets delivered from the bullet dispenser and to travel into and out of the stationary upper platen in a ram slot;
k. A ram slot formed in the top surface of the stationary upper platen extending from the circumference of the stationary upper platen through the housing to the center of the bullet dispenser tool positioned at one station of the operation;
l. A bullet dispenser base secured vertically to the top surface of the housing and vertically aligned with the ram slot with a dispenser hole formed vertically through the bullet dispenser base and vertically aligned with the ram slot to accept bullets from the bullet dispenser to drop one at a time by gravitation into the ram slot and into the circular hole formed in the bullet ram;
m. A bullet dispenser positioned vertically, upwardly above and recessed into the bullet dispenser base and disposed with a plurality of tubes formed vertically through the bullet dispenser to accept various sized bullets vertically stacked within the tubes and further disposed so that the bullet dispenser may be repositioned in the bullet dispenser base to vertically align one tube at a time with the dispenser hole to drop one bullet at a time through the dispenser hole into the ram slot at each cycle of the operation and further to allow the bullet dispenser to be repositioned with another tube vertically aligned with the dispenser hole as the preceding tube is emptied;
n. A bullet seating tool depending vertically, downwardly from the stationary upper platen at one operating station of the machine disposed at one end portion with a flange extending radially to position the bullet seating tool by means to the stationary upper platen and disposed with a chamber formed vertically into the other end to accept bullets introduced into the chamber from the ram slot by the ram drive through a pair of cross holes formed in the circumferential surface of the bullet seating tool and into the chamber to allow the bullet ram to pass through inwardly and outwardly from the chamber aligned with the ram slot at each cycle of operation;
o. An adjustable anvil positioned within the chamber of the bullet seating tool at the top portion of the chamber extending vertically upwardly through and secured to a locking nut atop the bullet seating tool to provide for adjustment for various size bullets being operated on by the machine and to engage and seat bullets introduced into shell casings positioned in the shell rim slot at the operating station simultaneously and in conjunction with the raising of the lower travelling platen by the positioning mechanism;
p. A locking nut secured to the adjustable anvil to adjust the anvil for various size bullets being operated on by the machine.
A further feature of the present invention is the improvement of a sizing and primer extractor tool as previously described which is to provide an apparatus for sizing, reforming, and reshaping cartridges and which may be employed as a separate machine or used with other machines known to the prior art.
An additional feature of the present invention is provided in that all cartridge shells both pistol and rifle can be reloaded with the use of the present invention due to the long stroke of the present invention. Additionally, the present invention is capable of reloading 600 to 800 rounds per hour.
A further additional feature of the present invention is provided by the bullet feed mechanism previously described which can be adjusted to accomodate all sizes of bullets being operated on by the machine.
As will be apparent from the foregoing summary it is a general object of the present invention to provide a novel and improved semi-automatic cartridge reloading machine. Other objects and a fuller understanding of the invention may be had by referring to the following description and claims taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
Drawing Number 1, FIG. 1 is a perspective rear view of the entire machine 127 of the present invention.
Drawing Number 2, FIG. 2 is a front elevation view of the entire machine 127 of the present invention.
Drawing Number 3, FIG. 3 is a cutaway sectional view through stationary upper platen 61.
Drawing Number 3, FIG. 4 is an exploded partial view of the bullet seating tool 75 and bullet ram 64.
Drawing Number 3, FIG. 5 is a cutaway sectional view through the lower travelling platen 16.
Drawing Number 3, FIG. 9 is an exploded partial view of the sizing and primer extractor tool 81.
Drawing Number 4, FIG. 6 is a partial top view of stationary upper platen 61.
Drawing Number 4, FIG. 7 is a cutaway top view of lower travelling platen 16 with indexing table 24 and shell holder plate 125 secured.
Drawing Number 4, FIG. 8 is a cutaway top view of lower travelling platen 16 with indexing table 24 and shell holder plate 125 removed.
DETAILED DESCRIPTION OF DRAWINGS
Reference is now made to the drawings wherein the present invention is illustrated in detail and wherein similar components bear the same reference numeral throughout the several views.
Drawing Number 1, FIG. 1 and Drawing Number 2, FIG. 2 illustrate one form of the entire machine generally referred to by numeral 127. A positioning mechanism indicated generally by the numeral 133 is illustrated interposed between the base structure 1 and the lower travelling platen 16 and comprises a pair of guide columns 7, drive shaft 6, drive shaft bearing block and guide column seats 2, a pair of primary cranks 12, a pair of crank keys 13, a pair of secondary cranks 14, a pair of crank pins 15, a pair of secondary crank trunions 17, a handle 10, and handle key 11.
FIGS. 1 and 2 further illustrate generally the lower travelling platen 16, a stationary upper platen 61, a pair of spaced drive shaft bearing block and guide columns seats 2 which rigidly interconnect with the base structure 1, a pair of spaced upstanding guide columns 7 which rigidly interconnect with the drive shaft bearing block and guide column seats 2 and are secured by a pair of guide column nuts 108 into correspondingly spaced guide column seats 62 recessed into the underside end regions of the stationary upper platen 61 and a pair of holes 128 formed through the lower travelling platen 16 containing guide column bearings 18 within to slideably receive the guide columns 7. Both figures illustrate in general the indexing table 24, the shell holder plate 125 secured to the lower travelling platen 16, shell rim slots 29 formed in the shell holder plate 125 and the finished shell remover 58 secured to the lower travelling platen 16.
Drawing Number 1, FIGS. 1 and Drawing Number 2, FIG. 2 further illustrate the indexing table drive mechanism and primer feed assembly referred to generally by the numeral 130 and several components comprising an indexing drive bar clevis 4, indexing ram drive control bar 48, indexing drive bar clevis pin 5, control bar slot 132, indexing ram drive crank pin 46, indexing ram drive crank 45, indexing ram drive pinion pin 44, a pair of indexing ram drive housings 42, indexing ram drive pinion 43, indexing ram drive key 49, indexing ram rack 41, indexing ram 33, primer dispenser 55, primer dispenser base 57, primer dispenser tube 56, and indexing ram reversible primer positioner 40.
Drawing Number 1, FIG. 1 and Drawing Number 2, FIG. 2 further illustrate the primer seating mechanism referred to generally by the numeral 138 and some components including primer seating anvil block 3, primer seating anvil 8, primer anvil seating anvil nut 9, primer seating housing tool 50, and primer seating tool plunger 51.
Drawing Number 1, FIG. 1 and Drawing Number 2, FIG. 2 further illustrate in general the sizing and primer extracting tool 81 comprised in part of the sizing and primer extractor tool shell centering sleeve 83 and the sizing and primer extractor tool primer extractor pin 84.
Drawing Number 1, FIG. 1 and Drawing Number 2, FIG. 2 further illustrate in general the belling and powder admit tool 89 comprised in part of belling and powder admit tool nut 92, a powder dispenser means 59 and the belling and powder admit tool mechanism referred to generally as numeral 124 comprised of a powder dispenser drive bar boss 21, a powder dispenser drive bar crank pin 137, a powder dispenser drive bar 60, a powder measure pin 141, a powder measure means 139, powder measure securing means 140, and powder dispenser drive bar slot 142.
Drawing Number 1, FIG. 1 and Drawing Number 2, FIG. 2 further generally illustrate the bullet crimping and seating tool 93 comprised in part of the bullet crimping and seating tool die 94, the bullet crimping and seating tool depth adjudgment nut 94 and the bullet crimping and seating tool lock nut 96.
Drawing Number 1, FIG. 1 and Drawing Number 2, FIG. 2 further generally illustrate the bullet feed assembly generally referred to by number 131 and a part of its component parts including bullet ram drive boss 22, a pair of bullet ram drive control columns 73, bullet ram drive cam follower block 143, adjustable cam block 126, bullet ram drive crank pin 71, a pair of bullet ram drive housings 67, bullet ram drive pinions 68, bullet ram drive pinion pins 69, bullet ram drive crank 70, bullet ram drive key 74, bullet ram rack 66, bullet ram 64, bullet seating tool 75, bullet dispenser 97, bullet dispenser base 99, bullet dispenser tube 98, bullet seating tool flange 77, and bullet seating tool hold down clamps 80.
Drawing Number 3, FIG. 3, is a cutaway sectional view through stationary upper platen 61 and illustrates in detail the sizing and primer extractor tool 81 comprised in part of the sizing and primer extractor tool plunger 82, the sizing and primer extractor tool shell centering sleeve 83, the sizing and primer extractor tool primer extractor pin 84, the sizing and primer extractor tool retainer 85, the sizing and primer extractor tool depth lock nut 86, the sizing and primer extractor tool securing means 87, and the sizing primer extractor tool spring 88 as positioned in die or tool hole 147 formed through stationary upper platen 61. Drawing Number 3, FIG. 3 further illustrates in detail the bullet feed assembly generally referred to as numeral 131 as positioned in die or tool hole 147 formed through stationary upper platen 61 and comprised in part of adjustable cam block 126, a pair of bullet ram drive control columns 73, a pair of bullet ram drive housings 67, bullet ram drive pinion 68, bullet ram drive pinion pins 69, bullet ram drive crank 70, bullet ram drive crank pins 71, bullet ram drive bearings 72, bullet ram drive key 74, bullet seating tool 75, bullet seating tool slot 76, bullet seating tool adjustable anvil 78, bullet seating tool anvil locking nut 79, bullet seating tool hold down clamp 80, bullet seating tool shaft 146, bullet dispenser 97, bullet dispenser tubes 98, bullet dispenser base 99, bullet ram 64, bullet ram delivery hole 65, and bullet ram rack 66. Drawing Number 3, FIG. 3 further illustrates an exploded cutaway view of the lower travelling platen 16 with indexing table 24, and shell holder plate 125 secured and further illustrates a shell casing 148 engaged with the bullet seating tool 75 and positioned in indexing table shell rim slot 29, indexing table shell retainer ball 30, indexing table shell retainer ball spring 31, shell retainer ball hole 123 formed in the lower travelling platen 16.
Drawing Number 3, FIG. 4 is an exploded partial view of the bullet seating tool 75 and a cutaway view of bullet ram 64 illustrating in detail the bullet seating tool cross holes 76, bullet seating tool flange 77, and bullet ram delivery hole 65.
Drawing Number 3, FIG. 5 is a cutaway sectional view through the lower travelling platen 16 and illustrates in detail the primer seating mechanism referred to generally by the numeral 138 and illustrates in detail a part of the component parts including indexing ram 33, the indexing ram reversible primer positioner 40, indexing ram rack 41, indexing ram drive housing 42, indexing ram drive pinion 43, indexing ram drive pinion pin 44, indexing ram drive crank 45, indexing ram drive crank pin 46, indexing ram drive bearing 47, indexing ram drive control bar 48, indexing ram drive key 49, indexing ram drive control bar slot 132, primer seating tool housing 50, primer seating tool plunger 51, primer seating tool cup 52, primer seating tool anvil 53, primer seating tool spring 54, primer dispenser 55, primer dispenser tubes 56, and primer dispenser base 57.
Drawing Number 3, FIG. 5 further illustrates in detail a cutaway view of the lower travelling platen 16 and illustrates in detail indexing table 24, shell holder plate 125, indexing table center pin 25, indexing table drive ratchet 26, indexing table drive key 27, indexing table centering pin nut 28, indexing table shell rim slot 29, indexing table register key slot 32, primer dispenser hole 117, indexing ram register key 38, and indexing ram register key spring 39.
Drawing Number 3, FIG. 9 is an exploded partial view of the sizing and primer extractor tool 81 and illustrates in detail sizing and primer extractor tool plunger 82, sizing and primer extractor tool shell centering sleeve 83, sizing and primer extractor tool primer extractor pin 84, sizing and primer extractor tool retainer 85, and sizing and primer extractor tool spring 88.
Drawing Number 4, FIG. 6 is a partial top view of stationary upper platen 61 and illustrates in general the sizing and primer extractor tool 81, the bullet crimping and seating tool 93, the powder dispenser means 59, powder dispenser drive bar boss 21, powder dispenser drive bar 60 and column guide seat 62. Drawing Number 4, FIG. 6 further illustrates a top view of the bullet dispenser 97, bullet dispenser tubes 98, bullet dispenser hole 145, bullet ram slot 63, bullet ram 64, bullet ram drive crank 70, bullet ram drive control columns 73, bullet ram drive crank pin 71, and bullet ram drive control boss 22.
Drawing Number 4, FIG. 7 is a cutaway top view of lower travelling platen 16 with indexing table 24 and shell holder plate 125 secured. Drawing Number 4, FIG. 7 illustrates in general lower travelling platen 16, guide columns 7, guide column bearings 18, secondary crank trunions 17, bullet ram drive control boss 22, indexing table shell rim slots 29 designated positions "A" through "E", shell holder plate flathead screws 120, powder dispenser drive boss 21, indexing table center pin 25, indexing table center pin nut 28, indexing ram register key 38, and finish shell remover 58.
Drawing Number 4, FIG. 8 is a cutaway top view of lower travelling platen 16 with indexing table 24 and shell holder plate 125 removed and shows in detail part of the indexing table drive mechanism and primer feed assembly referred to generally by the numeral 130 and component parts indexing ram slot 19, primer slot 20, indexing ram pawl return spring screw 116, indexing ram pawl stop screw 37, indexing ram pawl return spring 36, indexing ram pawl stop-set screw 111, indexing ram pawl return spring hole 112, indexing ram pawl 34, indexing ram pawl pin 35, indexing table center pin 25, indexing table drive ratchet 26, lower travelling platen recessed center hole 110, indexing ram 33, primer drop hole 23, indexing ram register key 38, primer positioner openings 121, primer seating tool guide hole 122, primer dispenser 55, primer dispenser tubes 56, primer dispenser base 57, primer dispenser hole 117, indexing ram reversible primer positioner 40, indexing ram drive housings 42, indexing ram drive pinion pin 44, indexing ram drive crank 45, indexing ram drive crank pin 46, indexing ram drive control bar 48, primer positioner key 134, and primer positioner slot 135. Drawing Number 4, FIG. 8 further illustrates in general powder dispenser drive bar boss 21, bullet ram drive control boss 22, guide columns 7, guide column bearings 18, and secondary crank trunions 17.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to Drawing 1 through 4 and FIGS. 1 through 9 a Semi-automatic Cartridge Reloading Machine is indicated generally by the numeral 127. The machine includes a base structure 1, a lower travelling platen 16, a stationary upper platen 61, a pair of spaced drive shaft bearing block and guide column seats 2 which rigidly interconnect with the base structure 1, a pair of spaced upstanding guide columns 7 which rigidly interconnect with the drive shaft bearing block and guide column seats 2 and are secured by a pair of guide column bolts 108 into correspondingly spaced guide column seats 62 recessed into the underside end regions of the stationary upper platen 61. A pair of holes 128 are formed through the lower travelling platen 16 and contain guide column bearings 18 within to slideably receive the guide columns 7.
A positioning mechanism indicated generally by the numeral 133 is interposed between the base structure 1 and the lower travelling platen 16 to move the lower travelling platen 16 along the guide columns 7 toward and away from the stationary upper platen 61. The positioning mechanism 133 comprises a drive shaft 6 which is journalled by the drive shaft bearing block and guide column seats 2. A pair of primary cranks 12 which are connected to the drive shaft 6 by a pair of crank keys 13 near opposite ends of the drive shaft 6 with the primary cranks 12 extending radially from the drive shaft 6, and a pair of secondary cranks 14 pivotedly connected with the primary cranks 12 by crank pins 15 and extending upwardly from the primary cranks 12 and pivotedly connected to opposite ends of the lower travelling platen 16 by secondary crank trunions 17. A handle 10 connects at either end of the drive shaft 6 for left or right handed operation by means of crank keys 13 and and handle key 11 contained within handle 10 and extends radially and upwardly from either end region of the drive shaft 6.
The lower travelling platen 16 underlies and supports a circular rotatable indexing table 24 which is secured to the lower travelling platen 16 by an indexing center pin nut 28 secured to an indexing table center pin 25 which extends vertically, upwardly from the center of the lower travelling platen 16 and which is recessed in a circular shaped lower travelling platen center recess hole 110 formed in the center of the top surface of the lower travelling platen 16. A circular shell holder plate 125 is secured to the indexing table 24 by ten shell holder plate flathead screws 120. The indexing table 24 and shell holder plate 125 are mounted for rotation to position shell cartridges 148 in operating stations beneath the stationary upper platen 61. Five radially inwardly extending indexing table shell rim slots 29 are formed in the shell holder plate 125. The indexing table shell rim slots 29 are equally circumferentially spaced about the shell holder plate 125 and are each sized to receive and support the rim of a shell cartridge 148. The shell holder plate 125 is quickly and easily interchangeable for various calibers of shell cartridges 148 by removing the ten shell holder plate flathead screws 120. The indexing table shell rim slots 29 are sized in each particular shell holder plate 125 to accept the corresponding desired caliber of shell cartridge 148. Two shell retainer ball holes 123 are formed and extend vertically downwardly into the indexing table 24 at opposite outside edges of each of the indexing table shell rim slots 29. An indexing table shell retainer ball 30 biased by an indexing table shell retainer ball spring 31 are positioned within each of the shell retainer ball holes 123 to bias each shell retainer ball 30 at opposite edges of indexing table shell rim slots 29 partially against the underside of the shell holder plate 125 and partially against the underside of shell cartridges 148 inserted into the indexing table shell rim slots 29 for the purpose of securing the shell casing 148 into the indexing table shell rim slots 29 on the indexing table 24 and shell holder plate 125 and to maintain the shell casings 148 in a vertical position and to keep the shell casings 148 from being flipped out of the shell holder plate 125 during operation of the machine. Five indexing table primer drop holes 129 are formed in the indexing table 24 aligned with the location of shell casing primers 150 when the shell casings 148 are inserted into the indexing table shell rim slots 29 of the shell holder plate 125 to provide for expelling of spent primers 150 and insertion of new primers 150 in the shell casing 148 at the appropriate operating stations of the machine. An additional corresponding primer drop platen hole 23 is formed through the lower travelling platen 16 at a position aligned with and in the same vertical axis below the sizing and primer extractor tool 81 depending from the stationary upper platen 61 and further aligned with and in the same vertical axis with the indexing table primer drop hole 129 in the indexing table 24 to provide for expelling the spent primer 150 from a shell casing 148 when operated on by the sizing and primer extractor tool 81 at one station of the operation of the machine.
The indexing table drive mechanism and primer feed assembly referred to generally by the numeral 130 extends generally radially from the circumference of the lower travelling platen 16 and is interposed between the base structure 1 and the lower travelling platen 16 and is provided for the purpose of rotating the indexing table 24 and for introducing new primers 150 into shell casings 148 secured in the indexing table shell rim slots 29 of the shell holder plate 125 at one station of the operation of the machine. The indexing table drive mechanism and primer feed assembly 130 comprises generally in combination the following components. An indexing drive bar clevis 4 is rigidly secured to the base structure 1, an indexing ram drive control bar 48 is pivotedly secured to the indexing drive bar clevis 4 by an indexing drive bar clevis pin 5 and extends upwardly, vertically from the indexing drive bar clevis 4. A control bar slot 132 is formed within the opposite upper end portion of the indexing ram drive control bar 48. An indexing ram drive crank pin 46 travels upwardly and downwardly within the indexing ram drive control bar slot 132 as the lower travelling platen 16 travels upwardly or downwardly. The indexing ram drive crank pin 46 contacts either top or bottom of the indexing ram drive control bar slot 132 rotating in one direction an indexing ram drive crank 45 which extends axially from and is rigidly connected to the indexing ram drive crank pin 46. The indexing ram drive crank 45 is of curvilinear shape with the indexing ram drive crank pin 46 disposed at one end and an indexing ram drive pinion pin 44 rigidly disposed at the other end and extending axially from the indexing ram drive crank 45 in the opposite direction of the indexing ram drive crank pin 46. The indexing ram drive pinion pin 44 is journalled by a pair of indexing ram drive housings 42 which extend radially from the circumference of the lower travelling platen 16. An indexing ram drive pinion 43 of cylindrical shape comprising a plurality of gear teeth is positioned between the indexing ram drive housings 42 and journals the indexing ram drive pinion pin 44 and is secured to the indexing ram drive pinion pin 44 by means of an indexing ram drive key 49. Rotation of the indexing ram drive crank 45 causes corresponding rotation of the indexing ram drive pinion 43 and engages the indexing ram rack 41. The indexing ram rack 41 comprises a plurality of corresponding gear teeth formed in the underside of the indexing ram 33. The indexing ram 33 is bar shaped with the indexing ram rack 41 disposed at the underside of one end and an indexing ram pawl 34 disposed at the opposite end pivotedly connected by an indexing ram pawl pin 35. The indexing ram 33 slides in a horizontal plane as the indexing ram rack 41 travels across the rotating indexing ram drive pinion 43 and in and out of an indexing ram slot 19 formed in top surface of the lower travelling platen 16 extending from the circumference to the center portion of the top surface of lower travelling platen 16. As the indexing ram 33 travels in and out of the indexing ram slot 19, the indexing ram pawl 34 pivots and engages with the gear shaped index table drive ratchet 26 which is secured to and extends axially from the index table center pin 25 within the lower travelling platen recess center hole 110 and rotates the indexing table 24 and the shell holder plate 125 seventy two degrees on each cycle of operation. An indexing ram pawl return spring 36 is contained within indexing ram pawl return spring hole 112 formed in the opposite end of indexing ram 33 and is biased against and between indexing ram pawl 34 and indexing ram pawl return spring screw 116 set in indexing ram pawl return spring hole 112 to return indexing ram pawl 34 to rest position after each cycle of operation. An indexing table register key slot 32 is formed in the center portion of the indexing ram 33 and travels across an indexing ram table register key 38 which extends vertically, upwardly from the indexing ram slot 19 and enters the indexing table register key slot 32 on each cycle of operation to assure stop lock action of the indexing table 24. The indexing ram table register key 38 is biased vertically, upwardly against the underside of indexing ram 33 by a flat indexing ram register key spring 39 which is secured to the underside of the indexing ram. An indexing ram pawl stop screw 37 is disposed at, and extends into, an indexing ram pawl stop screw hole 111 formed in the opposite end of the indexing ram 33 and engages with the indexing ram pawl 34 and may be adjusted into and out of the indexing ram 33 to correct for wear to the indexing ram pawl 34 and the indexing table drive ratchet 26.
A cylindrically shaped primer dispenser 55 is positioned vertically, upwardly above and recessed into a primer dispenser base 57 which is secured to the top surface of the pair of indexing ram drive housings 42. A plurality of primer dispenser tubes 56 are formed into the primer dispenser 55 and extend vertically through the primer dispenser 55 and are sized to accept various sizes of new shell casing primers 150 stacked vertically within the primer dispenser tubes 56. A primer dispenser hole 117 is formed in the primer dispenser base 57 above and vertically aligned with a primer ram slot 20 formed in the top surface of the lower travelling platen 16 to allow shell casing primers 150 vertically stacked in the primer dispenser tubes 56 to drop one at a time into the primer ram slot 20 by gravitation at each cycle of the operation. The primer dispenser 55 may be rotated and positioned so that each primer dispenser tube 56 is aligned with the primer dispenser hole 117 as the preceeding primer dispensing tube 56 is emptied. The primer ram slot 20 extends from the circumference of lower travelling platen 16 and extends parallel with and directly aside the indexing ram slot 19 previously described into the lower travelling platen 16 to a position above and aligned with and in the same vertical axis as the primer seating tool 50. An indexing ram reversible primer positioner 40 is a rectangular shaped bar which travels in a horizontal plane into and out of the primer ram slot 20 and has rounded primer positioner openings 121 formed at each end shaped to accept various sizes of shell casing primers 150 dispensed into the primer ram slot 20 from the primer dispenser 55. The indexing ram reversible primer positioner 40 may be removed, turned end over end thus reversed, and repositioned for operation of the machine with another size shell casing primer 150. The indexing ram reversible primer positioner 40 slides coextensively with the indexing ram 33 previously described and is secured to the indexing ram 33 by means of a primer positioner key 134 secured to and extending from the indexing ram 33 toward and into a primer positioner slot 135 formed and extending into the indexing ram reversible primer positioner 40. As the indexing ram 33 slides the indexing ram reversible primer positioner 40 slides coextensively and carries a new shall casing primer 150 from the primer dispenser 55 along the primer ram slot 20 to a primer seating tool guide hole 122 formed in the lower travelling platen 16 where the new primer 150 drops by gravitation to be seated at a position above and aligned with and in the same vertical axis with the primer seating tool housing 50.
The primer seating mechanism referred to generally by the numeral 138 is disposed between the base structure 1 and the lower travelling platen 16 positioned in alignment below and in the same vertical axis with the primer seating tool guide hole 122 and comprises a primer seating anvil block 3 rigidly secured to the base structure 1, a cylindrically shaped primer seating anvil 8 extending vertically upwardly from the primer seating anvil block 3 and secured thereto by primer seating anvil lock nut 9, primer seating tool housing 50 rigidly secured to and extending vertically downwardly from the underside of the lower travelling platen 16, a primer seating tool plunger 51 retained within the primer seating tool housing 50 by crimped bottom edges of the primer seating tool housing 50 and which depends from the primer seating tool housing 50 and travels upwardly through the primer seating tool housing 50 and vertically into the lower travelling platen 16 as the lower travelling platen 16 moves downwardly engaging the primer seating tool plunger 51 against the primer seating anvil 8, a primer seating tool anvil 53 extending axially from the upper end of the primer seating tool plunger 51 into a primer seating tool cup 52 formed in the lower travelling platen 16 which acts as a centering guide as the primer seating tool anvil 53 moves upwardly engaging the spherical face of a new shell casing primer 150 positioned in the primer seating guide hole 122 and forces the new shell casing primer 150 into a shell casing 148 positioned in indexing table shell rim slots 29 in the shell holder plate 125 at one station of operation, and a primer seating tool spring 54 which journals the primer seating tool anvil 53 within the primer seating tool housing 50 and is biased against the primer seating tool plunger 51 to force the primer seating tool plunger 51 downwardly to a ready position at the end of each cycle of the operation.
A finished shell remover 58 is disposed and secured by securing means to the circumference of the lower travelling platen 16 at a position in the front portion of lower travelling platen 16 following the last operation station and extends radially, vertically, upwardly, and horizontally over the lower travelling platen 16 and engages the shell casing 148 in the indexing table shell rim slots 29 and ejects the shell casing from shell holder plate 125.
The stationary upper platen 61 contains a plurality of dies or tools depending or extending from a stationary upper platen 61 and defines a series of five operating stations. The operating stations are spaced circumferentially about an imaginary circle having an axis centered between and paralleling the axis of guide columns 7. The dies or tools extend through five die and tool holes 147 formed in, and extending vertically through stationary upper platen 61 at each operating station.
The first tool in order of the operating reloading sequence is the sizing and primer extracting tool 81 which depends through die and tool hole 147 from stationary upper platen 61 at a position above, aligned with, and in the same vertical axis with the indexing table shell rim slot 29 designated slot "B" and comprises a cylindrical shaped sizing and primer extractor tool plunger 82 with sizing and primer extracting tool securing means 87 disposed at the upper end portion, a sizing and primer extracting tool shell centering sleeve 83 disposed at the opposite lower end which journals the sizing and primer extractor tool plunger 82 and slides upwardly and downwardly on the sizing and primer extracting tool plunger 82, a sizing and primer extractor tool retainer 85 extending axially and secured to the lower end of the sizing and primer extracting tool plunger 82 and recessed into the lower end of the sizing and primer extracting tool shell centering sleeve 83, a sizing and primer extractor tool primer extracting pin 84 extending axially, downwardly from the sizing and primer extracting tool retainer 85, and a sizing and extractor tool spring 88 which journals the middle portion of the sizing and primer extracting tool plunger 82 biasing the sizing and primer extracting tool shell centering sleeve 83. In operation the lower travelling platen 16 is moved upward engaging a shell casing 148 positioned in indexing table shell rim slot 29 designated slot "B" with the sizing and primer extracting tool shell centering sleeve 83 which centers the shell casing 148 for this operation and guides the shell casing 148 into the sizing and primer extracting tool 81. The shell casing 148 slides upwardly along the sizing and primer extracting tool plunger 82 until the sizing and primer extracting tool retainer 85 engages the spent primer 150 of the shell casing 148 and punches the spent primer 150 out of the casing and through the indexing table primer drop hole 129 and the platen primer drop hole 23 previously described. As the lower travelling platen 16 is moved downward the shell casing 148 travels downward correspondingly and the sizing and primer extracting tool shell centering sleeve 83 is returned to its original rest position by the sizing and primer extracting tool spring 88 and the cycle is completed.
The second tool in order of the operating sequence is the belling and powder admit tool 89 which is disposed at a die and tool hole 147 in the stationary upper platen 61 and secured thereto by belling and powder admit tool nut 92 at a position above, aligned with, and in the same vertical axis as the indexing table shell rim slot 29 designated slot "C". A powder dispenser means extends vertically, upwardly from the belling and powder admit tool 89. The belling and powder admit tool mechanism referred to generally as numeral 124 is disposed between the lower travelling platen 16 and the powder dispenser means 59 and comprises generally in combination the following components: A powder dispenser drive bar boss 21 rigidly secured and radially extending from the circumference of the lower travelling platen 16, a powder dispenser drive bar crank pin 137 extending radially from the powder dispenser drive bar boss 21, a powder dispenser drive bar 60 which extends vertically upwardly and is pivotally secured to a rotating powder measure means by powder measure pin 141, a powder measure means 139 secured to belling and powder dispenser tool 89 by powder measure securing means 140, and a powder measure slot 142 formed in the lower portion of the powder dispenser drive bar. In operation the powder dispenser drive bar crank pin 137 travels upwardly and downwardly within the powder measure slot 142 as the lower travelling platen 16 travels upwardly or downwardly. The powder dispenser drive bar crank pin 137 contacts the top portion of the powder measure slot as the lower travelling platen 16 is moved upward causing corresponding upward movement of the powder dispenser drive bar 60 which engages the rotating powder measure means 139 and delivers powder from the powder measure means 139 into the shell casing 148 which is positioned within the belling and powder admit tool 89. As the lower travelling platen 16 moves downwardly the powder dispenser drive bar crank pin 137 travels downwardly in the powder measure slot 142 causing downward movement of the powder dispenser drive bar 60 to its rest position.
The next tool in order of the operating sequence is the bullet feed assembly generally referred to as numeral 131 which is generally disposed at a die and tool hole 147 formed in the stationary upper platen 61 at a position above, aligned with, and in the same vertical axis as the indexing table shell rim slot 29 designated slot "D" and extending generally radially from the upper stationary platen 61 and further disposed between the upper stationary platen 61 and the lower travelling platen 16. The bullet feed assembly 131 comprises generally in combination the following components. A bullet ram drive boss 22 extends radially from and is rigidly secured to lower travelling platen 16, a pair of bulllet ram drive control columns 73 secured to the bullet ram drive boss 22 extend vertically, upwardly and are rigidly secured to a bullet ram drive cam follower block 143, an adjustable cam block 126 journals the upper middle portion of the pair of ram drive control columns 73 and may be adjusted upwardly or downwardly to accomodate various length shell casings being acted on in the machine. The bullet ram drive cam follower block 143 moves upwardly and downwardly corresponding with the movement of the lower travelling platen 16 and engages with and drives bullet ram drive crank pin 71 upwardly or downwardly. A pair of bullet ram drive housings 67 extends radially from the upper stationary platen 61 and journals a cylindrically shaped bullet ram drive pinion 68 comprising a plurality of gear teeth by means of a horizontally extending bullet ram drive pinion pin 69. A bullet ram drive crank 70 of curvilinear shape extends radially from and is secured to bullet ram drive pinion pin 69 by a bullet ram drive key 74. The bullet ram drive crank pin 71 previously described extends radially, horizontally away from bullet ram drive crank 70. As the bullet ram drive crank pin 71 moves upwardly or downwardly corresponding upward or downward movement of bullet ram drive crank 70 occurs which rotates bullet ram drive pinion pin 71 and the bullet ram drive pinion 68. Bullet ram rack 66 comprising a plurality of corresponding gear teeth is formed in the circumferential surface in the underside portion of and disposed at one end of bullet ram 64. Bullet ram 64 is bar shaped and slides across bullet ram drive pinion 70 on rotation of the bullet ram drive pinion 70 and travels inwardly and outwardly in a horizontal plane in bullet ram slot 63 formed in the top surface of stationary upper plate 61 and extending from the circumference of upper stationary platen 61 to the center of the bullet seating tool 75 positioned above, aligned with, and in the same vertical axis of indexing table rim slot 29 designated as slot "D". A bullet ram deliver hole 65 of circular shape is formed in the opposite end of bullet ram 64 and extends vertically through bullet ram 64 to accept and position bullets 149 dispensed from the bullet dispenser 97 into bullet ram slot 63. The bullet dispenser 97 is a cylindrically shaped tube extending vertically upwardly from a bullet dispenser base 99 rigidly mounted atop the bullet ram drive housings 67 and centered over the bullet ram slot 63. A plurality of bullet dispenser tubes 98 are formed in and extemnd vertically through the bullet dispenser 98 and are sized to accept bullets 149 stacked vertically within. A bullet dispenser hole 145 is formed in the bullet dispenser base 99 at a position above and aligned with the bullet ram slot 63 to allow the bullets 149 stacked in the bullet dispenser tube 98 positioned over the bullet dispenser hole 145 to drop by gravitation into the bullet dispenser slot 63 of bullet ram 634 one at a time for delivery by the bullet ram 64 to the bullet seating tool 75. The bullet dispenser 97 is seated in the bullet dispenser base 99 and may be rotated and positioned so that each bullet dispenser tube 98 is aligned with bullet dispenser hole 145 as the preceding bullet dispenser tube 98 is emptied. The bullet seating tool 75 is cylindrically shaped and extends vertically downwardly from and through die and tool hole 147 above aligned with and in the same vertical axis as indexing table shell rim slot 29 designated slot "D". A bullet seating tool flange 77 extends radially from the upper portion of bullet seating tool 75 for securing to the stationary upper platen 61 at die and tool hole 147 by means of a plurality of bullet seating tool hold down clamps 80. A cylindrically shaped bullet seating tool chamber 146 is formed vertically through the center of bullet seating tool 75 of bullet size diameter and a pair of bullet seating tool cross holes 76 are formed in the circumferential surface of bullet seating tool 75 to allow the bullet ram 64 to pass through and inwardly and outwardly from the bullet seating tool 75 from the bullet ram slot 63 to deposit a bullet 149 into the bullet seating tool chamber 146 for insertion into a bullet shell casing 148. An adjustable bullet seating tool anvil 78 which may be adjusted for any length bullet 149 is disposed at the upper portion of the bullet seating tool 75 and within the bullet seating tool chamber 146 and secured and adjusted by bullet seating tool locking nut 79 positioned on the outer top surface of bullet seating tool 75. The bullet seating tool anvil 78 secures and presses the bullet 149 positioned by bullet ram 64 in the bullet seating tool chamber 146 into the mouth of the shell casing 148 brought into alignment with the bullet 149 within bullet seating tool 75 when the lower travelling platen 16 is in raised position.
The final tool in order of the operating sequence is the bullet crimping and seating tool 93 which is disposed at a die and tool hole 147 in the stationary upper platen 61 at a position above, aligned with, and in the same vertical axis as the indexing table shell rim slot 29 designated as slot "E". The bullet crimping and seating tool 92 is secured to upper stationary platen 61 by bullet crimping and seating tool nut 96. A shell casing 148 seated in the indexing table shell rim slot 29 designated as slot "E" is operated upon by the bullet crimping and seating tool 93 as the lower travelling platen 16 is raised correspondingly raising the shell casing 148 upwardly and within the bullet crimping and seating tool 93 where the bullet 149 is crimped and seated by crimping and seating means disposed within bullet crimping and seating tool 93. As lower travelling platen 16 is lowered the completely reloaded shell casing 148 is brought to rest position at the completion of the cycle.
A fuller understanding of the preferred embodiment of the present invention may be had by referring to the following sequence of operation of the invention considered in conjunction with the foregoing detailed description of the invention.
Starting with the lower travelling platen 16 lowered and in its rest position an empty shell casing 148 is inserted into indexing table shell rim slot 29 designed slot "A". When the handle 10 is pulled forwardly and downwardly drive shaft 6 is rotated in one direction and the primary cranks 12 and secondary cranks 14 move upwardly and cause corresponding upward movemment of the lower travelling platen 16 toward the stationary upper platen 61. As lower travelling platen 16 travels upwardly the primer seating tool plunger 51 moves upwardly and away from the primer seating anvil 8 the indexing ram drive control bar 48 rotates the indexing ram drive crank 45 and the indexing ram drive pinion and moves the indexing ram reversible primer positioner inwardly into the lower travelling platen 16 to position a new primer 150, the bullet ram drive control column 73 moves upwardly rotating the bullet ram drive crank 70 and the bullet ram drive pinion and moves the bullet ram 64 into the upper stationary platen 61 to position a bullet 149, and the powder dispenser drive bar 60 moves upwardly to begin engagement with the powder dispenser means 59. When the lower travelling platen 16 reaches the top of the stroke the following operations occur simultaneously: the shell casing 148 entering the sizing and primer extractor tool 81 is engaged by the sizing and primer extractor tool sleeve 83 where the shell is centered and the spent primer 150 is extracted by the sizing and primer extractor tool pin 84 and the shell casing 148 is sized by the sizing and primer extractor tool plunger 82, the shell casing 148 entering the belling and powder admit tool 89 is belled and the powder dispenser drive bar 60 completes its upward travel and engages the powder dispenser means 59 and powder is dumped into the awaiting shell casing 148, the shell casing 148 entering the bullet seating tool 75 receives a bullet 149 from the bullet dispenser 97 positioned by the bullet ram 64 which drops through the bullet ram delivery hole 65 to meet the shell casing 148 and then the bullet 149 engages with the bullet seating tool anvil 78 and is pressed into the shell casing 148, the assembled shell casing 148 and bullet 149 entering the bullet crimping and seating tool 93 is fully seated and crimped.
When handle 10 is moved forwardly and upwardly drive shaft 6 is rotated in the opposite direction and the primary cranks 12 and secondary cranks 14 move downwardly and cause corresponding downward movement of the lower travelling platen 16 from the upper stationary platen 61 and the shell casings 148 inserted in the shell indexing table rim slot 29 are moved downwardly and away from the upper stationary platen 61. As the lower travelling platen 16 descends downwardly the following operations occur in quick succession: the powder dispenser drive bar 60 disengages with the powder dispenser means 59 and the powder dispenser means 59 is recharged with the next measured powder charge; the bullet ram drive control columns 73 move downwardly causing bullet ram drive crank 70 to rotate in the opposite direction, rotating the bullet ram drive pinion 68 moving the bullet ram 64 away from the bullet seating tool 75 and aligning the bullet ram delivery hole 65 with the bullet dispenser hole 145 in the bullet dispenser base 99 to receive a new bullet 149 from the bullet dispenser tube 98 which drop by gravity feed into the bullet ram delivery hole 65; the indexing ram drive control bar 48 rotates the indexing ram drive crank 45 and the indexing ram drive pinion 43 moving the indexing ram into the lower travelling platen 16 where the indexing ram pawl 34 engages and turns the indexing table drive ratchet 26, the indexing center pin 25, the indexing table 24 and the shell holder plate 125, seventy-two degrees (72°) on rotation of the indexing table 24 and shell holder plate 125 assembled shell casing 148 positioned in the indexing table shell rim slot 29 located at slot "E" is ejected from the shell holder plate 125 by the finished shell remover 58; the indexing ram register key 38 is biased upward by the indexing ram register key spring 39 and engages with the indexing table register key slot 32 and stops the rotation of the indexing table 24 and shell holder plate 125; the indexing ram pawl 34 moves past indexing table drive ratchet 26 allowing the indexing ram 33 to continue its motion into the lower travelling platen 16; the indexing ram primer positioner 40 then aligns the primer positioning opening with the primer dispenser hole 117 in the primer dispenser base 57 to receive a new primer 150 which drops by gravity feed from the primer dispenser tube 56 on to the primer ram slot 20.
As the lower travelling platen 16 reaches it lower down position the primer seating tool plunger 51 engages the primer seating anvil 8 and pressures the primer seating anvil 8 upwardly through the primer seating tool guide hole 122 and seats the new primer 150 in the shell casing 148 aligned and directly above.
The cycle is completed with the indexing table shell rim slot designated slot "A" unoccupied and a new shell casing 148 is placed in slot "A" and the operation repeats.
Although the invention has been described in perferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and numerous changes in the details of construction and the combination arrangement of parts may be resorted to without departing from the spirit and the scope of the invention as hereinafter claimed.
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A semi-automatic cartridge reloading machine of the type including a lower travelling platen with a rotatable support for sequentially positioning a plurality of cartridges in each of a series of operating stations and including an upper stationary platen with a plurality of tools or dies depending or extending downwardly and spaced circumferentially about the upper stationary platen and centered over the rotatable support defining a plurality of operating stations is provided with mechanisms for automatically rotating the support to reposition the cartridges in subsequent operating stations at the completion of each reloading step or operation, automatically centering cartridges and removing spent primers from cartridges, automatically belling and admitting powder into cartridges, automatically introducing and inserting new primers into cartridges, automatically introducing and inserting bullets into cartridges, and automatically crimping and seating bullets into cartridges simultaneously and in conjunction with the raising and lowering of the lower travelling platen. All mechanism are synchronized so that cartridges may be operated on and reloaded from start to finish without the necessity of manual intervention.
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FIELD OF THE INVENTION
[0001] This invention pertains to betaine esters and processes for the preparation and use thereof.
BACKGROUND OF THE INVENTION
[0002] There is an increasing industrial and societal need for the preparation of ingredients that reduce or eliminate organic solvents and irritants, employ reagents that are themselves biocompatible and that optimally use starting materials derived from a natural source or are “nature-equivalent.” This is of urgent interest in consumer-facing industries such as personal and household care. One class of materials that might be approached in a “greener” manner is surfactants. In particular, there is a need for new betaines that are made in a more environmentally-friendly manner. Betaines are zwitterionic surfactants used in the personal care, household care, and other industries. They are classified as specialty co-surfactants that complement the performance of the primary surfactants. These co-surfactants also increase the mildness of the formulation by reducing irritation associated with purely ionic surfactants.
[0003] Betaines are commonly produced by a multi-step process based on coconut or palm kernel oil. For example, one process for the preparation of a prototypical betaine, fatty acid amidopropyl betaine, involves the amidation of fatty acids with 3-dimethylaminopropylamine (DMAPA) at high temperatures (150-175° C.). The intermediate fatty aminoamide is then reacted with sodium chloroacetate to afford the final product. The amidation requires high temperatures for conversion and distillation to remove unreacted starting materials. These high reaction temperatures can generate by-products and impart color to the products, requiring additional steps to remove the by-products and the color. DMAPA is also a known sensitizer and is found in trace quantities in the final formulation. Thus, betaines prepared under mild conditions without the use of DMAPA would be of great interest.
[0004] It would be highly desirable for the production of the betaines to occur under mild conditions and in high yield. Such a process would take place at lower temperatures, with fewer processing steps and by-products and it would lessen environmental impacts.
BRIEF SUMMARY OF THE INVENTION
[0005] A first embodiment of the present invention concerns a compound represented by the general formula 1:
[0000]
[0006] wherein R is selected from the group consisting of C 1 -C 22 hydrocarbyl, C 3 -C 8 cycloalkyl, C 6 -C 20 carbocyclic aryl, and C 4 -C 20 heterocyclic wherein the heteroatoms are selected from the group consisting of sulfur, nitrogen, oxygen, and mixtures thereof;
[0007] R 1 and R 2 are the same or are independently selected from the group consisting of C 1 -C 6 alkyl, C 2 -C 6 alkenyl, C 4 -C 6 dienyl, and C 3 -C 8 cycloalkyl; and
[0008] A is selected from the group consisting of C 1 -C 10 divalent hydrocarbyl, C 3 -C 8 cycloalkylene, C 6 -C 10 carbocyclic arylene, and C 4 -C 10 divalent heterocyclic wherein the heteroatoms are selected from sulfur, nitrogen, and oxygen.
[0009] Another embodiment concerns a surfactant comprising the compound described above.
[0010] Yet another embodiment concerns a formulated product comprising the compound described above.
[0011] Still another embodiment concerns a process for the preparation of betaine, comprising:
[0000] a) producing an ester of formula 2:
[0000]
wherein R is selected from the group consisting of C 1 -C 22 hydrocarbyl, C 3 -C 8 cycloalkyl, C 6 -C 20 carbocyclic aryl, and C 4 -C 20 heterocyclic wherein the heteroatoms are selected from the group consisting of sulfur, nitrogen, oxygen, and mixtures thereof and and R 6 a C 1 -C 6 alkyl;
b) reacting a dialkylamino alcohol 3:
[0000]
with 2 in the presence of an enzyme to form an intermediate 4:
[0000]
wherein R 1 and R 2 are the same or are independently selected from the group consisting of C 1 -C 6 alkyl, C 2 -C 6 alkenyl, C 4 -C 6 dienyl, and C 3 -C 8 cycloalkyl, and
A is selected from the group consisting of C 1 -C 10 divalent hydrocarbyl, C 3 -C 8 cycloalkylene, C 6 -C 10 carbocyclic arylene, and C 4 -C 10 divalent heterocyclic wherein the heteroatoms are selected from sulfur, nitrogen, and oxygen; and
c) reacting intermediate 4 with sodium chloroacetate to produce a betaine.
DETAILED DESCRIPTION
[0018] The present invention comprises a series of betaine compounds represented by the general formula 1:
[0000]
[0000] wherein R is selected from substituted and unsubstituted, branched- and straight-chain, saturated, unsaturated, and polyunsaturated C 1 -C 22 hydrocarbyl, substituted and unsubstituted C 3 -C 8 cycloalkyl, substituted and unsubstituted C 6 -C 20 carbocyclic aryl, and substituted and unsubstituted C 4 -C 20 heterocyclic wherein the heteroatoms are selected from sulfur, nitrogen, and oxygen, or mixtures thereof, and R 1 and R 2 may be the same or may be independently chosen from substituted or unsubstituted straight- or branched-chain C 1 -C 6 alkyl, C 2 -C 6 alkenyl, C 4 -C 6 dienyl, and C 3 -C 8 cycloalkyl groups wherein the branching and/or substitution of R 1 and R 2 may connect to form a ring, and A is selected from substituted and unsubstituted, branched- and straight-chain, saturated, unsaturated, and polyunsaturated C 1 -C 10 divalent hydrocarbyl, substituted and unsubstituted C 3 -C 8 cycloalkylene, substituted and unsubstituted C 6 -C 10 carbocyclic arylene, and substituted and unsubstituted C 4 -C 10 divalent heterocyclic wherein the heteroatoms are selected from sulfur, nitrogen, and oxygen.
[0019] According to an embodiment, the betaine compounds are denoted by structure 1 wherein R is selected from substituted and unsubstituted, branched- and straight-chain saturated C 1 -C 22 alkyl, substituted and unsubstituted, branched- and straight-chain C 2 -C 22 alkenyl, substituted and unsubstituted, branched- and straight-chain C 4 -C 22 dienyl, substituted and unsubstituted, branched- and straight-chain C 6 -C 22 trienyl, substituted and unsubstituted C 3 -C 8 cycloalkyl, substituted and unsubstituted C 6 -C 20 carbocyclic aryl, substituted and unsubstituted C 4 -C 20 heteroaryl, R 1 and R 2 are selected from straight or branched chain C 1 -C 6 alkyl, C 2 -C 6 alkenyl or C 4 -C 6 dienyl, and A is selected from branched and straight chain C 1 -C 8 alkylene, branched- and straight-chain saturated C 2 -C 8 alkenylene, substituted and unsubstituted C 3 -C 8 cycloalkylene, substituted and unsubstituted C 6 -C 10 carbocyclic arylene, substituted and unsubstituted C 4 -C 12 divalent heterocyclic, or mixtures thereof.
[0020] The saturated, unsaturated, and polyunsaturated alkyl groups which may be represented by R may be straight- or branched-chain hydrocarbon radicals containing up to about 22 carbon atoms and may be substituted, for example, with one to five groups selected from C 1 -C 6 -alkoxy, carboxyl, amino, C 2 -C 16 aminocarbonyl, C 2 -C 16 amido, cyano, C 2 -C 7 -alkoxycarbonyl, C 2 -C 7 -alkanoyloxy, hydroxy, aryl, heteroaryl, thiol, thioether, C 2 -C 10 dialkylamino, C 3 -C 15 trialkylammonium and halogen. The terms “C 1 -C 6 -alkoxy”, “C 2 -C 7 -alkoxycarbonyl”, and “C 2 -C 7 -alkanoyloxy” are used to denote radicals corresponding to the structures —OR 3 , —CO 2 R 3 , and —OCOR 3 , respectively, wherein R 3 is C 1 -C 6 -alkyl or substituted C 1 -C 6 -alkyl. The terms “C 2 -C 16 aminocarbonyl” and “C 2 -C 16 amido” are used to denote radicals corresponding to the structures —NHCOR 4 , —CONHR 4 , respectively, wherein R 4 is C 1 -C 15 -alkyl or substituted C 1 -C 15 -alkyl. The term “C 3 -C 8 -cycloalkyl” is used to denote a saturated, carbocyclic hydrocarbon radical having three to eight carbon atoms.
[0021] The alkyl, alkenyl and dienyl groups which may be represented by R 1 and R 2 may be straight- or branched-chain hydrocarbon radicals containing up to about 6 carbon atoms and may be substituted, for example, with one to three groups selected from C 1 -C 6 -alkoxy, carboxyl, amino, C 2 -C 16 aminocarbonyl, C 2 -C 16 amido, cyano, C 2 -C 7 -alkoxycarbonyl, C 2 -C 7 -alkanoyloxy, hydroxy, aryl, heteroaryl, thiol, thioether, C 2 -C 10 dialkylamino, C 3 -C 15 trialkylammonium and halogen. The terms “C 1 -C 6 -alkoxy”, “C 2 -C 7 -alkoxycarbonyl”, and “C 2 -C 7 -alkanoyloxy” are used to denote radicals corresponding to the structures —OR 3 , —CO 2 R 3 , and —OCOR 3 , respectively, wherein R 3 is C 1 -C 6 -alkyl or substituted C 1 -C 6 -alkyl. The terms “C 2 -C 16 aminocarbonyl” and “C 2 -C 18 amido” are used to denote radicals corresponding to the structures —NHCOR 4 , —CONHR 4 , respectively, wherein R 4 is C 1 -C 15 -alkyl or substituted C 1 -C 15 -alkyl. The term “C 3 -C 8 -cycloalkyl” is used to denote a saturated, carbocyclic hydrocarbon radical having three to eight carbon atoms.
[0022] The divalent hydrocarbyl radicals which may be represented by A may be straight- or branched-chain saturated, unsaturated, and polyunsaturated alkylene and cycloalkylene groups containing up to about 10 carbon atoms and may be substituted, for example, with one to five groups selected from C 1 -C 8 -alkoxy, carboxyl, amino, C 2 -C 18 aminocarbonyl, C 2 -C 18 amido, cyano, C 2 -C 7 -alkoxycarbonyl, C 2 -C 7 -alkanoyloxy, hydroxy, aryl, heteroaryl, thiol, thioether, C 2 -C 10 dialkylamino, C 3 -C 15 trialkylammonium and halogen. The terms “C 1 -C 8 -alkoxy”, “C 2 -C 7 -alkoxycarbonyl”, and “C 2 -C 7 -alkanoyloxy” are used to denote radicals corresponding to the structures —OR 3 , —CO 2 R 3 , and —OCOR 3 , respectively, wherein R 3 is C 1 -C 8 -alkyl or substituted C 1 -C 8 -alkyl. The terms “C 2 -C 16 aminocarbonyl” and “C 2 -C 16 amido” are used to denote radicals corresponding to the structures —NHCOR 4 , —CONHR 4 , respectively, wherein R 4 is C 1 -C 15 -alkyl or substituted C 1 -C 15 -alkyl.
[0023] The aryl groups which R may represent (or any aryl substituents) may include phenyl, naphthyl, or anthracenyl and phenyl, naphthyl, or anthracenyl substituted with one to five substituents selected from C 1 -C 8 -alkyl, substituted C 1 -C 8 -alkyl, C 8 -C 10 aryl, substituted C 8 -C 10 aryl, C 1 -C 8 -alkoxy, halogen, carboxy, cyano, C 2 -C 7 -alkanoyloxy, C 1 -C 8 -alkylthio, C 1 -C 8 -alkylsulfonyl, trifluoromethyl, hydroxy, C 2 -C 7 -alkoxycarbonyl, C 2 -C 7 -alkanoylamino and —OR 5 , —S—R 5 , —SO 2 —R 5 , —NHSO 2 R 5 and —NHCO 2 R 5 , wherein R 5 is phenyl, naphthyl, or phenyl or naphthyl substituted with one to three groups selected from C 1 -C 8 -alkyl, C 8 -C 10 aryl, C 1 -C 8 -alkoxy and halogen.
[0024] The arylene groups which A may represent may include phenylene, naphthylene, or anthracenylene and phenylene, naphthylene, or anthracenylene substituted with one to five substituents selected from C 1 -C 6 -alkyl, substituted C 1 -C 6 -alkyl, C 6 -C 10 aryl, substituted C 6 -C 10 aryl, C 1 -C 6 -alkoxy, halogen, carboxy, cyano, C 2 -C 7 -alkanoyloxy, C 1 -C 6 -alkylthio, C 1 -C 6 -alkylsulfonyl, trifluoromethyl, hydroxy, C 2 -C 7 -alkoxycarbonyl, C 2 -C 7 -alkanoylamino and —OR 5 , —S—R 5 , —SC 2 —R 5 , —NHSO 2 R 5 and —NHCO 2 R 5 , wherein R 5 is phenyl, naphthyl, or phenyl or naphthyl substituted with one to three groups selected from C 1 -C 6 -alkyl, C 6 -C 10 aryl, C 1 -C 6 -alkoxy and halogen.
[0025] The heterocyclic groups which R may represent (or any heteroaryl substituents) include 5- or 6-membered ring containing one to three heteroatoms selected from oxygen, sulfur and nitrogen. Examples of such heterocyclic groups are pyranyl, oxopyranyl, dihydropyranyl, oxodihydropyranyl, tetrahydropyranyl, thienyl, furyl, pyrrolyl, imidazolyl, pyrazolyl, thiazolyl, isothiazolyl, oxazolyl, isoxazolyl, triazolyl, thiadiazolyl, oxadiazolyl, tetrazolyl, pyridyl, pyrimidyl, benzoxazolyl, benzothiazolyl, benzimidazolyl, indolyl and the like. The heterocyclic radicals may be substituted, for example, with up to three groups such as C 1 -C 6 -alkyl, C 1 -C 6 -alkoxy, substituted C 1 -C 6 -alkyl, halogen, C 1 -C 6 -alkylthio, aryl, arylthio, aryloxy, C 2 -C 7 -alkoxycarbonyl and C 2 -C 7 -alkanoylamino. The heterocyclic radicals also may be substituted with a fused ring system, e.g., a benzo or naphtho residue, which may be unsubstituted or substituted, for example, with up to three of the groups set forth in the preceding sentence.
[0026] The divalent heterocyclic groups which A may represent include 5- or 6-membered ring containing one to three heteroatoms selected from oxygen, sulfur and nitrogen. Examples of such heterocyclic groups are pyranyl, oxopyranyl, dihydropyranyl, oxodihydropyranyl, tetrahydropyranyl, thienyl, furyl, pyrrolyl, imidazolyl, pyrazolyl, thiazolyl, isothiazolyl, oxazolyl, isoxazolyl, triazolyl, thiadiazolyl, oxadiazolyl, tetrazolyl, pyridyl, pyrimidyl, benzoxazolyl, benzothiazolyl, benzimidazolyl, indolyl and the like. The heterocyclic radicals may be substituted, for example, with up to three groups such as C 1 -C 6 -alkyl, C 1 -C 6 -alkoxy, substituted C 1 -C 6 -alkyl, halogen, C 1 -C 6 -alkylthio, aryl, arylthio, aryloxy, C 2 -C 7 -alkoxycarbonyl and C 2 -C 7 -alkanoylamino. The heterocyclic radicals also may be substituted with a fused ring system, e.g., a benzo or naphtho residue, which may be unsubstituted or substituted, for example, with up to three of the groups set forth in the preceding sentence.
[0027] The term “halogen” is used to include fluorine, chlorine, bromine, and iodine.
[0028] Examples of the compounds of the invention include those represented by formula 1 wherein R is a mixture of C 9 to C 17 hydrocarbyl radicals (derived from coconut oil), R 1 and R 2 are methyl and A is 1,2-ethylene, 1,2-propylene, or 1,3-propylene.
[0029] Another embodiment concerns a process for the preparation of betaines. The first step of the process is the production of esters of the general formula 2:
[0000]
[0000] wherein R is defined above and R 6 may be C 1 -C 6 straight or branched chain alkyl.
[0030] Short chain esters 2 can be produced by any practical method, including the solvolysis of triglycerides in the presence of a lower alcohol and a base, acid or enzyme catalyst as is known in the art. Examples of lower alcohols include C 1 -C 4 alcohols such as methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, and isobutanol. The short-chain esters 2 may contain from 0-20% of residual lower alcohol.
[0031] The second step comprises the enzymatic reaction of a dialkylamino alcohol 3:
[0000]
[0000] with 2 in the presence of an enzyme with or without methods for the removal of the alcohol by-product to form the desired intermediate 4, wherein R, R 1 , R 2 and A are defined above.
[0000]
[0032] The process is carried out without solvent or in an inert solvent chosen from cyclic or acyclic ether solvents such as diethyl ether, diisopropyl ether, tert-butyl methyl ether, or tetrahydrofuran, aromatic hydrocarbons such as benzene, toluene, or xylene, aliphatic or alicyclic saturated or unsaturated hydrocarbons such as hexane, heptane, cyclohexane, or limonene, halogenated hydrocarbons such as dichloromethane, dichloroethane, dibromoethane, tetrachloroethylene, or chlorobenzene, polar aprotic solvents such as acetonitrile, dimethyl formamide, or dimethyl sulfoxide, or mixtures thereof.
[0033] The process may be carried out at a temperature from about −100° C. to about the boiling point of the solvent, from about 20 to about 80° C., or from about 50 to about 70° C. The amount of alcohol 3 may be from about 0.85 to about 20 equivalents based on the ester 2, or can be from about 1 to about 10 equivalents, or even from about 1 to about 1.5 equivalents. The use of short chain alcohol esters of carboxylic acids is beneficial to the success of the enzymatic esterification of the amino alcohol. Unmodified carboxylic acids may be used in the enzymatic esterification, however the acid forms a salt with the amino alcohol and limits the efficiency of the reaction.
[0034] The enzyme used in the process is chosen from a protease, a lipase, or an esterase. Moreover, lipases may be in the form of whole cells, isolated native enzymes, or immobilized on supports. Examples of these lipases include but are not limited to Lipase PS (from Pseudomonas sp), Lipase PS-C (from Psuedomonas sp immobilized on ceramic), Lipase PS-D (from Pseudomonas sp immobilized on diatomaceous earth), Lipoprime 50T, Lipozyme TL IM, or Novozym 435 ( Candida antarctica lipase B immobilized on acrylic resin).
[0035] Removal of the alcohol or water byproducts can be done chemically via an alcohol or water absorbent (e.g., molecular sieves) or by physical removal of the alcohol or water. According to an embodiment, this by-product removal can be done by evaporation, either by purging the reaction mixture with an inert gas such as nitrogen, argon, or helium, or by performing the reaction at reduced pressures, or both, as these conditions can afford >98% conversion of ester 2 to intermediate 4. According to an embodiment, pressure for the reaction is from about 1 torr to about ambient pressure, or from about 50 torr to about ambient pressure. Any organic solvent that is included in this process may or may not be removed along with the alcohol or water. Examples of 3 include dimethylaminoethanol and dimethylaminopropanol.
[0036] The third step to generate the final product 1 comprises the reaction of intermediate 4 with sodium chloroacetate. The process is carried out without solvent or in an inert solvent chosen from water, cyclic or acyclic alcohol solvents such as methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, isobutanol, ethylene glycol, 1,2-propanediol, or 1,3-propanediol, cyclic or acyclic ether solvents such as diethyl ether, diisopropyl ether, tert-butyl methyl ether, or tetrahydrofuran, aromatic hydrocarbons such as benzene, toluene, or xylene, aliphatic or alicyclic saturated or unsaturated hydrocarbons such as hexane, heptane, cyclohexane, or limonene, halogenated hydrocarbons such as dichloromethane, dichloroethane, dibromoethane, tetrachloroethylene, or chlorobenzene, polar aprotic solvents such as acetonitrile, dimethyl formamide, or dimethyl sulfoxide, or mixtures thereof. The preferred solvents are water, alcohols, no solvent or mixtures thereof. The process may be carried out at a temperature of from about −100° C. to about the boiling point of the solvent, from about 25 to about 150° C., or from about 50 to about 100° C. The amount of sodium chloroacetate may be from about 0.75 to about 20 equivalents based on 4, from about 1 to about 10 equivalents, or from about 1 to about 1.5 equivalents. If included, a base is chosen from metal hydroxides or metal carbonates. According to an embodiment, bases can be sodium hydroxide and potassium hydroxide. The amount of base can be from about 0 molar equivalents to about 1 molar equivalent based on ester 4 or in an amount high enough to keep the reaction mixture basic, for example at about pH 8-9.
[0037] The intermediate 4 and the product 1 of the process may be isolated using methods known to those of skill in the art, e.g., extraction, filtration, or crystallization.
[0038] Another embodiment of the invention is the use of the betaine esters 1 as surfactants. The surfactant properties of the betaine esters 1 can be determined by a number of tests including an ASTM foam height test and a test for critical micelle concentration.
[0039] The Standard Test Method for Foaming Properties of Surface-Active Agents (ASTM 1173-07) was used to determine the foaming properties of the betaine esters 1 described herein. This method generates foam under low-agitation conditions and is generally used for moderate- and high-foam surfactants. This test gathers data on initial foam height and foam decay. Foam decay provides information on foam stability.
[0040] The apparatus for carrying out this test includes a jacketed column and a pipet. The jacketed column serves as a receiver, while the pipet delivers the surface-active solution. Solutions of each surface-active agent were prepared. The betaine solution to be tested was added to the receiver (50 mL) and to the pipet (200 mL). The pipet was positioned above the receiver and opened. As the solution fell and made contact with the solution in the receiver, foam was generated. When the pipet was empty, the time was noted and an initial foam height was recorded. The foam height was recorded each minute for five minutes. Exact size specifications for the glassware can be found in ASTM 1173-07.
[0000]
TABLE 1
Foam height (cm) at time t (min)
1 g/L (0.1 weight %)
10 g/L (1.0 weight %)
t = 0
1
2
3
4
5
t = 0
1
2
3
4
5
Example
No.
4
9.0
9.0
9.0
9.0
9.0
9.0
16.5
16.5
16.0
16.0
16.0
16.0
5
15.0
14.0
14.0
13.5
13.5
13.5
17.0
16.5
16.0
15.5
15.5
15.0
6
16.0
15.5
15.5
15.5
15.5
15.5
15.0
15.0
15.0
15.0
15.0
15.0
8
14.0
13.5
13.5
13.5
13.0
13.0
17.0
16.0
15.5
15.5
15.0
15.0
9
15.5
15.0
15.0
14.5
14.5
14.0
17.0
16.0
15.5
15.5
15.5
15.0
11
10.0
10.0
10.0
10.0
9.5
9.5
21.0
19.5
19.0
19.0
18.5
18.5
Comparative
example no.
2
17.0
16.5
16.5
16.0
16.0
16.0
17.5
17.0
17.0
16.5
16.5
16.5
4
15.5
15.5
15.5
15.5
15.5
15.5
16.5
16.0
15.5
15.5
15.5
15.5
6
16.5
16.0
15.5
15.5
15.5
15.5
17.5
17.0
16.5
16.5
16.0
15.5
8
16.0
15.0
15.0
14.0
12.0
5.0
17.0
15.5
14.0
13.0
7.0
5.0
[0041] Data from the foam height test can be found in Table 1. Examples 4-6, 8, 9, and 11 are betaine esters, while Comparative Examples 2, 4, 6 and 8 are betaine amides for comparison. These compounds were prepared at 1 g/L and 10 g/L solutions. As the data in Table 1 indicate, solutions of the betaine esters generate large amounts of foam. Examples in which foam height does not decrease over time indicate good foam stability. Comparative Example 2 is a useful standard, in that this compound is used commercially as a betaine surfactant.
[0042] The critical micelle concentration (CMC) was also determined for each compound. The CMC is the concentration of surfactants above which micelles spontaneously form. CMC is an important characteristic of a surfactant. At surfactant concentrations below the CMC, surface tension varies widely with surfactant concentration. At concentrations above the CMC, surface tension remains fairly constant. A lower CMC indicates less surfactant is needed to saturate interfaces and form micelles. Typical CMC values for surface-active agents are less than 1 weight %.
[0043] The fluorimetric determination of CMC described by Chattopadhyay and London ( Analytical Biochemistry, 139, 408-412, 1984) was used to obtain the critical micelle concentrations found in Table 2. This method employs the fluorescent dye 1,6-diphenyl-1,3,5-hexatriene (DPH) in a solution of the surface-active agent. The analysis is based on differences in fluorescence upon incorporation of the dye into the interior of the micelles. As the solution exceeds CMC, a large increase in fluorescence intensity is observed. This method has been found to be sensitive and reliable, and has been demonstrated on zwitterionic, anionic, cationic and uncharged surface-active agents.
[0000]
TABLE 2
CMC
(weight %)
Example
No.
4
0.0050
5
0.0053
6
0.0007
8
0.0045
9
0.0023
11
0.0004
Comparative
Example No.
2
0.0029
4
0.0041
6
0.0025
8
0.0027
[0044] The data in Table 2 indicate that very low concentrations of the betaine esters are needed to reach CMC. Again, Examples 4-6, 8, 9, and 11 are betaine esters, while Comparative Examples 2, 4, 6 and 8 are betaine amides for comparison. As with foam height, all of these compounds appear similar. These values fall in the range of being useful as surface-active agents. As noted above, Comparative Example 2 is used commercially as a betaine surfactant and provides a reference point by which to compare values for the betaine esters 1.
[0045] The betaine esters are molecules possessing both hydrophilic and hydrophobic regions, making them useful as surfactants in a number of formulated product applications, including personal care products such as skin care, hair care or other cosmetic products, household and industrial surface cleaners, disinfectants, metal working, rust inhibitors, lubricants, agrochemicals, and dye dispersions. Betaines can also be used as emulsifiers and thickening agents in emulsions. Betaines are often formulated into products as secondary surface-active agents. Although a primary use is as humectants and foaming agents, betaines are also used for their anti-static and viscosity-controlling properties.
[0046] Such product formulations can contain from about 0.001 weight % to about 20 weight %, from about 0.01 weight % to about 15 weight %, or even from about 0.1 weight % to about 10 weight % of the betaine esters.
[0047] Product formulations of the invention may include other surfactants in addition to the betaine esters. These surfactants can include anionic surfactants (such as alcohol ether sulfates, linear alkylbenzene sulfonates, acyl isethionates), cationic surfactants (such as quaternary ammonium salts, fatty amine oxides, and ester quats), and non-ionic surfactants (such as alky polyglycosides, alcohol ethoxylates, and fatty alcanol amides). Such ingredients are known to those of skill in the art.
[0048] The cosmetic, skin, and hair care compositions of the invention may also contain other skin conditioning ingredients or cosmetically acceptable carriers in addition to the betaine esters.
[0049] Such formulations may also contain skin care ingredients/carriers such as retinol, retinyl esters, tetronic acid, tetronic acid derivatives, hydroquinone, kojic acid, gallic acid, arbutin, α-hydroxy acids, niacinamide, pyridoxine, ascorbic acid, vitamin E and derivatives, aloe, salicylic acid, benzoyl peroxide, witch hazel, caffeine, zinc pyrithione, and fatty acid esters of ascorbic acid. Such other ingredients are known to those of skill in the art.
[0050] Other ingredients that may be included in these formulations include conditioning agents (such as polyquaterniums and panthenol), pearlizing agents (such as glycol distearate, distearyl ether, and mica), UV filters (such as octocrylene, octyl methoxycinnamate, benzophenone-4, titanium dioxide, and zinc oxide), exfoliation additives (such as apricot seeds, walnut shells, polymer beads, and pumice), silicones (such as dimethicone cyclomethicone, and amodimethicone), moisturizing agents (such as petrolatum, sunflower oil, fatty alcohols, and shea butter), foam stabilizers (such as cocamide MEA and cocamide DEA), anti-bacterial agents such as triclosan, humectants such as glycerin, thickening agents (such as guar, sodium chloride, and carbomer), hair and skin damage repair agents (such as proteins, hydrolyzed proteins, and hydrolyzed collagen), and foam boosters such as cocamide MIPA. Such other ingredients are known to those of skill in the art.
[0051] Many preparations are known in the art, and include formulations containing acceptable carriers such as water, oils and/or alcohols and emollients such as olive oil, hydrocarbon oils and waxes, silicone oils, other vegetable, animal or marine fats or oils, glyceride derivatives, fatty acids or fatty acid esters or alcohols or alcohol ethers, lecithin, lanolin and derivatives, polyhydric alcohols or esters, wax esters, sterols, phospholipids and the like. These same general ingredients can be formulated into liquids (such as liquid soaps, shampoos, or body washes), creams, lotions, gels, or into solid sticks by utilization of different proportions of the ingredients and/or by inclusion of thickening agents such as gums or other forms of hydrophilic colloids.
EXAMPLES
[0052] The processes and compounds provided by the present invention are further illustrated by the following examples.
Example 1
Preparation of Methyl Cocoate
[0053] To a jar was added potassium hydroxide (1 g) and methanol (25 g). The solution was stirred for 1 hour. To a separate jar was added coconut oil (100 g). The solid was heated to a melt and the KOH/MeOH solution was added and the mixture was stirred overnight. The mixture was transferred to a separatory funnel and allowed to separate. The bottom (glycerol) layer was removed. The top layer was filtered to afford a pale yellow oil (100 g). 1 H NMR (300 MHz, CDCl 3 ) δ 3.65 (s, 3H), 2.28 (t, 2H), 1.60 (m, 2H), 1.24 (s, 16H), 0.86 (t, 3H).
Example 2
Preparation of Ethyl Cocoate
[0054] To a jar was added potassium hydroxide (2 g) and ethanol (72 g). The solution was stirred for 1 hour. To a separate jar was added coconut oil (200 g). The solid was heated to a melt and the KOH/EtOH solution was added and the mixture was stirred overnight. The mixture was transferred to a separatory funnel and allowed to separate. The bottom (glycerol) layer was removed. The top layer was filtered to afford a pale yellow oil (227 g). 1 H NMR (300 MHz, CDCl 3 ) δ 4.09 (t, 3H), 3.68 (q, 2H), 2.27 (t, 2H), 1.60 (m, 2H), 1.24 (s, 16H), 0.86 (t, 3H).
Example 3
Preparation of Dimethylaminoethyl Cocoate
[0055] To a 50 mL conical bottom plastic vial was added ethyl cocoate (10 g, 38.5 mmol), dimethylaminoethanol (5.09 g, 57.7 mmol, 1.5 eq) and Novozym 435 (400 mg). A syringe was inserted through the cap and two additional holes were punched for gas to exit. Nitrogen was bubbled at a rate sufficient to mix the contents. The vial was placed in a heating block set to 65° C. The reaction was monitored by GC/MS to observe the disappearance of starting material. The reaction was complete after approximately 24 hours. The reaction mixture was allowed to cool. The Novozym 435 was removed by filtration to afford the product as a pale yellow oil (8 g) without further purification. 1 H NMR (300 MHz, CDCl 3 ) δ 4.15 (t, 2H), 2.54 (t, 2H), 2.31 (t, 2H), 2.26 (s, 6H), 1.60 (m, 2H), 1.24 (s, 16H), 0.86 (t, 3H).
Example 4
Preparation of Dimethylaminoethyl Cocoate Betaine
[0056] To a 100 mL round bottom flask with a magnetic stir bar and a condenser was added dimethylaminoethyl cocoate (10 g, 35.3 mmol), sodium chloroacetate (4.11 g, 35.3 mmol, 1 eq) and water (32.9 g). The reaction mixture was heated at 98° C. for 8 hours. The pH was kept basic by the addition of 50% NaOH. When the reaction was complete, the mixture was neutralized with 1 M HCl and allowed to cool. The reaction mixture was filtered to afford the product as a 30% aqueous solution (43 g). 1 H NMR (300 MHz, DMSO d-6) δ 3.89 (t, 2H), 3.78 (t, 2H), 3.66 (s, 2H), 3.17 (s, 6H), 2.27 (t, 2H), 1.51 (m, 2H), 1.23 (s, 16H), 0.85 (t, 3H).
Example 5
Preparation of Dimethylaminoethyl Cocoate Betaine
[0057] To a 100 mL round bottom flask with a magnetic stir bar and a condenser was added dimethylaminoethyl cocoate (10 g, 35.3 mmol), sodium chloroacetate (4.11 g, 35.3 mmol, leg) and 1,3-propanediol (4.7 g). The reaction mixture was heated at 98° C. for 8 hours. When the reaction was complete by NMR, the mixture was allowed to cool. The mixture was filtered to afford the product as a viscous, 75% solution in 1,3-propanediol (14 g). 1 H NMR (300 MHz, DMSO d-6) δ 3.89 (t, 2H), 3.78 (t, 2H), 3.66 (s, 2H), 3.17 (s, 6H), 2.27 (t, 2H), 1.51 (m, 2H), 1.23 (s, 16H), 0.85 (t, 3H).
Example 6
Preparation of Dimethylaminoethyl Cocoate Betaine
[0058] To a 100 mL round bottom flask with a magnetic stir bar and a condenser was added dimethylaminoethyl cocoate (10 g, 35.3 mmol), sodium chloroacetate (4.11 g, 35.3 mmol, 1 eq) and isopropanol (15 mL). The reaction mixture was heated at reflux for 8 hours. When the reaction was complete by NMR, the mixture was allowed to cool. The mixture was filtered and isopropanol was removed in vacuo to afford the product as a viscous, semi-solid (13 g). 1 H NMR (300 MHz, DMSO d-6) δ 3.89 (t, 2H), 3.78 (t, 2H), 3.66 (s, 2H), 3.17 (s, 6H), 2.27 (t, 2H), 1.51 (m, 2H), 1.23 (s, 16H), 0.85 (t, 3H).
Example 7
Preparation of Dimethylaminopropyl Cocoate
[0059] To a 50 mL conical bottom plastic vial was added ethyl cocoate (10 g, 38.5 mmol), dimethylaminopropanol (4.76 g, 46.2 mmol, 1.2 eq) and Novozym 435 (400 mg). A syringe was inserted through the cap and two additional holes were punched for gas to exit. Nitrogen was bubbled at a rate sufficient to mix the contents. The vial was placed in a heating block set to 65° C. The reaction was monitored by GC/MS to observe the disappearance of starting material. The reaction was complete after approximately 24 hours. The reaction mixture was allowed to cool. The Novozym 435 was removed by filtration to afford the product as a pale yellow oil (9.2 g) without further purification. 1 H NMR (300 MHz, CDCl 3 ) δ 4.10 (t, 2H), 2.30 (m, 4H), 2.21 (s, 6H), 1.78 (t, 2H), 1.60 (m, 2H), 1.24 (s, 16H), 0.86 (t, 3H).
Example 8
Preparation of Dimethylaminopropyl Cocoate Betaine
[0060] To a 100 mL round bottom flask with a magnetic stir bar and a condenser was added dimethylaminopropyl cocoate (10 g, 35 mmol), sodium chloroacetate (4.1 g, 35 mmol, 1 eq) and 1,3-propanediol (14.1 g). The reaction mixture was heated at 98° C. for 8 hours. When the reaction was complete by NMR, the mixture was allowed to cool. The mixture was filtered to afford the product as a 50% solution in 1,3-propanediol (27 g). 1 H NMR (300 MHz, CDCl 3 ) δ 4.16 (t, 2H), 3.92 (t, 2H), 3.67 (t, 2H), 3.28 (s, 6H), 2.34 (q, 2H), 2.10 (t, 2H), 1.60 (m, 2H), 1.26 (s, 16H), 0.88 (t, 3H).
Example 9
Preparation of Dimethylaminopropyl Cocoate Betaine
[0061] To a 100 mL round bottom flask with a magnetic stir bar and a condenser was added dimethylaminopropyl cocoate (10 g, 35.3 mmol, 1 eq), sodium chloroacetate (4.11 g, 35.3 mmol, leg) and isopropanol (15 mL). The reaction mixture was heated at reflux for 8 hours. When the reaction was complete by NMR, the mixture was allowed to cool. The mixture was filtered and isopropanol was removed in vacuo to afford the product as a viscous, semi-solid (14 g). 1 H NMR (300 MHz, CDCl 3 ) δ 4.16 (t, 2H), 3.92 (t, 2H), 3.67 (t, 2H), 3.28 (s, 6H), 2.34 (q, 2H), 2.10 (t, 2H), 1.60 (m, 2H), 1.26 (s, 16H), 0.88 (t, 3H).
Example 10
Preparation of Dimethylamino-2-methylethyl Cocoate
[0062] To a 50 mL conical bottom plastic vial was added ethyl cocoate (10 g, 38.5 mmol), dimethylamino-2-methylpropanol (5.95 g, 57.7 mmol, 1.5 eq) and Novozym 435 (400 mg). A syringe was inserted through the cap and two additional holes were punched for gas to exit. Nitrogen was bubbled at a rate sufficient to mix the contents. The vial was placed in a heating block set to 65° C. The reaction was monitored by GC/MS to observe the disappearance of starting material. The reaction was complete after approximately 24 hours. The reaction mixture was allowed to cool. The Novozym 435 was removed by filtration to afford the product as a pale yellow oil (7 g) without further purification. 1 H NMR (300 MHz, CDCl 3 ) δ 5.01 (m, 1H), 2.61 (t, 2H), 2.31 (t, 2H), 2.29 (m, 7H), 1.60 (m, 2H), 1.24 (m, 19H), 0.86 (t, 3H).
Example 11
Preparation of Dimethylamino-2-methylethyl Cocoate Betaine
[0063] To a 100 mL round bottom flask with a magnetic stir bar and a condenser was added dimethylamino-2-methylethyl cocoate (5.6 g, 18.8 mmol), sodium chloroacetate (2.18 g, 18.8 mmol, 1 eq) and water (7.8 g). The reaction mixture was heated at 98° C. for 8 hours. The pH was kept basic by the addition of 50% NaOH. When the reaction was complete, the mixture was neutralized with 1 M HCl and allowed to cool. The reaction mixture was filtered to afford the product as a 50% solution in water (14 g). 1 H NMR (300 MHz, DMSO d-6) δ 4.96 (m, 1 H), 3.89 (t, 2H), 3.66 (s, 2H), 3.17 (s, 6H), 2.27 (t, 2H), 1.51 (m, 2H), 1.23 (m, 19H), 0.85 (t, 3H).
Comparative Example 1
Preparation of Dimethylaminopropyl Cocoamide
[0064] To a 50 mL conical bottom plastic vial was added ethyl cocoate (10 g, 38.5 mmol), dimethylaminopropylamine (5.9 g, 57.7 mmol, 1.5 eq) and Novozym 435 (400 mg). A syringe was inserted through the cap and two additional holes were punched for gas to exit. Nitrogen was bubbled at a rate sufficient to mix the contents. The vial was placed in a heating block set to 65° C. The reaction was monitored by GC/MS to observe the disappearance of starting material. The reaction was complete after approximately 24 hours. The reaction mixture was allowed to cool. The Novozym 435 was removed by filtration to afford the product as a pale yellow oil (8.9 g) without further purification. 1 H NMR (300 MHz, CDCl 3 ) δ 7.02 (s, 1 H), 3.28 (m, 2H), 2.32 (m, 2H), 2.18 (s, 6H), 2.10 (t, 2H), 1.59 (m, 4H), 1.21 (s, 16H), 0.84 (t, 3H).
Comparative Example 2
Preparation of Dimethylaminopropyl Cocoamide Betaine
[0065] To a 100 mL round bottom flask with a magnetic stir bar and a condenser was added dimethylaminopropyl cocoamide (10 g, 35 mmol), sodium chloroacetate (4.1 g, 35 mmol, 1 eq) and water (14.7 g). The reaction mixture was heated at 98° C. for 8 hours. The pH was kept basic by the addition of 50% NaOH. When the reaction was complete, the mixture was neutralized with 1 M HCl and allowed to cool. The reaction mixture was filtered to afford the product as a 45% solution in water (33 g). 1 H NMR (300 MHz, DMSO d-6) δ 8.07 (s, 1 H), 3.59 (s, 2H), 3.45 (m, 2H), 3.08 (s, 6H), 3.05 (m, 2H), 2.04 (t, 2H), 1.76 (m, 2H), 1.44 (m, 2H), 1.19 (s, 16H), 0.81 (t, 3H).
Comparative Example 3
Preparation of Diethylaminopropyl Cocoamide
[0066] To a 50 mL conical bottom plastic vial was added ethyl cocoate (10 g, 38.5 mmol), diethylaminopropylamine (7.52 g, 57.7 mmol, 1.5 eq) and Novozym 435 (400 mg). A syringe was inserted through the cap and two additional holes were punched for gas to exit. Nitrogen was bubbled at a rate sufficient to mix the contents. The vial was placed in a heating block set to 65° C. The reaction was monitored by GC/MS to observe the disappearance of starting material. The reaction was complete after approximately 24 hours. The reaction mixture was allowed to cool. The Novozym 435 was removed by filtration to afford the product as a pale yellow oil (11 g) without further purification. 1 H NMR (300 MHz, CDCl 3 ) δ 7.45 (s, 1 H), 3.29 (m, 2H), 2.47 (m, 6H), 2.08 (m, 2H), 1.58 (m, 4H), 1.23 (s, 16H), 0.99 (m, 6H), 0.84 (t, 3H).
Comparative Example 4
Preparation of Diethylaminopropyl Cocoamide Betaine
[0067] To a 100 mL round bottom flask with a magnetic stir bar and a condenser was added diethylaminopropyl cocoamide (5 g, 16 mmol), sodium chloroacetate (1.85 g, 16 mmol, 1 eq) and water (5.85 g). The reaction mixture was heated at 98° C. for 8 hours. The pH was kept basic by the addition of 50% NaOH. When the reaction was complete, the mixture was neutralized with 1 M HCl and allowed to cool. The reaction mixture was filtered to afford the product as a 38% solution in water (11 g). 1 H NMR (300 MHz, DMSO d-6) δ 8.05 (s, 1 H), 3.58 (s, 2H), 3.06 (q, 2H), 2.86 (m, 6H), 2.04 (t, 2H), 1.68 (m, 2H), 1.44 (m, 2H), 1.20 (s, 16H), 1.10 (t, 6H), 0.82 (t, 3H).
Comparative Example 5
Preparation of Dimethylaminoethyl Cocoamide
[0068] To a 50 mL conical bottom plastic vial was added ethyl cocoate (10 g, 38.5 mmol), dimethylaminoethylamine (5.09 g, 57.7 mmol, 1.5 eq) and Novozym 435 (400 mg). A syringe was inserted through the cap and two additional holes were punched for gas to exit. Nitrogen was bubbled at a rate sufficient to mix the contents. The vial was placed in a heating block set to 65° C. The reaction was monitored by GC/MS to observe the disappearance of starting material. The reaction was complete after approximately 24 hours. The reaction mixture was allowed to cool. The Novozym 435 was removed by filtration to afford the product as a pale yellow oil (8.6 g) without further purification. 1 H NMR (300 MHz, CDCl 3 ) δ 6.25 (s, 1 H), 3.25 (m, 2H), 2.34 (t, 2H), 2.16 (s, 6H), 2.10 (t, 2H), 1.54 (m, 2H), 1.18 (s, 16H), 0.80 (t, 3H).
Comparative Example 6
Preparation of Dimethylaminoethyl Cocoamide Betaine
[0069] To a 100 mL round bottom flask with a magnetic stir bar and a condenser was added dimethylaminoethyl cocoamide (8 g, 28.3 mmol), sodium chloroacetate (3.3 g, 28.3 mmol, 1 eq) and water (11 g). The reaction mixture was heated at 98° C. for 8 hours. The pH was kept basic by the addition of 50% NaOH. When the reaction was complete, the mixture was neutralized with 1 M HCl and allowed to cool. The reaction mixture was filtered to afford the product as a 50% solution in water (21 g). 1 H NMR (300 MHz, DMSO d-6) δ 8.33 (t, 1H), 3.65 (s, 2H), 3.61 (m, 2H), 3.42 (q, 2H), 3.14 (s, 6H), 2.06 (t, 2H), 1.45 (m, 2H), 1.20 (s, 16H), 0.83 (t, 3H).
Comparative Example 7
Preparation of Diethylaminoethyl Cocoamide
[0070] To a 50 mL conical bottom plastic vial was added ethyl cocoate (10 g, 38.5 mmol), diethylaminoethylamine (6.71 g, 57.7 mmol, 1.5 eq) and Novozym 435 (400 mg). A syringe was inserted through the cap and two additional holes were punched for gas to exit. Nitrogen was bubbled at a rate sufficient to mix the contents. The vial was placed in a heating block set to 65° C. The reaction was monitored by GC/MS to observe the disappearance of starting material. The reaction was complete after approximately 24 hours. The reaction mixture was allowed to cool. The Novozym 435 was removed by filtration to afford the product as a pale yellow oil (10.2 g) without further purification. 1 H NMR (300 MHz, CDCl 3 ) δ 6.21 (s, 1 H), 3.32 (m, 2H), 2.56 (m, 6H), 2.21 (m, 2H), 1.65 (m, 2H), 1.29 (s, 16H), 1.04 (m, 6H), 0.92 (t, 3H).
Comparative Example 8
Preparation of Diethylaminoethyl Cocoamide Betaine
[0071] To a 100 mL round bottom flask with a magnetic stir bar and a condenser was added diethylaminoethyl cocoamide (5 g, 16.7 mmol), sodium chloroacetate (1.94 g, 16.7 mmol, 1 eq) and water (14.7 g). The reaction mixture was heated at 98° C. for 8 hours. The pH was kept basic by the addition of 50% NaOH. When the reaction was complete, the mixture was neutralized with 1 M HCl and allowed to cool. The reaction mixture was filtered to afford the product as a 38% solution in water (18 g). 1 H NMR (300 MHz, DMSO d-6) δ 8.01 (s, 1 H), 3.54 (s, 2H), 3.20 (q, 2H), 2.70 (m, 6H), 2.04 (t, 2H), 1.45 (t, 2H), 1.21 (s, 16H), 1.03 (t, 6H), 0.83 (t, 3H).
Comparative Example 9
Preparation of Dimethylaminopropyl Cocoate (Transesterification)
[0072] To a 100 mL flask fitted with a distillation head and condenser was added methyl cocoate (10 g, 0.0467 mol) and dimethylaminopropanol (5.77 g, 0.0561 mol, 1.2 eq). To the mixture was added stannous oxalate (0.103 g, 1 mol %). The flask was heated to 100° C. slowly over 1 hour. Over several hours the temperature was increased to 130° C. The reaction was monitored by GC/MS. Methanol was collected in the receiver (ca. 1 mL). The reaction was allowed to cool to room temperature. The mixture was filtered to afford the product as a golden oil (10 g). 1 H NMR (300 MHz, CDCl 3 ) δ 7.02 (s, 1H), 3.28 (m, 2H), 2.32 (m, 2H), 2.18 (s, 6H), 2.10 (t, 2H), 1.59 (m, 2H), 1.21 (s, 16H), 0.84 (t, 3H).
Comparative Example 10
Preparation of Coconut Fatty Acid
[0073] To a 2 L flask was added coconut oil (100 g), methanol (435 mL) and water (307 mL). To this mixture was added 45% potassium hydroxide (88 g). The solution was heated at 45° C. overnight. The reaction was monitored by GC/MS. When the reaction was complete, the mixture was allowed to come to room temperature. To the flask was added methanol (275 mL) and heptane (200 mL). The mixture was stirred and transferred to a separatory funnel. The aqueous layer was returned to the 2 L flask. The organic layer was discarded. To the flask was added water (50 mL). The pH was brought to 1 with the addition of concentrated HCl (ca. 70 mL). The mixture was stirred well and transferred to a separatory funnel. The aqueous layer was removed. The organic layer was dried over MgSO 4 and concentrated in vacuo to afford the product as a yellow oil (80 g). 1 H NMR (300 MHz, CDCl 3 ) δ 11.68 (s, 1H), 2.36 (t, 2H), 1.65 (m, 2H), 1.28 (s, 16H), 0.90 (t, 3H).
Comparative Example 11
Preparation of Dimethylaminopropyl Cocoate (Direct Esterification)
[0074] To a 100 mL flask fitted with a distillation head and condenser was added coconut fatty acid (10 g, 0.05 mol,) and dimethylaminopropanol (6.18 g, 0.06 mol, 1.2 eq). The flask was heated to 40° C. (under nitrogen) to melt the fatty acid. To the molten mixture was added stannous oxalate (0.103 g, 1 mol %). The flask was heated to 100° C. slowly over 1 hour. Over several hours the temperature was increased to 150° C. The reaction was monitored by GC/MS. Water was collected in the receiver (ca. 1 mL). The reaction mixture was allowed to cool to room temperature. The mixture was diluted with diethyl ether and washed with saturated sodium bicarbonate solution. The organic layer was dried and concentrated in vacuo to afford the product as a yellow oil (2.6 g). 1 H NMR (300 MHz, CDCl 3 ) δ 7.02 (s, 1 H), 3.28 (m, 2H), 2.32 (m, 2H), 2.18 (s, 6H), 2.10 (t, 2H), 1.59 (m, 2H), 1.21 (s, 16H), 0.84 (t, 3H)
[0075] The invention has been described in detail with particular reference to preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
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A variety of betaine esters, including dial kylaminoalkyl cocoate betaines. These betaines were advantageously prepared in high yield and purity by a three-step chemoenzymatic process. These betaine esters have excellent surfactant properties.
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This invention relates to novel structural analogs of corosolic acid having anti-diabetic and anti-inflammatory properties. These compounds are found to exhibit potent hypoglycemic, 5-lipoxygenase inhibitory and antitumor activities.
TECHNICAL FIELD
Diabetes is perceived as a disorder of metabolism, where body's natural ability to utilize food that has been broken down by digestion is vitiated. The body utilizes glucose, a major metabolic product from food, for energy and for cell growth. Glucose disperses throughout the body through the blood stream and enters cells with the help of a hormone called insulin. Insulin is produced by pancreas, a large gland beneath the stomach. In people with diabetes mellitus, either the pancreas does not produce enough insulin to move the glucose into the cells or the cells do not respond to the insulin, even though plenty is produced (Reaven, G. M., Role of insulin resistance in human disease; Diabetes, 1998, 37, 1595-1607). As a result of this impairment, glucose builds up in the blood stream and excreted out of the body without ever having been used as fuel.
Untreated diabetes can lead to very serious chronic problems, including heart disease, kidney failure, blindness, nerve damage and amputations (Porte, D. et al., Science, 1996, 27, 699-700). Many experts believe that diabetes, cardiovascular disease and obesity all have a common factor linked by a condition called insulin resistance also known as Syndrome X (Bagchi, D., Syndrome X, The Diabetes, CVD and Obesity link, Health Products Business, June 2001, 62). But with proper management, the risk of such problems can be greatly reduced. The management plan depends on the type of diabetes: insulin-dependent diabetes mellitus (IDDM) or noninsulin-dependent diabetes mellitus (NIDDM).
BACKGROUND ART
There are a number of agents currently available in the market for diabetes management, which belongs to various structural types. For example, thiazolidinediones, sulfonyl ureas, alpha-glucosidase inhibitors and biguanides are some of the drug types currently available in the market. According to the American Diabetes Association, diabetes mellitus is estimated to effect 6% of the world population and the recent studies indicate that the number of diabetic patients could rise to 300 million by 2025. Worldwide sales of antidiabetic drugs reached 10 billion US dollars in 2002. Oral antidiabetics accounted for 63% of these sales and glucophase (metformin) was the leading product. With rising number of people suffering from diabetes worldwide, the market for diabetes medications could exceed $20 billion by 2006. In the natural products arena, a handful of herbal medications were proven to be effective against this terrible menace. For example, Fenugreek ( Trigonella foenumgraecum ), Gymnema ( Gymnema sylvestre ), Jamun/Jambolan ( Syzygium cumini ), Bitter melon/Karela ( Momordica charantia ) and Banaba ( Lagerstroemia speciosa ) are some of the products known to show hypoglycemic activity. Natural antidiabetic treatments have gained popularity in the recent years because of their proven safety from long history of usage in traditional medicine and also present usage in herbal treatments. Banaba, Lagerstroemia speciosa L, has gotten the worldwide attention in the past few years as organic insulin. It is widely distributed in Philippines, as well as in Malaysia, South China and tropical Australia. Corosolic acid or colosolic acid (2α-hydroxyursolic acid, CAS No. 4547-24-4), a triterpenoid compound isolated from the banaba extract was found to be responsible for the antidiabetic activity. Banaba has long been recognized for the treatment of diabetes and also for maintenance of low blood pressure and improved kidney function in Philippines and other East Asian countries. Clinical studies confirmed the hypoglycemic effects of corosolic acid (Judy, W. V. et. al., J. Ethnopharmacol., 2003, 87(1), 115-7). Indian species of Lagerstroemia ( Lagerstroemia parviflora, Lagerstroemia indica, Lagerstroemia speciosa , etc), which grows along east coast from Orissa to West Bengal, also produce corosolic acid. Matsuyama, U.S. Pat. No. 6,485,760 (2002) described the blood sugar lowering effect of Lagerstroemia extract.
Presently, there has been a tremendous surge in the demand for non-steroidal, plant based anti-inflammatory agents. 5-Lipoxygenase is the key enzyme for the biosynthesis of leukotrienes and 5(S)-HETE, the important mediators, for inflammatory, allergic and obstructive process, from arachidonic acid. 5-Lipoxygenase is the target enzyme for identifying inhibitors, which have the potential to cope with a variety of inflammations and hypersensitivity-based human diseases including asthma, arthritis, bowl diseases such as ulcerative colitis and circulatory disorders such as shock and ischaemia. Scientists around the world have invested major effort during the last ten years, in identifying 5-lipoxygenase inhibitors from plant sources. Gum resin of Boswellia species known as Indian frankincense has been used as an anti-inflammatory agent in traditional Ayurvedic Medicine in India. The source of anti-inflammatory actions has been attributed to boswellic acids (Safayhi, H., et al., Planta Medica, 1997, 63, 487-493 and J. Pharmacol. Exp. Ther., 1992, 261, 1143-46, both the journals published from USA), a group of triterpene acids isolated from the Boswellia resin (Padhy, R. S., et al., Indian J. Chem., 1978, 16B, 176-178). During our search for new anti-inflammatory agents, we have observed, to the best of our knowledge for the first time that corosolic acid is a potential inhibitor of 5-LOX. The inhibitory activity was found to be on par with 3-O-acetyl-11-keto-β-boswellic acid (AKBA).
The olenane and ursane triterpenoids also gained prominence recently for their antiproliferative actions. As 5-lipoxygenase (5-LOX) is the first enzyme in the metabolic pathway leading to the formation of leukotrienes and eicosanoids that are important in carcinogenesis process, inhibitors of 5-LOX may thus have profound influence on the growth and apoptosis of various cancer lines (Yong S. Park, et. al., Planta Medica, 2002, 68, 397-401). Boswellic acids, for example inhibited several leukemia cell lines in vitro and inhibited melanoma growth and induced apoptosis (Hostanska, K., et. al., Anticancer Res., 2002, 22(5), 2853-62). The acetyl boswellic acids were found to be unique class of dual inhibitors of human topoisomerages I and II α (Syrovets, T. et. al., Mol. Pharmacol., 2000, 58(1), 71-81). A number of oleanane and ursane tripenoids were found to be powerful inhibitors of nitric oxide production in macrophases, which can be correlated to their cancer chemoprevention activity (Honda, T. et. al., J. Med. Chem., 2000, 43, 1866-77). Corosolic acid, which has the gross structure very similar to AKBA and other ursane derivatives, may thus hold promise as an antitumor agent.
OBJECTS OF THE INVENTION
The present invention was aimed at producing novel analogs of corosolic acid for structure-activity relationship studies. The main objective was to make analogs with enhanced water solubility and increased hypoglycemic activity. The functional groups that can be expended to make new analogs are carboxyl group, trisubstituted double bond and vicinal diol. The hydroxyl groups found utility to couple with moieties like natural acids and aminoacids, which not only improves water solubility but also presumed to enhance the biological recognition to the parent compound in the transport process.
The acid function was utilized to attach highly polar amine moieties through an amide linkage. The same group can also be utilized to make ester compounds by reacting with alcohols or halides. The lower alkyl esters can be reduced with LAH (lithium aluminum hydride) to introduce an additional alcohol group as depicted in structure 23. Oxidizing agents suitable for allylic oxidation, such as chromium trioxide can be utilized to generate 11-ketocorosolic acid compounds. Allylic oxidation using NBS (N-bromosucinimide) however yielded a lactone 26. The acylation transformation can be controlled to yield monoacylated compounds or diacylated compound by limiting the quantities of acylating agent. The general strategy to attach amino acid unit was coupling of BOC (tert-butoxycarbonyl) protected amino acids like glycine and alanine etc. to corosolic acid using DCC (1,3-dicyclohexylcarbodiimide), DMAP [4-(dimethylamino)-pyridine] followed by deprotection of BOC group using HCl/dioxane to yield glycyl and alanyl derivatives, respectively, of corosolic acid.
SUMMARY OF THE INVENTION
This invention relates to a novel structural analogs of corosolic acid having the general formula I
wherein R 1 , R 2 , R 3 , R 4 and R 5 are as indicated below in each of said analogs:
1. R 1 =COCH 3 , R 2 =R 3 =R 4 =H, R 5 =COOH or R 1 =R 3 =R 4 =H, R 2 =COCH 3 , R 5 =COOH 2. R 1 =R 2 =COCH 3 , R 3 =R 4 =H, R 5 =COOH 3. R 1 =COC 5 H 4 N, R 2 =R 3 =R 4 =H, R 5 =COOH 4. R 1 =COCH 2 NH 2 .HCl, R 2 =R 3 =R 4 =H, R 5 =COOH 5. R 1 =COCH(CH 3 )NH 2 .HCl, R 2 =R 3 =R 4 =H, R 5 =COOH 6. R 1 =COCH:CHC 6 H 2 (OCH 3 ) 3 , R 2 =R 3 =R 4 =H, R 5 =COOCH 3 7. R 1 & R 2 =SO 2 , R 3 =R 4 =H, R 5 =COOH 8. R 1 =R 2 =R 3 =R 4 =H, R 5 =CONH 2 9. R 1 =R 2 =R 3 =R 4 =H, R 5 =CONHC 6 H 5 10. R 1 =R 2 =R 3 =R 4 =H, R 5 =CONHCH 2 CH 2 NH 2 11. R 1 =R 2 =R 3 =R 4 =H, R 5 =CON(CH 2 CH 2 ) 2 NH 12. R 1 =R 2 =R 3 =R 4 =H, R 5 =CONHCH 2 CH 2 OH 13. R 1 =R 2 =R 3 =R 4 =H, R 5 =COOCH 3 14. R 1 =R 2 =COCH 3 , R 3 =R 4 =H, R 5 =COOCH 3 15. R 1 =R 2 =H, R 3 & R 4 =O, R 5 =COOCH 3 16. R 1 =R 2 =COCH 3 , R 3 & R 4 =O, R 5 =COOCH 3 17. R 1 =R 2 =H, R 3 & R 4 =O, R 5 =COOH 18. R 1 =R 2 =COCH 3 , R 3 & R 4 =O, R 5 =COOH 19. R 1 & R 2 =SO 2 , R 3 & R 4 =O, R 5 =COOH 20. R 1 =R 2 =H, R 3 & R 4 =O, R 5 =CONH 2 21. R 1 =R 2 =R 3 =H, R 4 =OH, R 5 =CONH 2 22. R 1 =R 2 =R 3 =H, R 4 =OH, R 5 =COOCH 3 23. R 1 =R 2 =R 3 =R 4 =H, R 5 =CH 2 OH 24. R 1 =R 2 =R 3 =R 4 =H, R 5 =CHO 25. R 1 =R 2 =R 3 =R 4 =H, R 5 =COOCOC 6 H 2 (OCH 3 ) 3 26. R 1 =R 2 =R 3 =H, R 4 & R 5 =OCO
BRIEF DISCLOSURE OF THE INVENTION
Identification of corosolic acid analogs having the above substituents and establishing their potent antidiabetic and anti-inflammatory action have been achieved by the applicants.
The corosolic acid (purity >95%) used in this study was obtained from the leaves of Lagerstroemia speciosa , using solvent extraction, chromatography over silica gel column and crystallization.
A further aspect of the present invention is a pharmaceutical formulation comprising a compound as described above in a pharmaceutically acceptable carrier (e.g., an aqueous or a non aqueous carrier).
A still further aspect of the present invention is a method of treating diabetes, comprising administering to a human or animal subject in need thereof a treatment effective amount (e.g., an amount effective to treat, slow the progression of, etc.) of a compound as described above.
The pharmaceutical compositions of the “compound” as used herein, includes the pharmaceutically acceptable salts of the compound. Pharmaceutically acceptable salts are salts that retain the desired biological activity of the parent compound and do not impart undesired toxicological effects. Examples of such salts are (a) base addition salts formed from metal hydroxides, NH 4 OH, alkyl amines, pharmaceutically useful amine compounds etc. (b) acid addition salts formed with inorganic acids, for example hydrochloric acid, hydrobromic acid, sulfuric acid, phosphoric acid etc. on amine compounds represented by the formula I.
Active compounds of the present invention may be produced by the procedures described herein or variations thereof, which will be apparent to those skilled in the art. The intermediates useful for producing the compounds of the formula I, described herein are also an aspect of the present invention, as are methods useful for producing such intermediates and active compounds.
DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention is explained in greater detail in the following non-limiting examples.
Example 1
2-O-Acetylcorosolic acid and 3-O-acetylcorosolic acid (1): To an ice cold solution of corosolic acid (500 mg, 1.06 mmol) in pyridine (0.75 mL, 9.7 mmol) was added slowly acetic anhydride (0.1 mL) and continued the stirring for 2 h. The mixture was poured into crushed ice and vigorously stirred. The solid was filtered, washed with water, dried and subjected to silica gel column chromatography using hexane-ethyl acetate (10%) mixture as eluent to furnish a white solid (220 mg); IR (KBr): 3434, 2927, 2863, 1722, 1695, 1456, 1256, 1030 cm −1 ; It is a mixture of 3-O-acetyl and 2-O-acetyl derivatives in the ratio 1:2.7. NMR data corresponds to major product (2-O-acetyl derivative); 1 H NMR (400 MHz, CDCl 3 ) δ 0.78 (3H, s, CH 3 ), 0.84 (3H, d, J=6.0 Hz, CH 3 ), 0.86 (6H, s, 2×CH 3 ), 0.95 (3H, d, J=4.8 Hz, CH 3 ), 1.06 (3H, s, CH 3 ), 1.08 (3H, s, CH 3 ), 2.06 (3H, s, —COCH 3 ), 2.20 (1H, d, J=11.3 Hz, H-18), 3.20 (1H, d, J=10.0 Hz, H-3), 4.92-4.98 (1H, m, H-2), 5.24 (1H, br s, H-12); NMR data corresponds to minor product (3-O-acetyl derivative): 2.14 (s, —COCH 3 ), 3.78-3.82 (m, H-2), 4.50 (d, J=10.0 Hz, H-3), 5.24 (br s, H-12); LCMS (negative ion mode): m/z 513 (M−H) − .
3-O-Acetylcorosolic acid: IR (KBr): 3442, 2933, 2869, 1729, 1696, 1629, 1456, 1374, 1253, 1038 cm −1 ; LCMS (negative ion mode): m/z 513 (M−H) − .
Example 2
2,3-Di-O-acetylcorosolic acid (2): To a solution of corosolic acid (800 mg) in pyridine (5 mL) was added acetic anhydride (5 mL) and kept at rt for 16 h. The reaction mixture was worked up under the conditions noted in example 1, to give the diacetate, 2 (650 mg, 69%), m.p. 236-240° C.; IR (KBr): 3448, 2944, 2873, 1743, 1698, 1455, 1371, 1250, 1038, 962 cm −1 ; 1 H NMR (400 MHz, CDCl 3 ) δ 0.77 (3H, s, CH 3 ), 0.85 (3H, d, J=6.3 Hz, CH 3 ), 0.90 (6H, s, 2×CH 3 ), 0.95 (3H, d, J=5.9 Hz, CH 3 ), 1.07 (6H, s, 2×CH 3 ), 1.97 (3H, s, —COCH 3 ), 2.05 (3H, s, —COCH 3 ), 2.19 (1H, d, J=11.2 Hz, H-18), 4.75 (1H, d, J=10.3 Hz, H-3), 5.07-5.13 (1H, m, H-2), 5.24 (1H, br s, H-12); LCMS (negative ion mode): m/z 555 (M−H) − .
Example 3
2-O-Nicotinoylcorosolic acid (3): To a mixture of corosolic acid (250 mg, 0.53 mmol), nicotinic acid (200 mg, 1.62 mmol) and DMAP (catalytic) in acetonitrile (50 mL) was added DCC (400 mg, 1.94 mmol) and stirred at rt for 24 h. The solids were filtered off and the solvent was evaporated. The residue was chromatographed over silica gel column using chloroform-methanol (20%) as eluent to furnish 2-O-nicotinoylcorosolic acid (33 mg, 11%), which was crystallised from chloroform-hexane, m.p. 212-216° C.; IR (KBr): 3434, 2928, 2871, 1722, 1594, 1456, 1288, 1132, 955 cm −1 ; 1 H NMR (400 MHz, CDCl 3 ) δ 0.81 (3H, s, CH 3 ), 0.84 (3H, d, J=6.3 Hz, CH 3 ), 0.92 (3H, s, CH 3 ), 0.95 (3H, d, J=6.3 Hz, CH 3 ), 1.11 (6H, s, 2×CH 3 ), 1.12 (3H, s, CH 3 ), 3.39 (1H, d, J=9.9 Hz, H-3), 5.24-5.27 (1H, br s, H-12), 7.37-7.41 (1H, m, Ar—H), 8.29 (1H, d, J=7.7 Hz, Ar—H), 8.78 (1H, d, J=3.5 Hz, Ar—H), 9.22 (1H, s, Ar—H); LCMS (negative ion mode): m/z 576 (M−H) − .
Example 4
2-O-Glycylcorosolic acid hydrochloride (4): A mixture of corosolic acid (200 mg, 0.42 mmol), BOC protected glycine (82 mg, 0.47 mmol) and DMAP (30 mg) in dry dioxane (2 mL) at 0° C. was treated with DCC (130 mg, 0.63 mmol) under vigorous stirring. After 3 h, the reaction mixture was worked up as described in example 3, to give 2-O—(N—BOC-glycyl)corosolic acid (200 mg).
A solution of 2-(N—BOC-glycyl)corosolic acid (200 mg) in CH 2 Cl 2 (2 mL) was cooled to 0° C. and treated slowly with 2 mL of 1 N HCl in dioxane. After 30 min, the stirring was continued at rt for another 2 h. The reaction mixture was diluted with hexane (5 mL) and the precipitated solid was filtered, washed with hexane and dried to afford a white powder of 2-O-glycylcorosolic acid hydrochloride (190 mg), m.p. 268-272° C.; IR (KBr): 3432, 2979, 2926, 2859, 1749, 1690, 1461, 1243, 1050 cm −1 ; 1 H NMR (400 MHz, CD 3 OD) δ 0.82-1.14 (7×CH 3 ), 2.2 (1H, brd, J=10.0 Hz), 3.80 (1H, brm, H-3), 3.88 (2H, s, OCOC H 2 NH 3 Cl), 4.66 (1H, d, J=9.9 Hz, H-2), 5.24 (1H, m, H-12), LCMS (positive ion mode): m/z 530 (M-Cl) + .
Example 5
2-O-Alanylcorosolic acid hydrochloride (5): A mixture of corosolic acid (500 mg, 1.06 mmol), BOC protected alanine (240 mg, 1.23 mmol) and DMAP (75 mg) in dry dioxane (2 mL) at 0° C. was treated with DCC (327 mg, 1.59 mmol) under the conditions noted in example 4, obtained 2-O—(N—BOC-alanyl)corosolic acid (320 mg). This was deprotected as in example 4, to give 2-O-alanylcorosolic acid hydrochloride (250 mg) as white powder, m.p. 234-238° C.; IR (KBr): 3433, 2928, 2859, 1740, 1692, 1621, 1459, 1369, 1245, 1107, 1041 cm −1 ; 1 H NMR (400 MHz, DMSO-d 6 ) δ 0.57-1.35 (24H, m, 8×CH 3 ), 4.68-4.76 (1H, br s, —CH—N), 4.88-5.05 (1H, br s, H-3), 5.08-5.20 (1H, br s, H-12), 8.10-8.60 (3H, br s, NH 3 + ); LCMS (positive ion mode): m/z 544 (M−Cl) + .
Example 6
Methyl 2-O-(3,4,5-trimethoxycinnamoyl)corosolate (6): To a mixture of methyl corosolate (100 mg, 0.21 mmol), 3,4,5-trimethoxycinnamic acid (73 mg, 0.31 mmol) and DMAP (12 mg, 0.1 mmol) in CH 2 Cl 2 (1.5 mL) cooled in an ice-water bath was added slowly DCC (85 mg, 0.41 mmol) in 0.5 mL of CH 2 Cl 2 . The mixture was allowed to reach ambient temperature and continued the stirring. After 2 h, the mixture was worked-up under the conditions noted in example 4, to finish methyl 2-O-(3,4,5-trimethoxycinnamoyl)corosolate (90 mg, 62%), m.p. 198-206° C.; IR (neat): 3460, 2927, 2854, 1717, 1632, 1583, 1457, 1263, 1098, 1024, 805 cm −1 ; LCMS (positive ion mode): m/z 729 (M+Na) + .
Example 7
2α,3β-Dihydroxyurs-12-en-28-oic acid 2,3-cyclicsulphate (7): To a mixture of corosolic acid (200 mg, 0.42 mmol)) and pyridine (0.34 mL, 4.2 mmol) in THF (1.5 mL) was slowly added thionyl chloride (40 μL, 4.2 mmol) and stirred at rt for 2 h. The reaction mixture was poured into 0.2N HCl (20 mL). The white precipitate was filtered, washed with water and dried under vacuum. This sulphite (100 mg) was dissolved in acetonitrile (1 mL), water (0.8 mL) and CH 2 Cl 2 (1 mL) and treated with a solution of ruthenium trichloride monohydrate (100 μg) in acetonitrile (1 mL) followed by NaIO 4 (300 mg). The stirring was continued for 36 h. The mixture was poured into water and extracted with ethyl acetate. The organic layer was washed with brine, dried over Na 2 SO 4 and evaporated. The residue (90 mg) was subjected to silica gel column chromatography using hexane-ethyl acetate (20%) as eluent to furnish cyclicsulphate derivative 7 (40 mg), m.p. 182-186° C.; IR (neat): 3431, 2926, 2871, 1693, 1459, 1386, 1211, 995, 959 cm −1 . LCMS (negative ion mode): m/z 533 (M−H) − ;
Example 8
Corosolamide (8): A mixture of diacetylcorosolic acid (300 mg) and thionyl chloride (2 mL) was refluxed for 1 h and the excess reagent was removed under reduced pressure to give acid chloride. This crude acid chloride in THF (1 mL) was added drop wise to a stirred solution of conc. ammonia (5 mL) at ice-cold temperature for 5 min and continued stirring at the same temperature for 2 h. The reaction mixture was poured into ice-cold water and extracted with ethyl acetate. The organic layer was washed with dil. H 2 SO 4 , water, brine and dried over sodium sulfate. The solution was filtered and the solvent evaporated to give diacetyl corosolamide (300 mg). A solution of diacetyl corosolamide (300 mg) and methanolic-potassium hydroxide (4%, 25 mL) was refluxed for 1 h. The solvent was evaporated under reduced pressure and diluted with ice-cold water and acidified with dil. H 2 SO 4 . The solution was extracted with ethyl acetate and the organic layer was washed with water, brine and dried over sodium sulfate. The residue obtained after evaporation of the solvent was chromatographed over silica gel column using chloroform-methanol (10%) as eluent to furnish corosolamide (200 mg, 67%), which was recrystallised from chloroform-hexane, m.p. 208-210° C.; IR (KBr): 3495, 2927, 2870, 1671, 1602, 1457, 1376, 1049, 959 cm −1 ; 1 H NMR (400 MHz, CDCl 3 ) δ 0.83 (3H, s, CH 3 ), 0.86 (3H, s, CH 3 ), 0.87 (3H, d, J=6.7 Hz, CH 3 ), 0.96 (3H, br s, CH 3 ), 1.00 (3H, s, CH 3 ), 1.04 (3H, s, CH 3 ), 1.11 (3H, S, CH 3 ), 3.00 (1H, d, J=9.4 Hz, H-3), 3.67-3.73 (1H, m, H-2), 5.32 (1H, br s, H-12), 5.85 (2H, br s, CONH 2 ); LCMS (negative ion mode): m/z 470 (M−H) − .
Example 9
N-Phenylcorosolamide (9): Reaction of diacetylcorosolyl chloride (100 mg) with aniline (1 mL) in THF (10 mL) and triethyl amine (1 mL) under the conditions noted in example 8 gave N-phenylcorosolamide, which was crystallised from chloroform-methanol (60 mg, 61%), m.p. 168-174° C.; IR (KBr): 3408, 2927, 2868, 1652, 1599, 1529, 1502, 1442, 1312, 1235, 1048 cm −1 ; 1 H NMR (400 MHz, CDCl 3 ) δ 0.70 (3H, s, CH 3 ), 0.80 (3H, s, CH 3 ), 0.93-1.02 (12H, m, 2 methyl singlets merge with 2 methyl doublets), 1.14 (3H, s, CH 3 ), 3.00 (1H, d, J=7.76 Hz, H-3), 3.6-3.7 (1H, br. s, H-2), 5.45-5.50 (1H, br s, H-12), 7.07 (1H, br s, Ar—H), 7.28 (1H, br s, Ar—H), 7.44 (2H, br s, Ar—H), 7.67 (1H, br s, Ar—H); LCMS (positive ion mode): m/z 548 (M+H) + .
Example 10
N-(2-Aminoethyl)corosolamide (10): Reaction of diacetylcorosolyl chloride (200 mg) with ethylene diamine (1.0 g) in THF (10 mL) and work-up under the conditions noted in example 8 furnished N-(2-aminoethyl)corosolamide (110 mg, 60%), m.p. 118-120° C.; IR (KBr): 3403, 2926, 1633, 1527, 1454, 1383, 1048 cm −1 ; 1 H NMR (400 MHz, DMSO-d 6 ) δ 0.69 (3H, s, CH 3 ), 0.72 (3H, s, CH 3 ), 0.84 (3H, d, J=6.0 Hz, CH 3 ), 0.92-0.94 (9H, 2 br s, 2 methyl singlets and a methyl doublet), 0.99 (2H, d, J=7.2 Hz, —NCO—CH 2 —), 1.05 (3H, s, CH 3 ), 2.17 (1H, d, J=11.2 Hz, H-18), 2.57 (2H, q, J=7.0 Hz, NH 2 —CH 2 ), 2.70 (2H, t, J=6.7 Hz, NH 2 —CH 2 ), 2.75 (1H, d, J=9.2 Hz, H-3), 4.3-4.4 (1H, m, H-2), 5.23 (1H, br s, H-12); LCMS (positive ion mode): m/z 515 (M+H) + .
Example 11
N-(Corosolyl)piperazine (11): Reaction of diacetylcorosolyl chloride (100 mg) with piperazine (200 mg) in THF (10 mL) and triethyl amine (2 mL) and work-up under the conditions noted in example 8 gave N-(corosolyl)piperazine, which was crystallised from chloroform-hexane (50 mg, 52%), m.p. 226-230° C.; IR (KBr): 3434, 2924, 2868, 1628, 1455, 1226, 1049 cm −1 ; 1 H NMR (400 MHz, CDCl 3 ) δ 0.76 (3H, s, CH 3 ), 0.83 (3H, s, CH 3 ), 0.87 (3H, d, J=6.3 Hz, CH 3 ), 0.94 (3H, d, J=6.2 Hz, CH 3 ), 0.99 (3H, s, CH 3 ), 1.03 (3H, s, CH 3 ), 1.08 (3H, s, CH 3 ), 2.44 (1H, d, J=8.6 Hz, H-18), 2.83 (4H, s, N—CH 2 ), 3.00 (1H, d, J=9.5 Hz, H-3), 3.58 (4H, d, J=3.4 Hz, N—CH 2 ), 3.66-3.72 (1H, m, H-2), 5.23 (1H, br s, H-12); LCMS (positive ion mode): m/z 541 (M+H) + .
Example 12
N-(2-Hydroxyethyl)corosolamide (12): Reaction of diacetylcorosolyl chloride (100 mg) with 2-aminoethanol (1 mL) in THF (10 mL) and triethyl amine (1 mL) under the conditions noted in example 8 gave N-(2-hydroxyethyl)corosolamide, which was crystallised from chloroform-hexane to obtain 12 (43 mg, 47%), m.p. 152-158° C.; IR (KBr): 3408, 2963, 2926, 2856, 1632, 1529, 1455, 1262, 1094, 1026, 802 cm −1 ; 1 H NMR (400 MHz, CDCl 3 ) δ 0.81 (3H, s, CH 3 ), 0.83 (3H, s, CH 3 ), 0.87 (3H, d, J=6.2 Hz, CH 3 ), 0.96 (3H, br s, CH 3 ), 1.00 (3H, s, CH 3 ), 1.04 (3H, s, CH 3 ), 1.11 (3H, s, CH 3 ), 2.98 (1H, br s), 3.00 (1H, d, J=9.3 Hz, H-3), 3.21-3.26 (1H, m), 3.44-3.49 (1H, m, H-2), 3.68 (3H, br s, N—CH 2 CH 2 —), 5.34 (1H, s, H-12), 6.34 (1H, br s); LCMS (negative ion mode): m/z 514 (M−H) − .
Example 13
Methyl corosolate (13): A mixture of corosolic acid (2.0 g, 4.34 mmol), iodomethane (1 mL, 16 mmol), potassium carbonate (4.5 g, 32.6 mmol) and acetone (60 mL) was stirred at rt for 16 h. After completion of the reaction, the solids were filtered off and the solvent was evaporated under reduced pressure. The residue was chromatographed over silica gel column using chloroform-methanol (10%) as eluent to furnish methyl corosolate (1.7 g, 83%), which was recrystallised from chloroform-hexane, m.p. 208-210° C.; IR (KBr): 3432, 2946, 2872, 1728, 1455, 1230, 1197, 1049 cm −1 ; 1 H NMR (400 MHz, CDCl 3 ) δ 0.75 (3H, s, CH 3 ), 0.83 (3H, s, CH 3 ), 0.85 (3H, d, J=6.5 Hz, CH 3 ), 0.94 (3H, d, J=5.7 Hz, CH 3 ), 0.99 (3H, s, CH 3 ), 1.03 (3H, s, CH 3 ), 1.08 (3H, s, CH 3 ), 2.23 (1H, d, J=11.0 Hz, H-18), 3.0 (1H, d, J=8.4 Hz, H-3), 3.60 (3H, s, —COOCH 3 ), 3.62-3.71 (1H, m, H-2), 5.25 (1H, t, J=3.4 Hz, H-12); LCMS (negative ion mode): m/z 485 (M−H) − .
Example 14
Methyl diacetylcorosolate (14): Reaction of diacetylcorosolic acid (500 mg, 0.9 mmol) with iodomethane (0.25 mL, 4.0 mmol), potassium carbonate (1.0 g, 7.2 mmol) and acetone (25 mL) under the conditions noted in example 13 gave methyl diacetylcorosolate (0.4 g, 78%), which was crystallised from aq. methanol to obtain 14, m.p. 138-140° C.; IR (KBr): 2943, 1742, 1243, 1036, 964 cm −1 ; 1 H NMR (400 MHz, CDCl 3 ) δ 0.75 (3H, s), 0.85 (3H, d, J=6.4 Hz), 0.90 (3H, s), 0.91 (3H, s), 0.94 (3H, d, J=5.9 Hz), 1.07 (6H, s), 1.97 (3H, s), 2.05 (3H, s), 2.23 (1H, d, J=11.4 Hz, H-18), 3.60 (3H, s), 4.75 (1H, d, J=10.3 Hz, H-3), 5.07-5.14 (1H, m, H-2), 5.23-5.24 (1H, m. H-12); LCMS (positive mode): 594 (M+1) + .
Example 15
Methyl 11-ketocorosolate (15): Methyl corosolate (400 mg) was acetylated using pyridine (0.5 mL) and acetic anhydride (0.5 mL) under the conditions noted in example 2 to furnish methyl diacetylcorosolate (450 mg), which was dissolved in 1,4-dioxane (16 mL) and treated with N-bromosuccinimide (472 mg), water (1.6 mL) and calcium carbonate (472 mg). The reaction mixture was subjected to vigorous stirring for 3 h, and then filtered. The mother liquor was poured into cold water and extracted with ethyl acetate. The organic layer was washed with brine, dried over sodium sulfate and evaporated. The residue (360 mg) in methanol (2 mL) was added 8N KOH solution (1 mL) and stirred at 65° C. for 1 h, then poured into ice cold water, acidified with 2N HCl and extracted with ethyl acetate. The organic layer was washed with brine, dried over sodium sulfate and evaporated. The residue (340 mg) was purified over silica gel column using hexane-ethyl acetate (25%) as eluent to furnish methyl 11-ketocorosolate (240 mg), m.p. 101-105° C.; IR (neat): 3416, 2926, 2858, 1728, 1659, 1457, 1388, 1201, 1048 cm −1 ; 1 H NMR (400 MHz, CDCl 3 ) δ 0.84 (3H, s, CH 3 ), 0.87 (3H, d, J=6.5 Hz, CH 3 ), 0.91 (3H, s, CH 3 ), 0.97 (3H, d, J=6.3 Hz, CH 3 ), 1.05 (3H, s, CH 3 ), 1.19 (3H, s, CH 3 ), 1.30 (3H, s, CH 3 ), 2.35 (1H, s), 2.42 (1H, d, J=10.9 Hz), 3.02 (1H, d, J=9.5 Hz), 3.16 (1H, dd, J=12.6 & 4.3 Hz), 3.61 (3H, s, CH 3 ), 3.77 (1H, m, H-2), 5.61 (1H, s, H-12); LCMS (positive ion mode): m/z 501 (M+H) + .
Example 16
Methyl diacetyl-11-ketocorosolate (16): Reaction of methyl diacetylcorosolate, (500 mg, 0.9 mmol) in 1,4-dioxane (20 mL) with N-bromosuccinimide (0.75 g, 4.2 mmol) and calcium carbonate (0.75 g, 7.5 mmol) in water (2 mL) under the conditions noted in example 15 gave methyl diacetyl-11-ketocorosolate (300 mg, 59%), which was crystallized from aq. methanol to obtain 16, m.p. 264-266° C.; IR (KBr): 2952, 1734, 1660, 1241, 1038, 985 cm −1 ; 1 H NMR (400 MHz, CDCl 3 ) δ 0.86 (3H, d, J=6.4 Hz), 0.89 (3H, s), 0.91 (3H, s), 0.93 (3H, s), 0.97 (3H, d, J=6.3 Hz), 1.25 (3H, s), 1.29 (3H, s), 1.95 (3H, s), 2.04 (3H, s), 3.18 (1H, dd, J=12.8, 4.6 Hz, H-18), 3.60 (3H, s), 4.72 (1H, d, J=10.3 Hz, H-3), 5.20-5.26 (1H, m, H-2), 5.61 (1H, s, H-12); LCMS (positive ion mode): m/z 608 (M+H) + .
Example 17
11-Ketocorosolic acid (17): A mixture of corosolic acid (400 mg, 0.85 mmol), pyridine (0.4 mL, 5.1 mmol) and acetic anhydride (1.5 mL, 15.2 mmol) was stirred at rt for 6 h. To the cooled reaction mixture after diluting with acetic acid (1.5 mL) and acetic anhydride (2 mL) was added chromium trioxide (254 mg) and stirred for 5 h. The reaction mixture was poured into ice-cold water and the precipitated solid was filtered and washed with water. The solid in methanol (4 mL) was treated with 8N KOH (2 mL) and stirred at rt for 14 h and then the mixture was filtered through celite. The mother liquor was poured into ice water, acidified and extracted with ethyl acetate. The organic layer was washed with brine, dried over sodium sulphate and evaporated. The residue (390 mg) was purified over silica gel column using hexane-ethyl acetate (30%) as eluent to furnish 11-ketocorosolic acid (60 mg), m.p. 238-242° C.; IR (neat): 3417, 2927, 2857, 1692, 1659, 1460, 1386, 1051, 974 cm −1 ; LCMS (negative ion mode): m/z 485 (M−H) − .
Example 18
Diacetyl-11-ketocorosolic acid (18): Reaction of diacetyl corosolic acid (500 mg, 0.9 mmol) in dichloroethane (2 mL), acetic acid (2 mL) and water (1 mL) with a solution of chromium trioxide (1.5 g, 15 mmol), acetic acid (2 mL) and water (2 mL) under the conditions noted in example 17 gave diacetyl-11-ketocorosolic acid (200 mg, 39%), which was crystallized from chloroform-hexane to obtain 18, m.p. 318-320° C.; IR (KBr): 3184, 2975, 1742, 1641, 1253, 1036 cm −1 ; 1 H NMR (400 MHz, CDCl 3 ) δ 0.86 (3H, d, J=6.4 Hz), 0.90 (3H, s), 0.91 (6H, s), 0.98 (3H, d, J=6.2 Hz), 1.26 (3H, s), 1.30 (3H, s), 1.95 (3H, s, —OCOCH 3 ), 2.05 (3H, s, —OCOCH 3 ), 3.18 (1H, dd, J=12.7, 3.2 Hz, H-18), 4.72 (1H, d, J=10.3 Hz, H-3), 5.19-5.26 (1H, m, H-2), 5.61 (1H, s, H-12); LCMS (negative mode): 569 (M−H) − .
Example 19
2α,3β-Dihydroxyurs-12-en-11-one-28-oic acid 2,3-cyclicsulphate (19): To a mixture of corosolic acid-2,3-sulfite (1.1 g, 2.12 mmol), dichloromethane (7 mL) and acetonitrile (4 mL) was added ruthenium chloride (2 mg) in acetonitrile (2 mL), followed by sodium periodate (1.5 g). After stirring the mixture at rt for 2 h, an additional amount (0.5 g) of sodium periodate was added and after 2 h of stirring, the reaction mixture was worked up under the conditions noted in example 7 to give 2,3-cyclicsulphate derivative 19 (600 mg), m.p. 210-216° C.; IR (neat): 3429, 2924, 2356, 1705, 1658, 1618, 1380, 1206 cm −1 ; 1 H NMR (400 MHz, DMSO-d 6 ) δ 0.82 (3H, d, J=6.3 Hz, CH 3 ), 0.90 (3H, s, CH 3 ), 0.94 (3H, s, CH 3 ), 0.95 (3H, d, J=6.4 Hz, CH 3 ), 1.07 (3H, s, CH 3 ), 1.20 (3H, s, CH 3 ), 1.31 (3H, s, CH 3 ), 3.20 (1H, dd, J=11.6 & 4.2 Hz, H-18), 4.63 (1H, d, J=10.4 Hz, H-3), 5.20-5.30 (1H, m, H-2), 5.44 (1H, s, H-12); LCMS (negative ion mode): m/z 547 (M−H) − .
Example 20
11-Ketocorosolamide (20): Diacetyl-11-ketocorosolyl chloride (prepared from the 11-ketoacid, 150 mg and thionyl chloride 2 mL) was dissolved in THF (2 mL) and the solution was added dropwise to a stirred solution of conc. ammonia (5 mL) at ice cold temperature for 5 min and the solution was stirred at the same temperature for 2 h. The reaction mixture was worked up as described in example 8 to furnish 11-ketocorosolamide (40 mg, 31%), m.p. 220-222° C.; IR (KBr): 3427, 2970, 2930, 2871, 1659, 1459, 1384, 1200, 1048, 971 cm −1 ; 1 H NMR (400 MHz, DMSO-d 6 ) δ 0.72 (3H, s, CH 3 ), 0.82 (3H, d, J=6.3 Hz, CH 3 ), 0.89 (3H, s, CH 3 ), 0.93 (3H, s, CH 3 ), 0.95 (3H, d, J=6.3 Hz, CH 3 ), 1.08 (3H, s, CH 3 ), 1.27 (3H, s, CH 3 ), 2.32 (1H, s), 2.36 (1H, d, J=11.1 Hz, H-18), 2.75 (1H, dd, J=12.7 & 4.2 Hz), 2.86 (1H, dd, J=12.7 & 4.2 Hz), 3.48 (1H, br s, H-2), 4.23 (1H, d, J=3.8 Hz), 4.34 (1H, d, J=3.8 Hz), 5.47 (1H, s, H-12), 6.83 (1H, s, OH), 6.97 (1H, s, OH); LCMS (positive ion mode): m/z 486 (M+H) + .
Example 21
11-Hydroxycorosolamide (21): To a magnetically stirred ice cold (10-15° C.) solution of 11-ketocorosolamide (50 mg, 0.10 mmol) in ethanol (10 mL) was added sodium borohydride (200 mg, 5.26 mmol) and the solution was slowly brought to rt and stirred for 14 h. After completion of the reaction, the mixture was poured into ice-cold water and acidified with dil HCl. The solution was extracted with ethyl acetate and the organic layer was washed with water, brine and dried over sodium sulfate. The residue obtained after evaporation of the solvent was chromatographed over silica gel column using chloroform-methanol (95:5) as eluent to give 11-hydroxycorosolamide (20 mg, 40%), which was crystallised from chloroform-methanol, m.p. 196-198° C.; IR (KBr): 3432, 2929, 1659, 1600, 1383, 1048, 968 cm −1 ; 1 H NMR (400 MHz, DMSO-d 6 ) δ 0.73 (3H, s, CH 3 ), 0.77 (3H, s, CH 3 ), 0.90-0.94 (9H, m, 2 methyl doublets and a methyl singlet), 1.02 (3H, s, CH 3 ), 1.11 (3H, s, CH 3 ), 2.11 (1H, d, J=10.7 Hz, H-18), 2.42-2.46 (1H, m), 2.73 (1H, dd, J=9.1 & 3.7 Hz, H-3), 3.42 (1H, m, H-2), 4.01-4.03 (2H, m, H-11 & 11-OH), 4.15 (1H, br s, NH 2 ), 4.28 (1H, br s, NH 2 ), 5.17 (1H, s, H-12), 6.68 (1H, s, OH), 6.73 (1H, s, OH); LCMS (negative ion mode): m/z 486 (M−H) − .
Example 22
Methyl 11-hydroxycorosolate (22): To a magnetically stirred ice cold (10-15° C.) solution of methyl 11-ketocorosolate (360 mg, 0.72 mmol) in ethanol (40 mL) was added sodium borohydride (1.0 g, 26 mmol) and the solution was slowly brought to rt and stirred for 14 h. After completion of the reaction, the mixture was worked up as described in example 21 to give methyl 11-hydroxycorosolate (32 mg), m.p. 148-152° C.; IR (Neat): 3416, 2927, 2872, 1719, 1648, 1455, 1388, 1220, 1146, 1047, 999, 960, 770 cm −1 ; 1 H NMR (400 MHz, CDCl 3 ) δ 0.86 (6H, s, 2×CH 3 ), 0.95 (3H, d, J=6.0 Hz, CH 3 ), 1.01-1.03 (12H, 3 methyl singlets and a methyl doublet), 2.31 (1H, d, J=11.3 Hz, H-18), 2.44 (1H, dd, J=12.0 & 4.2 Hz), 3.02 (1H, d, J=9.3 Hz, H-3), 3.80-3.83 (1H, m, H-2), 4.39 (1H, m, H-11), 5.35 (1H, d, J=3.8 Hz, H-12); LCMS (negative ion mode): m/z 501 (M−H) − .
Example 23
Corosolinol (23): To an ice cold dispersion of lithium aluminum hydride (97 mg) in THF (3 mL) was slowly added methyl corosolate (500 mg) in THF (1 mL) and stirred for 2 h. The reaction mixture was diluted with ethyl acetate (3 mL) and poured into ice water. The mixture was acidified with 2 N HCl and extracted with ethyl acetate (50 mL). The organic layer was washed with brine, dried over Na 2 SO 4 and evaporated. The residue (400 mg) was chromatographed over silica gel column using hexane-ethyl acetate (80:20) as eluents to yield corosolinol (220 mg), m.p. 140-146° C.; IR (neat): 3392, 2926, 2867, 1619, 1456, 1388, 1047, 1024, 760 cm −1 ; 1 H NMR (400 MHz, CDCl 3 ) δ 0.81 (3H, d, J=5.4 Hz, CH 3 ), 0.84 (3H, s, CH 3 ), 0.94 (3H, d, J=5.3 Hz, CH 3 ), 0.99 (3H, s, CH 3 ), 1.03 (3H, s, CH 3 ), 1.04 (3H, s, CH 3 ), 1.11 (3H, s, CH 3 ), 2.03 (1H, dd, J=12.3 & 4.5 Hz), 3.01 (1H, d, 3=9.6 Hz), 3.19 (1H, d, J=11.0 Hz), 3.53 (1H, d, J=11.0 Hz), 3.70 (1H, m, H-2), 5.15 (1H, t, J=3.4 Hz, H-12); LCMS (negative ion mode): m/z 457 (M−H) − .
Example 24
Corosolinal (24): To a cooled solution of Dess-Martin Periodinane (23 mg) in CH 2 Cl 2 (2 mL) was slowly added corosolinol (20 mg) dissolved in CH 2 Cl 2 (2 mL) and the solution was allowed to ambient temperature and continued the stirring for 2 h. The mixture was diluted with Et 2 O (20 mL) and poured into an ice-cold mixture of Na 2 S 2 O 3 .5H 2 O (90 mg) in saturated aqueous NaHCO 3 (5 mL). The layers were separated and the organic layer was washed with saturated aqueous NaHCO 3 (10 mL), water (20 mL), brine (20 mL) and dried over MgSO 4 . The solution was filtered and evaporated to give corosolinal (15 mg) as a colorless oil. IR (neat): 3433, 2925, 2855, 1721, 1451, 1387, 1094 cm −1 ; LCMS (negative ion mode): m/z 455 (M−H) − .
Example 25
Corosolyl tri-O-methylgallate (25): A mixture of tri-O-methylgallic acid (200 mg, 0.9 mmol) and SOCl 2 (0.5 mL) was refluxed for 0.5 h. The excess reagent was removed under high vacuum and the residue in CH 2 Cl 2 (1 mL) was added to a mixture of corosolic acid (200 mg, 0.42 mmol) and DMAP (30 mg) in dioxane (5 mL). The reaction mixture was stirred at rt for 2 h and then poured into ice-cold water. The mixture was extracted with ethyl acetate (60 mL) and the organic layer was washed with 0.1 N HCl (40 mL), water (40 mL), brine and dried over Na 2 SO 4 . The residue obtained after evaporation of the solvent was chromatographed over silica gel column using hexane-ethyl acetate (85:15) as eluent to yield corosolyl tri-O-methylgallate (25) as a white solid (75 mg), m.p. 158-162° C.; IR (KBr): 3439, 2930, 2853, 1793, 1728, 1627, 1584, 1460, 1336, 1233, 1129, 1019 cm −1 ; 1 H NMR (400 MHz, CDCl 3 ) δ 0.83 (3H, s, CH 3 ), 0.89 (3H, s, CH 3 ), 0.99 (3H, s, CH 3 ), 1.04 (3H, s, CH 3 ), 1.13 (3H, s, CH 3 ), 1.25 (3H, s, CH 3 ), 2.35 (1H, s), 2.30 (1H, d, J=11.0 Hz), 3.00 (1H, d, J=9.3 Hz), 3.70 (1H, brm), 3.90 (9H, s, 3×CH 3 ), 5.37 (1H, s, H-12), 7.28 (2H, s, Ar—H); LCMS (positive ion mode): m/z 689 (M+Na) + .
Example 26
2α,3β-Dihydroxyurs-12-en-11,28-olide (26): To a solution of corosolic acid (200 mg) in dioxane (6 mL) and water (0.6 mL) was added NBS (188 mg) and CaCO 3 and the mixture stirred at rt for 4 h. The mixture was poured in to ice water (30 mL) and extracted with ethyl acetate (2×30 mL). The combined organic layer was washed with water (30 mL) followed by brine and dried over Na 2 SO 4 . The solvent was evaporated and the residue was subjected to silica gel column chromatography using hexane and ethyl acetate mixtures as eluents to obtain the lactone, 26 as a semisolid (60 mg); IR (neat): 3339, 2925, 2854, 1763, 1465 1261, 1021 cm −1 ; 1 H NMR (400 MHz, CDCl 3 ) δ 0.75-1.25 (7×CH 3 ), 3.02 (1H, br s), 3.75 (1H, brm), 5.56 (1H, brd, J=8.2 Hz), 5.98 (1H, brd, J=8.2 Hz); LCMS (negative ion mode): m/z 469 (M−H) − .
Hypoglycemic activity: Hypoglycemic activity was tested by the inhibition of sucrose-induced raise in serum glucose levels (SGL), by the test substances in Albino wistar rats. The procedure involves fasting the rats for overnight at ad libitum water, numbered weighed and randomly divided into groups of six animals each. Prior to treatment blood samples were drawn from sinus orbital plexus of all animals using heparin coated glass capillaries under mild ether anesthesia. The blood samples were tested for serum glucose levels using enzymatic GOD/POD method. Optical densities were measured at 500 nm, SGL was calculated as follows. SGL=(test OD/Standard OD)×100 and the results were expressed in mg/dL. All the groups were treated orally with corresponding test substances, standard, vehicle (5% gum acacia). After 30 minutes, all animals were given 20 mL/kg of 20% sucrose solution orally using gastric tube. One hour after treatment, blood samples were drawn again under mild ether anesthesia and tested for serum glucose levels in a same procedure as described above for initial serum glucose estimation. The data was subjected to statistical treatment using t-test and inhibitory rate was calculated by comparing mean increase in serum glucose levels of control and treated groups.
5-Lipoxygenase activity: The corosolic acid analogs were screened for their 5-Lipoxygenase inhibitory potential using colorimetric method. The assay mixture contained 50 mM phosphate buffer pH 6.3, 5-Lipoxygenase, various concentrations of test substances in dimethyl sulphoxide and linoleic acid in a total volume of 0.5 mL, after 5 min incubation of above reaction mixture, 0.5 mL ferric xylenol orange reagent was added and OD was measured after two minutes at 585 nm using spectrophotometer. Controls were run along with test in a similar manner except using vehicle instead of test substance solution. Percent inhibition was calculated by comparing absorbance of test solution with that of control.
Brine shrimp lethality: Brine shrimp ( Artemia salina ) nauplii were hatched using brine shrimp eggs in a conical shaped vessel (1 L), filled with sterile artificial sea water (prepared using sea salt 38 g/L and adjusted to pH 8.5 using 1 N NaOH) under constant aeration for 48 h. After hatching, 10 nauplii were drawn through a pepette and placed in each vial containing 4.5 mL brine solution and added various concentrations of drug solutions and volume was made upto 5 mL using brine solution and maintained at 37° C. for 24 h under the light of incandescent lamps and surviving larvae were counted. Each experiment was conducted along with control (vehicle treated), at various concentrations of the test substance in each set that contains 6 tubes and the average results are reported. The percentage lethality was determined by comparing the mean mortal larvae of test and control tubes. LC 50 values were obtained from the plot of concentration (μg) vs. percentage lethality. Podophyllotoxin was used as a positive control.
The corosolic acid analogs of this invention are found to show better hypoglycemic activity (Table 1; hypoglycemic activity is expressed in serum glucose level inhibitory rate values; higher the inhibitory rate value, higher is the activity) than the corosolic acid.
The corosolic acid analogs of this invention are found to show good 5-lipoxygenase activity (Table 2; 5-lipoxygenase activity is expressed in % of inhibition at 100 μM and 250 μM; higher the % inhibitory values, higher is the activity).
The corosolic acid analogs of this invention are found to show significant brine shrimp lethality (Table 3; brine shrimp lethality is expressed in LC 50 at μM concentration; lower the LC 50 value, higher is the activity).
TABLE I
Hypoglycemic activity
Oral dose
SGL
Inhibitory
S. No
Comp. No.
in mg/Kg
(mean ± SE)
rate
t-value
1
Control
5% GA
134.56 ± 1.47
2
Corosolic
1 mg
121.43 ± 6.27
9.78
2.04
acid
3
1
1 mg
109.54 ± 2.80
32.75
13.83
4
3
1 mg
115.86 ± 3.77
13.9
4.62
5
4
1 mg
119.23 ± 9.58
26.8
4.39
6
5
1 mg
113.49 ± 4.11
22.39
7.68
7
6
1 mg
114.15 ± 6.62
21.94
4.78
8
8
1 mg
110.14 ± 3.18
18.15
6.97
9
9
1 mg
117.97 ± 0.37
27.58
16.78
10
10
1 mg
113.57 ± 3.80
30.28
10.64
11
11
1 mg
107.88 ± 4.61
19.83
5.51
12
12
1 mg
103.49 ± 7.12
36.47
7.82
13
13
1 mg
118.94 ± 8.61
11.6
1.79
14
15
1 mg
120.79 ± 4.85
17.4
5.11
15
17
1 mg
120.90 ± 9.66
25.78
4.19
16
19
1 mg
129.16 ± 4.66
11.67
3.56
17
20
1 mg
142.81 ± 7.30
12.33
2.58
18
21
1 mg
121.57 ± 2.62
25.37
11.08
19
23
1 mg
113.06 ± 2.61
30.59
13.40
20
25
1 mg
131.84 ± 7.77
9.84
1.83
21
26
1 mg
136.03 ± 4.43
6.97
2.23
TABLE 2
5-Lipoxygenase inhibitory activity
% inhibition of
5-Lox activity
at various
concentrations
S. No
Comp. No.
100 μM
250 μM
1
Corosolic acid
13.48
29.26
2
1
15.47
24.05
3
2
20.08
44.54
4
3
28.54
53.19
5
4
17.04
27.83
6
5
29.14
67.03
7
6
—
13.47
8
7
—
16.90
9
8
26.13
51.29
10
9
8.16
21.77
11
10
21.74
40.87
12
11
35.42
64.99
13
12
17.74
32.96
14
13
17.3
40.04
15
14
—
1.9
16
15
—
25.09
17
16
—
3.82
18
19
—
11.81
19
20
18.57
42.79
20
21
25.57
50.83
21
22
24.56
49.40
22
23
2.91
19.63
23
25
—
38.83
24
26
—
10.47
25
AKBA
17.45
25.3
26
NDGA
70.4
91.55
AKBA: Acetyl ketoboswellic acid
NDGA: Nordihydroguaiaretic acid
TABLE 3
Brine Shrimp Lethality Test
S. No
Compound No.
LC 50 (μM)
1
Corosolic acid
3.0
2
1
9.7
3
2
1.8
4
3
86.6
5
4
3.9
6
5
3.4
7
6
>200
8
7
15.0
9
8
29.0
10
9
>100
11
10
97.2
12
11
9.2
13
12
>100
14
13
10.2
15
14
42.1
16
15
40.9
17
16
82.3
18
18
87.7
19
19
>100
20
20
>100
21
21
>100
22
22
19.9
23
23
30.7
24
25
>200
25
26
87.0
26
podophyllotoxin
7.7
|
This invention relates to novel corosolic acid analogs of the formula I, wherein R 1 , R 2 , R 3 , R 4 and R 5 are described herein. These compounds exhibit good hypoglycemic and 5-lipoxygenase inhibitory activities. They also inhibit tumour growth. Pharmaceutical compositions containing known adjutants and the title compounds are also within the scope of this invention.
| 2
|
RELATED APPLICATION
[0001] This application claims priority to Provisional Application No. 60/205,728 which was filed on May 19, 2000.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates generally to computer personalization information, and, more particularly, to a migration tool and methods for migrating computer personalization information from one computer to another.
[0004] 2. Related Art
[0005] [0005]FIG. 1 illustrates a computer 100 having a processor 102 , and also having memory such as RAM and ROM memory 104 which is accessible to the processor 102 . The computer 100 includes user I/O components 106 , such as a keyboard, monitor or other display, mouse, and/or other I/O device(s) intended to let the computer 100 exchange data with a human user. System I/O components 108 on a given computer 100 may include a diskette drive, IOMEGA Zip disk drive, serial port, parallel port, Universal Serial Bus (“USB”) port, infrared port, radio frequency (“RF”) port, network connection, and/or other I/O device(s) intended to permit data exchanges between the computer 100 and another device.
[0006] The computer 100 also has a “disk” 110 , which may include one or more magnetic disks or other nonvolatile storage media. The disk 110 will often have space 112 which is not yet allocated for use by file system structures 114 or use by the data that is organized by those structures 114 . As discussed below and elsewhere herein, the data on the disk 110 typically includes both generic data 116 and personalization data 118 .
[0007] Examples of generic information 116 include much operating system software, file system software, peripheral device drivers, application software, and their associated help files, associated graphics or sound files, and so on, although each of these may often also be customized in some manner by the inclusion of some personalization information 118 . Generic information 116 may be generic because it is being used by many people, or it may be generic because it is in a form suited for installation or use by an as-yet-unspecified person.
[0008] For instance, computer vendors typically install an operating system, a set of business applications, some games, and other software on a machine 100 . This may be done before the 40 machine is purchased, or it may be done after purchase by using disk images and/or templates that are also used for many or all of the other machines being configured for other purchasers. In either case, most of the installed software information is not specific to any particular person or any particular computer, in the sense that it is interchangeable with copies of that information installed on other computers. Packaged software is also generic, in the sense that much or all of its behavior has not yet been tailored to a specific person or organization.
[0009] By contrast, personalization information 118 includes information that pertains specifically to a given user or specific subset of all users. Examples include: personal information such as a user's name, a licensee/owner's business name, and contact information such as postal or email addresses and telephone numbers; personal preferences of the type typically set through software tools such as “Options”, “Preferences”, “Customize”, or similar menu entries; passwords; user data, such as spreadsheets, presentations, graphics, databases, contact lists, address books, and word processor files created by a particular user or by a business or personal contact of the user; and tailored system configuration data, such as programs to run on starting the system 100 , other system settings, Ethernet or IP addresses, licensed software serial numbers or Security IDs, and information of the type found in the config.sys,*.ini, autoexec.bat, and registry files in many Microsoft operating system environments.
[0010] Various tools and techniques focused on managing personalization information are conventionally known, including examples such as: tools for editing a registry; tools for preventing transmission of personal information such as a social security number or credit card number; tools for recovering forgotten passwords; and various tools for saving and restoring information from files such as WIN.INI, SYSTEM.INI, CONFIG. SYS, AUTOEXEC.BAT, and the Microsoft Windows Registry.
[0011] In particular, tools and techniques for migrating personalization information between computers are known. For instance, as illustrated in FIG. 2, tools and techniques are available for reading personalization data 118 (FIG. 1) from a source computer 200 (FIG. 2), sending it over a network connection to a network server 202 , and then sending it from the server 202 over a network connection to a destination computer 204 . In a peer-to-peer network, personalization data 118 may similarly be sent over a network connection from the source computer 200 directly to the destination computer 204 .
[0012] As illustrated in FIG. 3, tools and techniques are also available for transferring personalization data 118 from a source computer 300 to a destination computer 304 when the computers 300 , 304 do not necessarily have network connections. Using a system I/O device 108 (FIG. 1) such as a tape drive or diskette drive, the personalization data 118 is sent to an intermediate storage medium 302 by a transport application 306 that runs on the computers 300 , 304 . Unlike the network transfer scenario, the transport application 306 in this case does not necessarily run on both computers 300 , 304 at the same time.
[0013] Various types of transport applications 306 exist, such as disk imaging applications 306 , migration applications 306 , and registry management applications 306 . Disk imaging applications 306 read the disk 110 of the source computer 300 and create an image of the disk 110 on the storage 302 . The image can then be restored to the source computer 300 after the data on that computer is damaged, for instance. The image can also be copied to the disk of a different computer, such as the destination computer 304 . The image often includes personalization data 118 . However, disk imaging applications 306 do not normally distinguish between generic data 116 and personalization data 118 , although users may be able to specify which partitions or files are imaged or restored from an image.
[0014] Migration applications 306 are specifically designed to transfer application programs, system settings, application settings, data files, and applications between machines. However, other types of personalization data 118 are not necessarily identified, much less transferred. Conventional migration applications 306 also run on the source and destination computers, and use either a network connection or unassisted intermediate storage 302 to transfer the data 118 . Thus, resource and security constraints are imposed.
[0015] Registry management applications 306 likewise permit one to transfer specified application programs and their associated information from one computer 300 to another computer 304 . The associated information includes information kept in the registry on Microsoft Windows systems. Registry information is an example of personalization data 118 . However, registry management applications 306 do not necessarily identify personalization data 118 that is not needed to transfer an application program between computers. Moreover, registry management applications 306 run on the source 300 and destination 304 computers, using the underlying operating system and file system of the computers 300 , 304
[0016] In view of the foregoing, there is a need in the art for a migration tool and methods for migrating computer personalization information from one computer to another when a network is not available, when a network is available but use of the network is undesirable for some reason, and/or when the computer which is the source of the data being migrated has limited or unknown resources to support conventional forms of data migration.
SUMMARY OF THE INVENTION
[0017] The present invention addresses the problem of migrating personalization information from one computer to another. More particularly, the invention addresses migration of personalization data when a network is not available, when a network is available but use of the network is undesirable for some reason, and/or when the computer which is the source of the data being migrated has limited or unknown resources to support conventional forms of data migration.
[0018] In a first aspect of the invention is provided a method for migrating personalization data from a source computer to a destination computer, comprising the steps of connecting to the source computer a migration tool having a processor, memory, and means for identifying personalization data; copying personalization data from the source computer to the migration tool using a minimal file system on the source computer and without using a network; connecting the migration tool to the destination computer; and transferring personalization data from the migration tool to the destination computer using a minimal file system on the destination computer and without using a network.
[0019] In a second aspect of the invention is provided a migration tool comprising a memory in operable communication with a processor, a means for exchanging information with another computer, and a means of using the memory and processor for identifying personalization data.
[0020] In a third aspect of the invention is provided a signal set embodied in a computer, the signal set comprising the combination of a command to read data, personalization data read in response to the command, and minimal migration file system software used to read the personalization data from a source computer disk.
[0021] A fourth aspect of the invention provides a method comprising the steps of connecting a migration tool to a source computer, requesting information from the source computer, analyzing the information received, identifying personalization information to be retrieved, and retrieving at least a portion of the identified personalization information.
[0022] The foregoing and other features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The preferred embodiments of this invention will be described in detail, with reference to the following figures, wherein like designations denote like elements, and wherein:
[0024] [0024]FIG. 1 shows a prior art computer;
[0025] [0025]FIG. 2 shows a prior art network environment in which personalization data is transferred from one computer to another;
[0026] [0026]FIG. 3 shows a prior art data transfer scenario in which an intermediate storage medium is used and the computers do not necessarily have network connections;
[0027] [0027]FIG. 4 shows a migration tool and environment for migrating personalization information from one computer to another in accordance with the present invention; and
[0028] [0028]FIG. 5 shows a flowchart of selected embodiments of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] Referring to FIG. 4, the present invention relates to methods, articles, signals, and systems for migrating personalization information 118 from one computer to another. A conventional source computer such as the computer 100 (FIG. 1) is reconfigured with inventive minimal software to become a novel source computer 400 that can access files, disk sectors, the registry, or other places personalization information 118 is stored and do so on behalf of an intelligent external migration tool 402 . The reconfiguration may be accomplished in various ways, such as (a) running a small inventive program that has access to places where the personalization information 118 may be stored and can transfer it on request to the external migration tool 402 ; (b) convincing software already present on source computer 400 to retrieve personalization information 118 and present it on request to the external migration tool 402 (such software may or may not have been designed for that purpose);(c) booting from a diskette that is configured with inventive software capable of retrieving personalization information 118 and presenting it to the external migration tool 402 upon request; and/or (d) overriding the normal boot process to avoid loading a normally used file system and operating system of the computer 100 and running instead inventive minimal migration software capable of retrieving personalization information 118 and presenting it to the external migration tool 402 .
[0030] The migration of information is not controlled entirely by the software and systems just described on reconfigured computer 400 . Instead, an intelligent external migration tool 402 uses reconfigured computer 400 as if it were a peripheral or access device. In one embodiment, the external migration tool 402 executes a four-part process, which is described below, to retrieve personalization information 118 from computer 400 .
[0031] This process allows the intelligent external migration tool 402 to retrieve personalization information 118 from reconfigured computer 400 with little or no assistance from software previously contained on computer 400 . Among advantages of this inventive approach are that it allows migration to be accomplished in some cases when it would otherwise not be possible because: (a) there is no easy way to load a transport application 306 ; (b) there is no common storage medium 302 configured; (c) there is no network connection on the source computer; (d) the file system or operating system normally deny access to some or all the personalization information 118 ; (e) software on the source computer is corrupted or inoperable; (f) the selection of appropriate personalization information 118 is beyond the capabilities of the processor 102 or the memory 104 of the source computer; and/or (g) the source computer doesn't know which of its files, configuration information, keys, and other data are unique to it (personalization information 118 ) and which are generic data 116 , because it can't easily compare its information to data found in other systems.
[0032] Migration Process
[0033] In a first step, the migration tool 402 is connected to the source computer through a port or other means. During this step, the source computer 400 either begins running a small migration program (possibly loaded from diskette) which will respond to the migration tool 402 , or, it is rebooted from a migration diskette or over a USB port or other port. In either case, the source computer 400 runs the minimal file system and I/O software described here, rather than the normal operating system and file system software of the source computer 100 . Thus, the source computer 400 is prepared to respond to migration tool 402 over one of its ports or via a diskette.
[0034] In a second step, the external migration tool 402 requests information from reconfigured computer 400 to determine the type of computer it is, its configuration, and information about locations in which personalization information 118 may be stored. To do so, external migration tool 402 may ask reconfigured computer 400 to read directories, read file names, and/or read files, using BIOS or similar sector I/O routines of the computer 400 . It may also read the boot sector, partition table, and similar system data on the source disk 110 to determine what type of file system (e.g., FAT-12, FAT-16, FAT-32, HPFS, Linux, etc.) is present; in other embodiments the migration file system software simply assumes a particular file system is used on the disk 110 . In some embodiments the reconfigured computer 400 loaded in the first step a minimal migration access program which uses normal operating system calls to access disk storage, registry entries, and/or other locations where personalization information 118 may be present.
[0035] The reconfigured software on computer 400 may be directed by intelligent migration tool 402 to execute commands, e.g., “read root directory and send me the files and/or subdirectories it lists”, “read file named X and send me the contents”, “write this data to location Y on disk”. Commands may be sent to the migration file system software over a system I/O link using a serial port, parallel port, USB port, infrared port, SCSI bus, ATA bus, RF port, RFC 1394 (“firewire”) port, or similar port. The migration tool 402 may likewise receive responsive status codes and/or data using such communication means. If the computer 100 has a network port, that port could also be used by disconnecting the computer 100 from the network and connecting it directly to the migration tool 402 ; note that the network itself is not used but the port and some of the wiring could be used. In addition or as an alternative to using a port, the commands, status codes, and/or data could be transferred using a designated buffer space on a diskette.
[0036] In a third step, the external migration tool 402 analyzes the information received and determines the set of personalization information 118 to be retrieved, its location, and the method(s) of retrieving it. In some embodiments, the external migration tool 402 is able to consult lists of known generic files and/or information about them such as their sizes, dates, and/or checksums to eliminate them from the possible set of data that constitutes personalization information 118 . In some embodiments, the external migration tool 402 is able to consider the directories, folders, file names, or registry keys under which information is stored to help determine which data is personalization information 118 . In some embodiments, the external migration tool 402 is able to look for files or other information created by specific user-ids, associated with certain applications, having certain file name extensions, created or modified at certain times, containing certain strings or keys or codes, having specified metadata, identified by human analysis, processed by certain computers or networks, and/or other identifying characteristics which identify it as possible personalization information 118 . In some embodiments, external migration tool 402 is able to consider information it found on other computers 400 , which it has previously examined. Information found on other computers 400 may be used to distinguish between generic data 116 and personalization information 118 and/or to determine whether the same or similar personalization information 118 has already been retrieved from a previous computer 400 .
[0037] In some embodiments, the tool 402 uses one or more of the following: tools and techniques that are also used by conventional transport applications 306 to identify personalization data 118 corresponding to application programs; rules that are also used by conventional anti-virus or similar data protection programs to identify critical data to be protected; rules that are used by security modules to detect the security ID, registration number, and/or address of a particular program and/or machine; heuristics for identifying personal information such as social security numbers and credit card numbers; and/or naming conventions, embedded identifiers, and other criteria for identifying word processor documents, spreadsheets, and other files created by a user.
[0038] In a fourth step, the external migration tool 402 retrieves the desired personalization information 118 from reconfigured computer 400 . Using similar techniques to those available to the second step, the external migration tool 402 may command the source computer 400 to retrieve personalization information 118 in any of the many possible ways described above under the second step and to present it to the migration tool 402 over a port, by a disk, or using another communication means.
[0039] After any non-zero number of executions of these steps one through four on various source computers 400 , the external migration tool may be directed in a fifth step to use the personalization information 118 it has collected by doing one or more of the following:
[0040] (a) Downloading the personalization information 118 to a destination computer 404 . A destination computer 404 is connected to the migration tool 402 , and the personalization data 118 is copied or merged into the destination computer 404 . A destination computer may be able to perform network transfers with the migration tool 402 or it may receive the personalization information 118 using minimal software and one of its ports or other communication means. In the latter case, the commands may include commands from the tool 402 to the migration software on the destination computer 404 to write personalization data 118 into files and/or sectors on the destination disk 110 . In some cases, the data 118 will overwrite current data 118 on the destination disk 110 , as when the destination is fresh from the vendor, or has just been the target of a generic disk image restore, so default settings are overwritten, for instance. In some cases the personalization data 118 will be merged into existing destination data 118 , as when registry entries are modified. In some cases the data 118 will be new in the sense that no corresponding data 118 was previously on the destination 404 , as when user-created files are transferred from the source 400 . This step may be completely automated, or a user or administrator who is performing the data 118 migration may be required to specify which data 118 to transfer. This step optionally includes validation efforts to identify and avoid possible inconsistencies that would result from copying data 118 to the destination 404 . Such validation efforts may be modeled on conventional migration applications 306 . More generally, this step may draw on known migration tools and techniques, with suitable modifications according to the present invention, such as running most of the code on the migration tool 402 instead of running it on the source and/or destination computers.
[0041] (b) Archiving or otherwise storing the personalization information 118 so that it can be later restored to a new or repaired source computer 400 (or its replacement or clone) when an original source computer 400 has failed or lost its personalization data.
[0042] (c) Analyzing the personalization information 118 for computer viruses or to detect other anomalies, using familiar tools and techniques. Alternatively, or in addition, the personalization information 118 may be analyzed for statistical purposes, again using known tools and techniques in the present inventive context.
[0043] (d) Cloning or otherwise using personalization information 118 in order to create duplicate machines.
[0044] (e) Modifying or otherwise updating personalization information 118 as it is restored to multiple machines. This may be done, for example, by changing a serial number or a security ID.
[0045] (f) Retaining or storing the personalization information 118 as a baseline for later comparison to detect corrupted or changed personalization information.
[0046] (g) Assessing the data 118 to determine whether the source computer 400 should be upgraded and/or whether additional storage should be added.
[0047] (h) Archiving, storing, or otherwise preserving the personalization information 118 for posterity (such as for museum use, or for use by the National Records Administration).
[0048] (i) Saving personalization information 118 for legal or forensic discovery.
[0049] (j) Compressing and/or encrypting personalization data 118 prior to performing any of the preceding steps.
[0050] (k) Converting the personalization data 118 to a different version or format prior to performing any of the preceding steps. For instance, directory locations may be changed. Similarly, user file formats may be converted, particularly if the source computer 400 and the destination computer 404 (or the other closing or archival destination of the data 118 ) make use of different versions of a word processor or another application program with which the user files are accessed. Conventional techniques for format conversion may be used, but with the invention they can run on the migration tool 402 instead of running on a source computer or a destination computer.
[0051] (l) If, in addition to transferring the information 118 to migration tool 402 , the information is also erased from source computer 400 as or after it is transferred, then the effect is to remove personal information 118 from computer 400 so that the source computer 400 can then be reused, reallocated, or discarded without revealing the private personalized information 118 it originally contained.
[0052] Additional Comments
[0053] The minimal migration software loaded on source computer 400 differs from transport applications 306 in that it contains little or no intelligence about what to migrate; instead it is a slave responding to the external migration tool 402 . The minimal migration software loaded on source computer 400 differs from at least some transport applications 306 , in that the migration software does not necessarily use the file system software or operating system software (except possibly BIOS routines) of the computer 100 . When implemented in this way, it allows the invention to migrate personalization data 118 despite the presence of security modules, anti-virus modules, registry access control software, and other data access constraints or barriers that may be present on a given computer 100 during its normal operation.
[0054] The migration software differs from registry management applications 306 , which do not necessarily identify the desired personalization data 118 . The migration software goes beyond the Windows registry, DLL libraries, and *.INI files, by seeking out and identifying data that includes other personalization information 118 of the type(s) noted herein.
[0055] The migration software also differs from transport applications 306 which rely on a network connection to transfer personalization data 118 , as illustrated in FIG. 2, in that the migration software does not use a network to transfer data 118 . This allows the invention to migrate personalization data 118 despite the presence of network security constraints, bandwidth limitations, protocol requirements, network interface hardware requirements, network address requirements, and other complexities of network usage. It also allows the invention to migrate personalization data 118 when the source computer is not networked.
[0056] The migration software also differs from transport applications 306 which rely on transferring personalization data 118 to a simple storage medium, as illustrated in FIG. 3, in that the migration tool 402 has a processor and memory in addition to a storage medium. The processor and memory are configured to perform at least the steps of identifying and copying personalization data 118 as discussed herein. Use of a separate memory and processor outside the source computer permits much of the migration software to reside on, and to run on, the migration tool 402 instead of on the source computer. This in turn allows the invention to avoid undesired interactions with the standard operating system and/or file system software. It also allows the invention to migrate personalization data 118 when the source computer disk 110 lacks enough free space 112 to hold a transport application 306 or to hold the migration software.
[0057] Minimizing the migration code that runs on the source computer 400 also allows the invention to migrate personalization data 118 when the source computer processor 102 is of a different type than the type expected by the migration software on the tool 402 . For instance, the source computer processor 102 might be in the Motorola family of processors, while the migration tool 402 processor is in the Intel family. Similarly, the migration tool 402 processor might be a special purpose processor which is tailored for personalization data 118 migration at the microcode or silicon level, such as a processor using application specific integrated circuits (“ASICs”) or field programmable gate arrays (“FPGAs”).
[0058] Referring to FIG. 5, selected embodiments of the invention are further illustrated by the flowchart shown. The invention also includes methods and/or method steps, systems, signals, configured media, and other embodiments which are described in the text of this application but not shown (or only partially shown) in FIG. 5. During a connecting step 500 , the migration tool 402 is connected to the source computer through a port or other means as described above. During step 502 , the source computer either begins running a small migration program which will respond to the migration tool, or is rebooted from a migration diskette or over a USB port or other port, so that the source computer 400 is running the minimal file system and I/O software as described above, rather than the normal operating system and file system software of the source computer 100 .
[0059] During an identifying step 504 , the migration tool 402 identifies personalization data 118 on the source computer 400 . This may be accomplished by reading directory contents and/or file contents from the source computer disk 110 , sending them over the port or other link to the tool 402 , and analyzing them on the tool 402 using any one or more of various guidelines or criteria. In particular, and without limitation, the tool 402 may use: tools and techniques that are also used by conventional transport applications 306 to identify personalization data 118 corresponding to application programs; rules that are also used by conventional anti-virus or similar data protection programs to identify critical data to be protected; rules that are used by security modules to detect the security ID, registration number, and/or address of a particular program and/or machine; heuristics for identifying personal information such as social security numbers and credit card numbers; and/or naming conventions, embedded identifiers, and other criteria for identifying word processor documents, spreadsheets, and other files created by a user. Some or all of the identified personalization data 118 is copied 506 over the link to the disk on the migration tool 402 .
[0060] During an optional converting step 508 , some of the personalization data 118 is converted to a different version or format. For instance, directory locations may be changed if the source computer 400 uses a different operating system version than the destination computer 404 . Similarly, user file formats may be converted if the source computer 400 and the destination computer 404 use different versions of a word processor or another application program with which the user files are accessed. Conventional techniques for conversion may be used, with the understanding that they are implemented to run on the migration tool 402 instead of running on a source computer or a destination computer.
[0061] The migration tool 402 is disconnected 510 from the source computer 400 and connected 512 to the destination computer. The destination computer is booted from a migration diskette or otherwise configured to run the minimal migration file system and I/O software. The selected personalization data 118 is then copied over the link to the destination computer 404 . In some cases, the data 118 will overwrite current data 118 on the destination disk 110 , as when the destination is fresh from the vendor, or has just been the target of a generic disk image restore, so default settings are overwritten, for instance. In some cases the personalization data 118 will be merged into existing destination data 118 , as when registry entries are modified. In some cases the data 118 will be new in the sense that no corresponding data 118 was previously on the destination 404 , as when user-created files are transferred from the source 400 . The step 516 may be completely automated, or a user or administrator who is performing the data 118 migration may be required to specify which data 118 to transfer.
[0062] The step 516 preferably includes validation efforts to identify and avoid possible inconsistencies that would result from copying data 118 to the destination 404 . Such validation efforts may be modeled on conventional migration applications 306 . More generally, the step 516 may draw on known migration tools and techniques, with suitable modifications according to the present invention, such as running most of the code on the migration tool 402 instead of running it on the source and destination, and avoiding use of a network to transfer data.
[0063] Finally, the tool 402 is disconnected 518 from the destination 404 and the destination 404 is rebooted to use its normal operating system and file system software.
[0064] Although a specific sequence of steps is shown in FIG. 5 and/or discussed in the text, it will be appreciated that steps may be reordered, performed concurrently, omitted, repeated, grouped differently, and/or renamed, in various embodiments of the invention. For instance, steps 500 and 502 could be performed in the reverse order, or they could overlap in execution. Steps 504 and 506 could be repeated some number of times before step 510 . Step 510 might not be performed until some time after step 512 begins. Steps 512 and 514 could be performed in the reverse order, or they could overlap in execution. Moreover, any one or more of the steps grouped above for convenience under the optional “fifth step” (namely, downloading, storing, analyzing, cloning, updating, retaining, assessing, preserving, saving, compressing, encrypting, converting, erasing) could be performed at various points. It will be apparent that other variations are also possible.
[0065] The inventive migration software or a portion thereof may be embodied in a configured storage medium. Suitable configured storage media include magnetic, optical, or other computer-readable storage devices having specific physical substrate configurations. Suitable storage devices include diskettes, Iomega Zip disks, hard disks, tapes, CDROMs, PROMs, RAM, and other computer system storage devices. The substrate configuration represents data and instructions which cause the computer 400 , 402 , and/or 404 to operate in a specific and predefined manner as described herein. Thus, in some cases the medium tangibly embodies a program, functions, and/or instructions that are executable by a source computer 400 and/or destination computer 404 to perform file and port I/O steps of the present invention substantially as described herein. In other cases the medium tangibly embodies a program, functions, and/or instructions that are executable by a migration tool 402 to perform port I/O, data 118 identification, and other steps of the present invention substantially as described herein.
[0066] Although particular systems and methods embodying the present invention are expressly illustrated and/or textually described herein, it will be appreciated that apparatus, signal, and article embodiments may also be formed according the present invention. Unless otherwise expressly indicated, the discussion herein of any type of embodiment of the present invention therefore extends to other types of embodiments in a manner understood by those of skill in the art.
[0067] The invention may be embodied in other specific forms without departing from its essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. 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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A migration tool and methods for migrating computer personalization information from one computer to another when a network is not available, when a network is available but use of the network is undesirable for some reason, and/or when the computer which is the source of the data being migrated has limited or unknown resources to support conventional forms of data migration.
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BACKGROUND OF THE INVENTION
This invention relates to a system for controlling the air intake of an engine, or more in particular to a system for controlling the idling speed of engine revolutions and the pressure in its air intake tube at the time of deceleration for a spark-ignition type of engine.
Generally, in the idling operation of a spark-ignition type of engine that is cold, viscosity of the lubricant is high and therefore friction loss is large. Thus more air than when the engine is warm is supplied to the engine to enable the engine to run against the friction and preferably the number of revolutions or engine speed is maintained high in order to shorten the warm-up period.
In a known system to achieve this purpose, an air duct tube bypassing the throttle valve is provided with a bi-metal air control valve midway thereof. In accordance with the engine temperature, the amount of air flowing through the duct tube is controlled, thus controlling the engine speed.
If the pressure in the air intake tube is reduced at the time of deceleration, pressure at the time of ignition in the engine combustion chamber is reduced, with the result that the fuel is fired erroneously, thereby discharging a great amount of harmful HC gases into the atmosphere. In the case where the exhaust system includes a catalyst reactor as an exhaust gas purifier, a great amount of HC reacts in the catalyst reactor, and the resulting heat of reaction overheats the catalyst reactor, often causing it to melt.
According to a known method for obviating such a problem, a special device having a diaphragm valve is mounted by which when the pressure in the air intake tube is reduced below a predetermined level, additional air is supplied into the engine, thus preventing the pressure in the air intake tube from decreasing below the setting.
In the above-mentioned engine speed control system, only the engine temperature is used as a control parameter. Therefore, the disadvantage is that when different types of engine lubricant are involved, the difference in lubricant viscosity makes it impossible to attain a high design speed or results in an engine speed higher than the design speed.
Another disadvantage of the above-mentioned conventional system is that since the engine speed control system and the air intake tube pressure control device for deceleration are mounted separately from each other, a larger mounting space is required. This necessitates the use of more air duct tubes and increases the cost of the system.
SUMMARY OF THE INVENTION
The present invention has been developed in view of the above-described shortcomings of the conventional systems. The engine intake air control system according to the present invention comprises an air duct tube bypassing a throttle valve of the air intake tube for taking in the air to be supplied to the engine, valves for regulating the amount of air flowing through the air duct tube, and a control device therefor. The idling or loaded operation of the engine is discriminated by the opening of the throttle valve. During the idling operation, a signal representing a reference number of revolutions depending on the engine temperature is generated, the actual engine speed is compared with the reference speed, and by use of the result of comparison, the amount of air flowing through the bypass is controlled so that the engine revolutions are rendered identical to the reference revolutions. In the case of a loaded operation, on the other hand, the amount of air in the bypass is controlled in accordance with the air intake pressure downstream of the throttle valve, thus maintaining constant the air intake pressure downstream of the throttle valve.
An object of the present invention is to provide an engine air control system able to accurately control the engine idling speed for different types of engine lubricants and at the same time to prevent the pressure in the air intake tube from decreasing below a predetermined level, resulting in a reduced mounting space and cost.
According to the present invention, the engine idling speed is properly controlled in accordance with the warm-up condition of the engine and the on-off state of the air conditioner. At the time of deceleration, the pressure in the air intake tube is prevented from dropping below the predetermined level. Further, the need for a plurality of control devices which are provided for different purposes in the conventional system is eliminated. Due to these great advantages, both the mounting space and cost are reduced, design freedom is improved, and thus the number of component parts is reduced for an improved reliability.
Also, by the use of closed loop control in which the idling speed is controlled by comparing the actual speed with a desired speed setting, the engine operation is not affected by various external factors including difference in viscosity of engine oil, thus making it possible to control the engine speed stably as intended by the design engineers.
Furthermore, if an integrator circuit is used as the circuit for generating a control signal associated with the engine speed, the control speed is increased the greater, the larger the deviation of the engine speed from the speed setting, resulting in the advantage that the actual speed is corrected to attain the set speed stably and sensitively.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing the configuration of an embodiment of the system according to the present invention.
FIG. 2 is an electrical circuit diagram showing the electronic air control unit included in FIG. 1.
FIG. 3 is a diagram showing signal waveforms produced at various parts in FIG. 2.
FIGS. 4 and 5 are characteristics diagrams for explaining the operation of the system shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention will be explained below with reference to an embodiment shown in the drawings. In FIG. 1, reference numeral 10 shows a known engine of four-cycle spark ignition type for an automobile, which takes in air through an air cleaner 11, an air flowmeter 12, an air intake tube 13 and an intake manifold 14, while fuel such as gasoline is supplied by injection from an electromagnetic fuel injection valve 15 provided on the intake manifold 14. Also, the exhaust gas from the engine 10 is discharged into atmosphere through a catalyst reactor and a quenching muffler neither of which are shown in the drawings. The amount of air taken in by the engine 10 is regulated by the throttle valve 16 operated as desired. The amount of fuel injected is adjusted by the electronic fuel control unit 17. The electronic fuel control unit 17 is a known device for determining the amount of fuel to be injected from basic parameters including the engine revolution speed detected by the ignition distributor 18 functioning as an engine speed sensor, and the amount of the air taken in as measured by the air flowmeter 12. Signals from the engine warm-up sensor 19 for detecting the temperature of the engine cooling water are also applied to the electronic fuel control unit 17, thus increasing or decreasing the amount of fuel injection.
The air duct tubes 21 and 22 are provided in a manner to bypass the throttle valve 16. Between the duct tubes 21 and 22, an air control valve 30 is provided for regulating the auxiliary air taken in. An end of the duct tube 21 is connected to the air inlet provided between the throttle valve 16 and air flowmeter 12, while an end of the duct tube 22 is connected to the air outlet provided downstream of the throttle valve 16.
The air control valve 30 is of diaphragm control type for transmitting the vibrations of the diaphragm 33 with the periphery thereof inserted between the housings 31 and 32, to the valve body secured to the shaft 34, thus opening or closing the valve seat 36. The diaphragm 33 is displaced by the pressure difference between diaphragm chamber 37 and atmospheric pressure chamber 38 and energized by the compression coil spring 39 through a spring support, thus providing the valve-opening force for the valve body 35.
The valve body 35 is essentially a needle valve acting in such a manner that the distribution area formed by it and the valve seat 36 is continuously changed in accordance with the displacement of the diaphragm 33, i.e., the pressure of the chamber 37, thus controlling the amount of air flowing from the inlet pipe 41 to the outlet pipe 42. The valve body 35 is arranged in reverse way to an ordinary needle valve so that it is opened with the increase in the pressure of the chamber 37 and closed with the decrease in the pressure of the chamber 37.
The valve body 35 is provided with the valve-opening force from the comparatively weak coil spring 43 through the spring support and the shaft 34.
A holding plate 44 is secured to the housing 32. The shaft 34 is guided by the holding plate 44 and the support 45 of the housing. Atmospheric air is introduced into the atmospheric pressure chamber 38 through the small hole 46.
For introducing the atmospheric pressure, the diaphragm chamber 37 is connected to the port 48 upstream of the throttle valve 16 through the tube 47. Also for introducing a negative pressure, the diaphragm chamber 37 is connected to the intake manifold 14 downstream of the throttle valve 16 through the tube 49 and the constricting section 50. Midway of the tube 47, there is provided an electro-magnetic valve mechanism or an electromagnetic valve 51 for controlling the opening of the air control valve 30 by opening or closing the tube 47.
The electromagnetic valve 51 is connected to the electronic air control unit 60 for controlling the magnetic excitation thereof. The electronic air control unit 60 is connected to the distributor 18, the engine warm-up sensor 19, the air-conditioning switch 23, the throttle switch 24 for detecting the closed-up state or a slight opening in the neighbourhood thereof of the throttle valve 16, and the pressure sensor 25 for detecting the pressure in the intake manifold downstream of the throttle valve 16. The electronic air control unit 60 is impressed with an engine speed signal, a cooling water temperature signal, a throttle signal, an air-conditioner on-off signal and an air intake tube pressure signal.
The air-conditioning switch 23 is for operating the air conditioner of the automobile. When this switch 23 is turned on, the electromagnetic clutch 27 is actuated with the result that the compressor 28 for the air conditioner is connected as a load of the engine 10. The pressure sensor 25 is comprised, for example, of a switch untilizing a diaphragm and turned on to produce a "1" signal when the air intake tube pressure is reduced below a predetermined value, say, -500 mmHg (assuming that the atmospheric pressure is 0 mmHg) as at the time of engine deceleration.
The electronic air control unit 60 will be described in detail below with reference to FIG. 2. The D-A converter 100 is impressed with an ignition pulse signal synchronous with the engine rotation from the ignition distributor 18. The waveform of this signal is shaped as shown in (A) of FIG. 3 by the waveform shaping section including the resistors 101, 102, 103 and 104, the capacitor 106 and the transistor 108. The pulse signal thus shaped in waveform is D-A converted by the capacitors 107 and 111 and the diodes 109 and 110, thus producing at the terminal B a voltage as shown in (B) of FIG. 3, which is the result of superimposition of an analog DC voltage proportional to the engine speed on a saw-tooth voltage of a frequency synchronous with the engine speed (intermittent signal). The function voltage generator circuit 200 is impressed with the output signal of the engine warm-up sensor 19 and the on-off signal of the air-conditioning switch 23. The output of the engine warm-up sensor 19 is amplified by a known amplifier circuit 201 and thus converted into a voltage signal corresponding to the engine warm-up condition. This voltage signal is applied to the first comparator circuit 300 via the resistor 202 and the diode 203, while the on-off signal from the air-conditioning switch 23 is applied to the first comparator circuit 300 via the resistor 204 and the diode 205, thus supplying a function voltage (with reference level of D) to the first comparator circuit 300.
The first comparator circuit 300 is comprised of the resistors 301, 302 and 303, the comparator 304 and the transistor 305 connected between the reversing input terminal and the output terminal of the comparator 304. The first comparator circuit 300 thus compares the output voltage of the D-A converter 100 with the function voltage (with reference level of D) of the function voltage generator circuit 200. The output characteristics of the function voltage generator circuit 200 are such that as shown in FIG. 4, the lower the engine temperature W, the larger the output voltage thereof. When the air-conditioning switch 23 is off, the output of the circuit 200 takes the form as shown by the solid line in FIG. 4, and when the air-conditioning switch 23 is turned on, the output voltage is increased as shown by the dashed line in FIG. 4. Only as long as the output voltage of the D-A converter 100 is lower than the reference level D, the comparator circuit 300 produces signal C of "1" level as shown in (C) of FIG. 3.
The integrator circuit 400 is for charging or discharging at constant current the capacitor 401 in response to the signal C, and comprises the constant-current circuits 402 and 403 and the diodes 404 and 405. As long as the output signal C of the comparator circuit 300 is at "1" level, the capacitor 401 is charged at constant current and therefore the output voltage E of the integrator circuit 400 increases as shown by the dashed line in (E) of FIG. 3; while as long as the output voltage is at "0" level, the capacitor 401 is discharged at constant current and therefore the output voltage E is decreased.
The triangular wave oscillator 500 is a known device for producing the triangular wave voltage F of regular cycles as shown by the solid line in (E) of FIG. 3.
The second comparator circuit 600 is for comparing the output voltage E of the integrator circuit 400 with the triangular wave voltage F of the oscillator 500 applied thereto, and comprises the resistor 601 and the comparator 602. This circuit 600 produces a pulse signal G which is maintained at "1" level only as long as the output voltage E of the integrator circuit 400 is higher than the triangular wave voltage F as shown in (G) of FIG. 3.
The amplifier circuit 700 is a known device for amplifying the output signal G of the second comparator circuit 600. The amplified output of the circuit 700 is applied to the electromagnetic coil 52 of the electromagnetic valve 51 making up an electromagnetic mechanism.
The command circuit 800 is connected to the throttle switch 24, the pressure sensor 25 and the starter switch 29 for generating a "1" level signal only when the starter for starting the engine 10 is driven. The command circuit 800 comprises the resistors 801 to 806, diode 807, and transistors 808 and 809. The collector of the transistor 808 is connected via the resistor 805 to the transistor 305 of the first comparator circuit 300. When a "1" level signal is applied from the throttle switch 24 or starter switch 29, the transistor 808 conducts, thus causing the transistor 305 of the first comparator circuit 300 to conduct. Thus, the comparator 304 of the first comparator circuit 300 is operated as an impedance converter.
When a "1" level signal is applied from the pressure sensor 25, on the other hand, the transistor 809 is turned on, so that the transistor 808 is turned off irrespective of the output signal of the throttle switch 24, while the comparator 304 acts as a comparator. At the same time, the output signal of the pressure sensor 25 is applied to the terminal D through the resistor 806 and diode 807, thereby increasing the voltage of reference level D and producing a "1" level signal at the output of the comparator 304.
Circuits 100, 300, 400, 500, 600 and 700 make up a closed loop control circuit.
Operation of the above-mentioned system will be described below. Assume that the engine 10 is idling with the throttle valve 16 closed. If the idling speed is lower than the speed setting corresponding to the function voltage (reference level D) determined by the function voltage generator circuit 200 of the electronic air control unit 60, the output of the D-A converter 100 is also reduced with respect to the reference level D. As a result, the output of the D-A converter 100 is always lower or only slightly higher than the reference level D as shown at the central part in (B) of FIG. 3. Therefore, the output signal of the first comparator circuit 300, as shown at the central part of (C) of FIG. 3, is always at "1" level, or at "0" level for a very short period of time. Thus the output voltage E of the integrator circuit 400 increases as shown by dashed line at the central part of (E) of FIG. 3.
As a result, in the second comparator circuit 600, the period T for which the integrated voltage E is higher than the triangular wave voltage F of the oscillator 500, i.e., the period for which the comparator 602 produces a "1" level signal is lengthened, and the proportion of time for which power is supplied to the electromagnetic coil 52 of the electromagnetic valve 51 is increased. In other words, the opening of the air control valve 30 is increased, with the result that the amount of auxiliary air bypassing the throttle valve 16 is increased, thus increasing the speed of the engine 10.
When the engine speed is higher than the set speed, on the other hand, the output of the D-A converter 100 is always higher or slightly lower than the reference level D representing the set speed as shown on the right side of (B) of FIG. 3. Also, the output signal of the first comparator circuit 300 is always at "0" level or at "1" level for a very short period of time as shown on the right side of (C) in FIG. 3. As a result, the output voltage E of the integrator circuit 400 decreases as shown by the dashed line on the right side in (E) of FIG. 3.
Thus, in the second comparator circuit 600, the period of time T during which the integrated voltage E is higher than the triangular wave voltage F of the oscillator 500 (i.e., the period for which the output of the comparator 60 is "1" signal) is reduced, so that the proportion of time for which the electromagnetic coil 52 of the electromagnetic valve 51 is energized is reduced. As a result, the opening of the air control valve 30 is lessened, and the amount of auxiliary air bypassing the throttle valve 16 decreases, thereby reducing the speed of the engine 10.
In this way, during the idling operation with the throttle valve 16 closed, the engine speed is regulated by the electronic air control unit 60 at the set speed corresponding to the reference level D determined by the output of the function voltage generator circuit 200. As shown by the solid line in FIG. 4, the reference level D on which the set speed depends is higher, the lower the engine temperature W in accordance with the output of the engine warm-up sensor 19. During the engine warm-up, therefore, the engine speed is increased in accordance with the engine temperature W, thus making possible stable idling operation. Further, when the air-conditioning switch 23 is turned on with the compressor 27 for the automobile cooler or like connected to the engine 10, the ON signal of the air-conditioning switch 23 is applied to the function voltage generator circuit 200, which raises the reference level D as shown by dashed line in FIG. 4, thus changing the set speed upward. As a result, the compressor 27 is driven at a sufficiently large driving force without any engine stall.
Now, assume that the engine 10 transfers from idling to loaded run with the throttle valve 16 opened. The transistor 808 of the command circuit 800 is turned on, so that the transistor 305 of the first comparator circuit 300 conducts. The comparator 304 of the first comparator circuit 300 thus operates as an impedance converter. The output voltage of the function voltage generator circuit 200, i.e., the reference level D is directly produced from the impedance converter. The output voltage of the integrator circuit 400 approximates the reference level D. Thus the second comparator circuit 600 produces a pulse signal G of predetermined width associated with the reference level D of the function voltage generator circuit 200. The air control valve 30 supplies a predetermined amount of auxiliary air associated with the engine temperature W bypassing the throttle valve 16. This results in the advantages mentioned below.
Generally, the engine speed is higher in loaded operation than in idling operation. Therefore, if the speed control is effected without the command circuit 800, the auxiliary air duct tubes 21 and 22 are closed so that no auxiliary air is supplied. At the time of transfer from loaded to idling run, the engine speed is reduced temporarily below the set speed, thus causing an engine stall or unstable engine condition until the set speed is attained. In the embodiment under consideration, however, such a problem is eliminated for the reason that during the loaded run when the throttle valve 16 is opened, a predetermined amount of auxiliary air is supplied in accordance with the engine condition (or engine temperature in this embodiment).
According to the embodiment under consideration, when the starter is driven to start the engine, the starter switch 29 produces a "1" level signal. In this case, like in the above-mentioned case where the throttle valve 16 is opened, the transistor 808 of the command circuit 800 conducts and issues a command. Thus the output of the integrator circuit 400 approximates that of the function voltage generator circuit. In other words, the second comparator circuit 600 produces a pulse signal of predetermined pulse width in accordance with the engine condition or engine temperature in this case while maintaining the amount of auxiliary air constant in accordance with the engine condition, thus improving the engine starting characteristics.
Further, at the time of automobile deceleration, the throttle valve 16 is closed at high engine speed. When the pressure P of the air intake tube is reduced below the predetermined value P1 as shown in FIG. 5, the pressure sensor 25 produces a "1" level signal as shown in (H) of FIG. 5. The transistor 809 is turned on, and the transistor 808 is turned off in the absence of the signal from the throttle switch 24. At the same time, the voltage level at the input terminal D of the comparator 304 is raised, so that the output signal of the comparator 304 is maintained at "1" level without regard to the output signal of the D-A converter 100.
Thus the output signal of the integrator circuit 400 increases as shown for the period T1 in (E) of FIG. 5. In the second comparator circuit 600, the period of time T when the integrated voltage E is higher than the triangular wave voltage F of the oscillator 500 is increased, so that the proportion of time for which the electromagnetic coil 52 is energized is increased. The result is that the opening of the air control valve 30 is increased, thus increasing the amount of auxiliary air and the pressure P of the air intake tube downstream of the throttle valve 16.
When the pressure P of the air intake tube is increased beyond the predetermined level, the pressure sensor 25 produces a "0" level signal. As a result, as long as the throttle switch 24 is off, the reference level D is reduced to the level determined by the output signals of the engine warm-up sensor 19 and the air-conditioning switch 23, and therefore the output signal of the comparator 304 is reduced to "0" level, thus reducing the output voltage E of the integrator circuit 400. Also when the throttle switch 24 is on, the output voltage E is decreased. The proportion of time of energization of the electromagnetic coil 52 is reduced, so that the opening of the air control valve 30 is lessened, thus reducing both the amount of auxiliary air and the pressure P of the air intake tube. When the pressure P of the air intake tube is reduced below the predetermined value P1, the pressure sensor 25 produces again a "1" level signal, thus repeating the above-mentioned processes of operation.
In this way, at the time of automobile deceleration, the pressure P of the air intake tube is substantially regulated at predetermined value P1 and not reduced considerably below that level, thereby reducing the amount of HC exhaust or preventing the overheat of the catalyst reactor.
In the above-mentioned embodiment, the function voltage from the function voltage generator circuit 200 is controlled by the command circuit 800 in such a manner that energization of the electromagnetic valve 51 is controlled at the time of automobile deceleration. Instead, the output level of the triangular wave oscillator 51 may be controlled or the output signal of the amplifier circuit 700 may be directly controlled.
Also in place of the diaphragm valve used as an air control valve for controlling the auxiliary air and the electromagnetic valve as an electromagnetic mechanism in the above-mentioned embodiment, a combination of a butterfly valve and a motor such as a pulse motor or a combination of a needle valve and an electromagnetic actuator with the plunger displaced by an electromagnetic coil may be used alternatively.
In such a case, the output signal of the integrator circuit 400 is connected to a known driving circuit to drive the electromagnetic mechanism.
Further, although the amount of auxiliary air supply is controlled by causing it to bypass the throttle valve in the embodiment described above, the throttle valve itself may act as an air control valve. In this case, the system is so constructed that the air of an amount associated with the closed-up state of the throttle valve is supplied to the engine, and the closed-up state of the throttle valve is controlled by the electromagnetic mechanism.
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A system for controlling the amount of air taken in by an engine comprises an air duct tube bypassing a throttle valve of an intake tube for taking in air supplied to an automobile engine, a plurality of valves for regulating the amount of air passing through the air duct tube, and control device therefor. The amount of air in the bypass is controlled in accordance with the temperature and number of revolutions of the engine and the air intake pressure downstream of the throttle valve. During the idling of the engine, the air intake control system generates a signal representing the standard engine idling revolutions in accordance with the engine temperature, compares the actual engine revolutions with a reference, and regulates the amount of air flowing in the bypass by use of the results of a comparison, thus rendering the actual engine revolutions identical to the reference. During the loaded engine operation, by contrast, the amount of bypass air is so controlled that the air intake pressure downstream of the throttle valve is maintained at predetermined constant value.
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FIELD OF THE INVENTION
[0001] The invention relates to a method for separation and purification of epothilones. In particular, the invention relates to a method for separation and purification of epothilones B and A.
BACKGROUND OF THE INVENTION
[0002] Epothilone is a novel natural cytotoxic compound produced by myxobacteria as a new cytotoxic active component stabilizing microtubules (See Gerth, K, et. al., J. Antibiot. 49: 560-563 (1966)). It is biologically similar to paclitaxel which has significant antineoplastic activity on various solid tumors of human beings. That is, epothilone induces tubulin-polymers to form a super stable state one, inhibits mitosis, and thereby suppresses reproduction of tumor cells in a manner similar to paclitaxel.
[0003] Epothilones are superior to paclitaxel-based medicines in sources, synthesis methods, hydrophilicity, antineoplastic activity, antitumor spectrum and so on. In addition, epothilones, preferably epothilone A and most preferably epothilone B, have various advantages than current therapies, particularly the treatment using paclitaxel which has induced drug tolerance of tumors. Therefore, as a novel antitumor drug, epothilones are deemed as a promising candidate to replace paclitaxel with great market potential. The structures of epothilones B and A are shown below.
[0000]
[0004] Since the antineoplastic activity of epothilones has been discovered in 1995, epothilones have been widely and deeply investigated from many aspects including chemistry, biology, medicine, pharmacy and so on, and certain results have been obtained.
[0005] With the advancement of research, there is an increasing need for epothilones with a high purity. Thus, how to separate and purify epothilones becomes an urgent problem to be solved. Many works have been made in China and oversea on epothilones, particularly processes for separation and purification of epothilones B and A. Chinese Patent No. ZL01820141.5, for example, discloses a method of separation and purification of epothilones, wherein desorption of epothilones, particularly epothilone A and/or epothilone B from a resin is disclosed. Chinese Patent No. ZL02110067.5 relates to a method of separation and purification of epothilones from fermentation broth of myxobacteria, wherein it discloses that technical means including adsorption by mixed resins, solid-liquid stepwise extraction, molecular sieve chromatography, crystallization and HPLC, etc are used to separate and obtain epothilones from fermentation broth of myxobacteria. In Chinese Patent No. ZL99803121.6, RP-HPLC is disclosed as a method used to purify epothilones B and A, while in patent No. CN03822662.6, normal HPLC is used to separate epothilones B and A.
[0006] Current techniques mainly use preparative chromatographic columns to separate and purify epothilones B and A, which not only need expensive apparatuses, but also consume a great amount of methanol or acetonitrile, with only a limited amount of product obtained in one time.
SUMMARY OF THE INVENTION
[0007] With respect to defects existing in the art of separation and purification of epothilone B and epothilone A, the object of the invention is to provide a novel method for separation and purification of epothilone B and epothilone A by using normal phase silica gel chromatography.
[0008] The method of the invention comprises:
[0009] dissolving a sample containing epothilones B and A in C 1 -C 7 alkyl halide compound(s) to form a mixture, wherein the mixture is mixed with silica gel or not;
[0010] loading the mixture on a silica gel column;
[0011] gradient eluting the silica gel column with a normal phase silica gel column eluent;
[0012] collecting fractions; and
[0013] obtaining products.
[0014] Preferably, the method of the invention using normal phase silica gel chromatography for separation and purification of epothilone B and epothilone A further comprises the following steps:
[0015] dissolving a sample containing epothilones B and A in C 1 -C 7 alkyl halide compound(s) to form a mixture, wherein the mixture is mixed with silica gel of a first normal phase silica gel column or not;
[0016] loading the mixture on the first normal phase silica gel column;
[0017] gradient eluting the silica gel column with a normal phase silica gel column eluent;
[0018] collecting fractions containing epothilone B and epothilone A;
[0019] combining the fractions containing epothilone B and epothilone A;
[0020] concentrating the combined fractions followed by crystallization to obtain a crude crystal containing epothilones B and A;
[0021] dissolving the crude crystal containing epothilones B and A in C 1 -C 7 alkyl halide compound(s) to form a second mixture, wherein the second mixture is mixed with silica gel of a second normal phase silica gel column or not;
[0022] loading the second mixture on a second normal phase silica gel column;
[0023] gradient eluting the silica gel column with a normal phase silica gel column eluent;
[0024] collecting fractions containing epothilone B and fractions containing epothilone A respectively.
[0025] Epothilone B, after crystallization, is dissolved in t-butanol and lyophilized to obtain amorphous powder with a high purity; and epothilone A is dissolved in t-butanol and lyophilized to obtain amorphous powder with a high purity.
[0026] In the method of the invention using normal phase silica gel chromatography for separation of epothilones B and A, both of the first and second normal phase silica gel columns are those common in the art. In present invention, silica gel used in the first and second normal phase silica gel columns may be the same or different, and the same silica gel used for both columns is preferred.
[0027] In the method of the invention using normal phase silica gel chromatography for separation of epothilones B and A, the preferred amount of the silica gel used in the first normal phase silica gel column has a mass ratio of the silica gel to the sample of 5-10:1, and the amount of the silica gel used in the second normal phase silica gel column has a mass ratio of the silica gel to the crystal sample of 50-200:1.
[0028] The normal phase silica gel column is preferred to be balanced by a solvent of C 1 -C 7 alkyl halide compound(s) before use so as to obtain better yields of epothilone B and epothilone A. Preferably, C 1 -C 7 alkyl halide compound(s) may be one or more of dichloromethane, trichloromethane and bromoethane, wherein dichloromethane, trichloromethane or a combination thereof is more preferred.
[0029] The gradient eluent of the normal phase silica gel columns of the invention may be C 1 -C 7 hydrocarbons, C 1 -C 7 alkyl halide compound(s), C 1 -C 7 ketones, C 1 -C 7 esters or any combinations thereof, wherein
[0030] C 1 -C 7 hydrocarbons may be one or more selected from petroleum ether, n-hexane, cyclohexane and n-heptane, wherein petroleum ether is further preferred;
[0031] C 1 -C 7 alkyl halide compound(s) may be one or more selected from dichloromethane, trichloromethane and bromoethane, wherein dichloromethane is further preferred;
[0032] C 1 -C 7 ketones may be selected from acetone, butanone and a combination thereof; wherein acetone is further preferred;
[0033] C 1 -C 7 esters may be selected from ethyl acetate, isobutyl acetate and a combination thereof; wherein ethyl acetate is further preferred.
[0034] The more preferred gradient eluent of the normal phase silica gel column of the invention may be one or a combination of two or more selected from petroleum ether, ethyl acetate, acetone, trichloromethane and dichloromethane.
[0035] Preferably, the eluent of the first normal phase silica gel column is a combination of acetone and petroleum ether, or a combination of ethyl acetate and petroleum ether. In the combination of acetone and petroleum ether, the preferred volume ratio of acetone and petroleum ether is 1:3-9, and in the combination of ethyl acetate and petroleum ether, the preferred volume ratio of ethyl acetate and petroleum ether is 1:1-9.
[0036] Preferably, the eluent of the second normal phase silica gel column is a combination of acetone and petroleum ether, or a combination of petroleum ether and acetone with either dichloromethane or trichloromethane. In the combination of acetone and petroleum ether, the volume ratio of acetone and petroleum ether is 1:3-9, and in the combination of petroleum ether and acetone with either dichloromethane or trichloromethane, the volume ratio of acetone and petroleum ether is 1:3-9, and the volume of dicholomethane or trichloromethane is 5%-50% of the total volume.
[0037] In the process of separation and purification of epothilone B and epothilone A by normal phase silica gel chromatography, crystallization of epothilones B and A may be performed by any conventional techniques in the art. In order to achieve better performance, it is preferred to use n-heptane, ethyl acetate, or a combination thereof as the solvent for crystallization. It is more preferred that crystallization solvent is a mixture of n-heptane and ethyl acetate with a volume ratio of 1:1. The crystallization may be preferably performed by solving the crude product containing epothilones B and A, or the crude product containing epothiloine B in an appropriate amount of ethyl acetate, adding n-heptane therein and letting the solution stand at room temperature, then cooling to 4° C. so as to obtain crystals.
[0038] In the process of separation and purification of epothilone B and epothilone A by normal phase silica gel chromatography, the sample containing epothilones B and A that is loaded on the first normal phase silica gel column is obtained by treating a fermentation broth of a strain of myxobacteria that generates epothilones with conventional means and then removing impurities therein.
[0039] In order to achieve the object of the invention better, the sample containing epothilones B and A that is loaded on the first normal phase silica gel column is a crude product obtained by treating a fermentation broth containing epothilones B and A with non-polar macroporous polymeric adsorbents. Specifically, the method is performed as:
[0040] adding a resin of a first non-polar macroporous polymeric adsorbent column into the fermentation broth of myxobacteria, and filtering by a vibrating screen and washing by water to remove impurities at the same time, and then loading the resin in a column, gradient eluting with an alcohol solution, and combining fractions containing epothilones B and A;
[0041] diluting the combined fractions containing epothilones B and A to an appropriate concentration, then loading the diluted solution on a second non-polar macroporous polymeric adsorbent column, gradient eluting with an alcohol solution, collecting fractions containing epothilones B and A, combining the fractions and then obtaining the sample containing epothilones B and A.
[0042] In present invention, the first non-polar macroporous resin and the second non-polar macroporous resin are non-polar macroporous polymeric adsorbents used to separate epothilones from the fermentation broth. The non-polar macroporous polymeric adsorbents may be the same or different.
[0043] The preferred first non-polar macroporous polymeric adsorbent of present invention may be XAD-1600 or HP-20, such as Amberlite XAD-1600 (Rohm & Haas, America) and Diaion HP-20 (Mitsubishi Chemical, Japan), wherein XAD-1600 is more preferred.
[0044] The preferred second non-polar macroporous polymeric adsorbent of present invention may be non-polar macroporous polymeric adsorbents of H41 or H60 (produced by Chinese Academy of Forestry Institute of Chemical Engineering, Nanjing Science and Technology Development Corporation), wherein non-polar macroporous polymeric adsorbents of H41 are more preferred.
[0045] The eluent used in the first non-polar macroporous polymeric adsorbent and the second non-polar macroporous polymeric adsorbent is an alcohol solution, such as a solution of ethanol or methanol. An ethanol solution is preferred. A more preferred eluent used for the first non-polar macroporous polymeric adsorbent is an ethanol solution of 30%-100% by volume; and an eluent used for the second non-polar macroporous polymeric adsorbent is an ethanol solution of 30%-80% by volume.
[0046] In the process of separation and purification of epothilone B and epothilone A by normal phase silica gel chromatography, the fractions eluted from the adsorbents and the fractions eluted from the normal phase silica gel columns are measured by HPLC, and the fractions preferred to be collected are those:
[0047] fractions from the first non-polar macroporous polymeric adsorbent have over 50 ferment units based on total of epothilones B and A by analysis of HPLC;
[0048] fractions from the second non-polar macroporous polymeric adsorbent have over 50 ferment units based on total of epothilones B and A by analysis of HPLC;
[0049] fractions from the first normal phase silica gel column have more than 80% chromatographic purity based on total of epothilones B and A by analysis of HPLC; and
[0050] fractions from the second normal phase silica gel column have more than 97.5% chromatographic purity based on epothilone B and more than 92.5% chromatographic purity based on epothilone A by analysis of HPLC.
[0051] The analysis of HPLC may be performed by any conventional methods in the art, wherein the following process is preferred:
[0052] a reversed-phase semi-preparative column (Agilent ZORBAX Eclipse XDB-C18), 250*9.4 mm, 5 μm of particle diameter of fillers, 1.5 mL/min of flow rate, measured at 249 nm, and methanol:water=80:20 as mobile phase; or
[0053] an analytical column (SHIMADZU XOD-C18), 150*6.0 mm, 5 μm of particle diameter of fillers, 1.0 mL/min of flow rate, measured at 249 nm, and acetonitrile:methanol:water=40:20:50 as mobile phase.
[0054] According to a preferred embodiment of the invention for separation and purification of epothilone B and epothilone A by normal phase silica gel chromatography, the method comprises the following steps:
[0055] (1) filtering the fermentation broth wherein XAD-1600 type resin is added by a vibrating screen and washing by water to remove impurities at the same time, then loading the resin in a column, gradient eluting with an ethanol solution of 30%-100% by volume, collecting fractions sectionally, collecting respectively fractions containing epothilone B and epothilone A after analysis by HPLC, and then combining fractions containing epothilone B and epothilone A;
[0056] (2) diluting the combined fractions containing epothilones B and A to form an alcohol solution with an appropriate concentration, or concentrating combined fractions to a suitable volume by vacuum evaporation and then diluting to form an alcohol solution with an appropriate concentration, loading the alcohol solution on H41 type resin column, and gradient eluting with an alcohol solution of 30%-80% by volume, collecting fractions sectionally, collecting fractions containing epothilone B and epothilone A after analysis by HPLC, combining fractions containing epothilone B and epothilone A, concentrating the combined fractions by vacuum evaporation until dry so as to obtain a sample containing epothilones B and A;
[0057] (3) dissolving the sample containing epothilones B and A in trichloromethane or dichloromethane, wherein the mixture is mixed with silica gel of a first normal phase silica gel column or not; then loading the mixture on the first normal silica gel column, gradient eluting by a mixture of petroleum ether/acetone or a mixture of petroleum ether/ethyl acetate, collecting fractions sectionally, collecting fractions containing epothilone B and epothilone A after analysis by HPLC, combining fractions containing epothilone B and epothilone A, concentrating combined fractions by vacuum evaporation until dry, performing crystallization by a mixed solvent of ethyl acetate/n-heptane to obtain crude crystal containing epothilones B and A;
[0058] (4) dissolving the crude crystal containing epothilones B and A in trichloromethane or dichloromethane, wherein the second mixture is mixed with silica gel of a second normal phase silica gel column or not; then loading the second mixture on the second normal silica gel column, gradient eluting by a mixture of petroleum ether/acetone or a mixture of petroleum ether/acetone/trichloromethane, collecting fractions sectionally, collecting respectively fractions containing epothilone B and fractions containing epothilone A after analysis by HPLC;
[0059] (5) performing crystallization on fractions containing epothilone B by ethyl acetate/n-heptane, then dissolving the crystal in t-butanol and lyophilizing the solution to obtain product in a form of amorphous power with a high purity; dissolving epothilone A in t-butanol and lyophilizing the solution to obtain a product in a form of amorphous power with a high purity.
[0060] According to actual requirement on purity, epothilone B or epothilone A obtained from step (5) may be further purified. For example, epothilone B may be further purified by re-crystallization as described in the invention, and epothilone A may be purified by the second normal phase silica gel column of the invention again, so that epothilone B or epothilone A with a higher purity, such as 99.0% or above, may be obtained.
[0061] Epothilone B: ESIMS m/z 508 [M+H] + ; 1 H NMR (CDCl 3 , 400 MHz) δ: 6.98 (1H, s, H-19), 6.60 (1H, bs, H-17), 5.42 (1H, dd, J=7.9, 2.8 Hz, H-15), 4.24 (1H, m, H-3), 3.77 (1H, dd, J=8.4, 4.2 Hz, H-7), 3.30 (1H, m, H-6), 2.82 (1H, dd, J=7.7, 4.5 Hz, H-13), 2.70 (3H, s, H-21), 2.54 (1H, dd, J=14.1, 10.6 Hz, H-2a), 2.38 (1H, dd, J=14.1, 3.0 Hz, H-2b), 2.10 (1H, m, H-14a), 2.09 (3H, d, J=1.0 Hz, H-27), 1.90 (1H, m, H-14b), 1.72 (2H, m, H-8, H-11a), 1.49 (2H, m, H-10), 1.41 (3H, m, H-9, and H-11b), 1.39 (3H, s, H-23), 1.28 (3H, s, H-26), 1.17 (3H, d, J=6.8 Hz, H-24), 1.08 (3H, s, H-22), 1.00 (3H, d, J=7.0 Hz, H-25); 13 C NMR (CDCl 3 , 100 MHz) δ 220.6 (s, C-5), 170.6 (s, C-1), 165.2 (s, C-20), 151.8 (s, C-18), 137.6 (s, C-16), 119.6 (d, C-17), 116.1 (d, C-19), 76.7 (d, C-15), 74.1 (d, C-7), 72.8 (d, C-3), 61.7 (d, C-12), 61.4 (s, C-13), 53.1 (s, C-4), 42.9 (d, C-6), 39.2 (t, C-2), 36.4 (d, C-8), 32.4 (t, C-11), 32.1 (t, C-14), 30.7 (t, C-9), 22.7 (q, C-26), 22.3 (t, C-10), 21.5 (q, C-23), 19.5 (q, C-22), 19.1 (q, C-21), 17.1 (q, C-25), 15.9 (q, C-27), 13.6 (q, C-24).
[0062] Epothilone A: ESIMS m/z 494 [M+H] + ; 1 H NMR (CDCl 3 , 400 MHz) δ 6.98 (1H, s, H-19), 6.60 (1H, bs, H-17), 5.44 (1H, dd, J=8.7, 2.1 Hz, H-15), 4.20 (1H, m, H-3), 4.10 (1H, br s, 3-OH), 3.79 (1H, dd, J=8.4, 4.2 Hz, H-7), 3.22 (1H, m, H-6), 3.04 (1H, m, H-13), 2.92 (1H, m, H-12), 2.70 (3H, s, H-21), 2.52 (1H, dd, J=14.5, 10.6 Hz, H-2a), 2.42 (1H, dd, J=14.5, 3.2 Hz, H-2b), 2.12 (1H, m, H-14a), 2.09 (3H, d, J=1.0 Hz, H-27), 1.88 (1H, m, H-14b), 1.75 (2H, m, H-8, H-11a), 1.56 (1H, m, H-10a), 1.44 (4H, m, H-9, H-10b and H-11b), 1.41 (3H, s, H-23), 1.17 (3H, d, J=6.8 Hz, H-24), 1.10 (3H, s, H-22), 1.00 (3H, d, J=7.0 Hz, H-25); 13 C NMR (CDCl 3 , 75 MHz) δ 220.1 (s, C-5), 170.6 (s, C-1), 165.1 (s, C-20), 151.8 (s, C-18), 137.5 (s, C-16), 119.8 (d, C-17), 116.2 (d, C-19), 76.5 (d, C-15), 74.5 (d, C-7), 73.0 (d, C-3), 57.5 (d, C-12), 54.7 (d, C-13), 53.0 (s, C-4), 43.3 (d, C-6), 39.0 (t, C-2), 36.2 (d, C-8), 31.5 (t, C-14), 30.5 (t, C-9), 27.2 (t, C-11), 23.4 (t, C-10), 21.7 (q, C-23), 20.1 (q, C-22), 19.1 (q, C-21), 17.1 (q, C-25), 15.8 (q, C-27), 14.1 (q, C-24).
[0063] According to present invention, a flow chart for illustration of separation and purification of epothilones B and A is shown in FIG. 1 .
[0064] The method of the invention can well separate epothilone B from epothilone A to obtain epothilone B and epothilone A with a purity of over 95.0%, preferably over 99.0%. Furthermore, comparing with techniques for separation of epothilones B and A in the art, the method of the invention has many advantages such as higher yield, simpler process and better operability. The method of the invention needs no expensive apparatus for preparing chromatographic columns, and is more suitable for industrial production. In addition, the method of the invention doesn't consume a great amount of solvent having high toxicity, such as methanol and acetonitrile.
BRIEF DESCRIPTION OF THE DRAWINGS
[0065] FIG. 1 is a flow chart for illustration of separation and purification of epothilone B and epothilone A;
[0066] FIG. 2 is a HPLC chromatogram of epothilone B having a chromatographic purity of higher than 99.0% after the separation and purification;
[0067] FIG. 3 is a HPLC chromatogram of epothilone A having the chromatographic purity of higher than 99.0% after the separation and purification;
[0068] FIG. 4 is a PXRD graph of the amouphous powder of lyophilized epothilone B (2θ(degree), using Cukα, λ=0.154056 nm); and
[0069] FIG. 5 is a PXRD graph of the amouphous powder of lyophilized epothilone A (2θ(degree), using Cukα, λ=0.154056 nm).
DETAILED DESCRIPTION OF THE INVENTION
Example 1
[0070] 3 ton fermentation broth of epothilones, wherein XAD-1600-type resin had been added, was filtered by a vibrating screen and washed by water. The resin was loaded in a column using a 30% ethanol solution, and then the column was eluted by an ethanol solution of 95%. Fractions were collected sectionally, and fractions containing epothilones B and A were collected and combined after analysis by HPLC. The combined fractions was condensed to 10 L, which contained 54.38 g epothilone B and 110.50 g epothilone A after analysis by HPLC (external standard method).
[0071] The obtained 10 L solution was prepared to be an ethanol solution of 30%. The ethanol solution was loaded on a H41-type resin column (20 cm*300 cm, bed volume: 70 L), and then the column was eluted with ethanol solutions of 30%, 40%, 50% and 60% in sequence with a two bed volume per concentration. The column was eluted by a 70% ethanol solution at last. Fractions were collected sectionally, and fractions containing epothilones B and A were collected and combined after analysis by HPLC. The combined fractions was condensed until dry so as to obtain a sample containing epothilones B and A.
[0072] The sample containing epothilones B and A was dissolved in CHCl 3 . The dissolved sample was loaded on a first normal phase silica gel column (silica:sample=5:1), and then eluted by petroleum ether/ethyl acetate (80:20 by volume) for three bed volumes first, followed by petroleum ether/acetone (85:15 by volume) for two bed volumes and petroleum ether/acetone (80:20 by volume) for four bed volumes in sequence. Fractions were collected sectionally. Desired fractions containing epothilones B and A were collected after analysis by HPLC, combined, and then concentrated until dry.
[0073] The concentrated product was crystallized twice by using ethyl acetate/n-heptane of a ratio of 1:1 so as to obtain crude crystal containing epothilones B and A, which contains 40.26 g epothilone B and 31.81 g epothilone A measured by HPLC (external standard method) with a total chromatographic purity of 97.9%.
Example 2
[0074] After dissolving 5 g crude crystal containing epothilones B and A obtained from Example 1 in 5 ml dichloromethane, the solution was loaded on a second normal phase silica gel column (4 cm*80 cm, 300 g silica gel). The silica gel column was balanced by dichloromethane, and then gradient eluted in sequence with petroleum ether/acetone with ratios of 90:10, 85:15, 83:17 and 80:20. Fractions were collected sectionally. Desired fractions containing epothilone B and desired fractions containing epothilone A were collected and combined respectively after analysis by HPLC, and then condensed respectively until dry. Finally, 2.40 g epothilone B of 98.7% (yield 89%) and 1.90 g epothilone A of 95.8% (yield 92%) were obtained.
Example 3
[0075] After dissolving 5 g crude crystal containing epothilones B and A obtained from Example 1 in 5 ml trichloromethane, the solution was loaded on a second normal phase silica gel column (4 cm*80 cm, 300 g silica gel). The silica gel column was balanced by trichloromethane, and then gradient eluted in sequence with petroleum ether/acetone/trichloromethane with ratios of 90:10:10, 85:15:10, 83:17:10 and 80:20:10. Fractions were sectionally collected. Desired fractions containing epothilone B and desired fractions containing epothilone A were collected and combined respectively after analysis by HPLC, and then condensed respectively until dry. Finally, 2.48 g epothilone B of 98.9% (yield 92%) and 1.88 g epothilone A of 96.7% (yield 90%) were obtained.
Example 4
[0076] After dissolving 5 g crude crystal containing epothilones B and A obtained from Example 1 in 5 ml dichloromethane, the solution was loaded on a second normal phase silica gel column (6 cm*100 cm, 800 g silica gel). The silica gel column was balanced by dichloromethane, and then gradient eluted in sequence with petroleum ether/acetone/dichloromethane with the ratios of 90:10:40, 85:15:30, 83:17:20 and 80:20:10. Fractions were sectionally collected. Desired fractions containing epothilone B and desired fractions containing epothilone A were collected and pooled respectively after analysis by HPLC, and then condensed respectively until dry. Finally, 2.53 g epothilone B of 98.5% (yield 94%) and 1.94 g epothilone A of 97.8% (yield 92%) were obtained.
Example 5
[0077] Epothilone B with a high purity was obtained by re-crystallization of epothilone B obtained from Example 2-4; and epothilone A with a high purity was obtained by purifying obtained epothilone A by silica gel again.
[0078] 10 g epothilone B sample with a HPLC chromatographic purity of 98.5% was dissolved in 15 ml ethyl acetate by heating to 52° C., and then 15 ml n-heptane was added therein. The obtained solution stood at room temperature and then was cooled to 4° C. for 24 hours. The solution was filtered and above steps were repeated on obtained crystal. Finally, 8.7 g crystal pure epothilone B of 99.4% was obtained.
[0079] After dissolving 5 g epothilone A with a HPLC chromatographic purity of 97.5% obtained from Examples 2-4 in 5 ml dichloromethane, the solution was loaded on a second normal phase silica gel column (300 g silica gel). The silica gel column was balanced by dichloromethane, and then gradient eluted in sequence with petroleum ether/acetone/dichloromethane with ratios of 90:10:40, 85:15:30, 83:17:20 and 80:20:10. Fractions were collected sectionally. Desired fractions containing epothilone A were collected, combined after analysis by HPLC, and then condensed until dry. Finally, 4.3 g epothilone of A 99.5% was obtained.
[0080] The HPLC chromatograms of pure products of epothilone B and epothilone A obtained according to above methods are shown in FIGS. 2 and 3 respectively.
Example 6
Preparation of Amorphous Powders of Epothilone B and Epothilone A
[0081] Epothilone B and epothilone A with high purities obtained from Example 5 were dissolved in t-butanol respectively and lyophilized so as to obtain amorphous powders.
[0082] 0.52 g epothilone B was dissolved in 50 ml t-butanol by heating, and then cooled to room temperature. The solution was then lyophilized at −20° C. for 48 hours in VIRTIS Genesis freeze-dryer. The lyophilized product was further dried at 30° C. for 96 hours under high vacuum, and then at 52° C. for 48 hours under high vacuum. Obtained lyophilized powder was measured by X-ray diffraction.
[0083] 0.41 g epothilone A was dissolved in 30 ml t-butanol by heating, and then cooled to room temperature. The solution was then lyophilized at −20° C. for 48 hours in VIRTIS Genesis freeze-dryer. The lyophilized product was further dried at 30° C. for 96 hours under high vacuum, and then at 52° C. for 48 hours under high vacuum. Obtained lyophilized powder was measured by X-ray diffraction.
[0084] The PXRD graphs of epothilone B and epothilone A obtained according to above methods are shown in FIGS. 4 and 5 (The measurement of the powders by X-ray diffraction was performed on Rigaku D/max-2200).
Comparative Example 1
[0085] After dissolving 5 g crude crystal containing epothilones B and A obtained from Example 1 in 5 ml dichloromethane, the solution was loaded on a second normal phase silica gel column (4 cm*80 cm, 300 g silica gel). The silica gel column was balanced by petroleum ether/acetone with a ratio of 1:1, and then gradient eluted in sequence with petroleum ether/acetone with ratios of 90:10, 85:15, 83:17 and 80:20. Fractions were collected sectionally. Desired fractions containing epothilone B and desired fractions containing epothilone A were collected and combined respectively after analysis by HPLC, and then condensed respectively until dry. Finally, 0.94 g epothilone B of 98.3% (yield 35%) and 0.72 g epothilone A of 95.2% (yield 35%) were obtained.
Comparative Example 2
[0086] After dissolving 5 g crude crystal containing epothilones B and A obtained from Example 1 in 5 ml dichloromethane, the solution was loaded on a second normal phase silica gel column (4 cm*80 cm, 300 g silica gel). The silica gel column was balanced by petroleum ether/dichloromethane with a ratio of 1:1, and then gradient eluted in sequence with petroleum ether/acetone/trichloromethane with ratios of 90:10:10, 85:15:10, 83:17:10 and 80:20:10. Fractions were collected sectionally. Desired fractions containing epothilone B and desired fractions containing epothilone A were collected and combined respectively after analysis by HPLC, and then condensed respectively until dry. Finally, 0.97 g epothilone B of 98.4% (yield 36%) and 0.83 g epothilone A of 95.7% (yield 40%) were obtained.
Comparative Example 3
[0087] After dissolving 5 g crude crystal containing epothilones B and A obtained from Example 1 in 5 ml dichloromethane, the solution was mixed with silica gel, and the mixture was dried under vacuum. The dried mixture was loaded on a second normal phase silica gel column (4 cm*80 cm, 300 g silica gel). The silica gel column was filled by dry process and compacted by vacuumizing, and then gradient eluted in sequence with petroleum ether/acetone/dichloromethane with ratios of 90:10:10, 85:15:10, 83:17:10 and 80:20:10. Fractions were collected sectionally. Desired fractions containing epothilone B and desired fractions containing epothilone A were collected and combined respectively after analysis by HPLC, and then condensed respectively until dry. Finally, 0.81 g epothilone B of 98.7% (yield 30%) and 0.70 g epothilone A of 95.4% (yield 34%) were obtained.
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The invention discloses a method for the separation and purification of epothilones, especially discloses a method for the separation and purification of epothilones B and A using normal phase silica gel chromatography, which comprises loading the sample after dissolving the sample containing epothilones B and A with C 1 -C 7 alkyl halide compounds or mixing the sample with silica gel, then gradient eluting silica gel column by an elution solvent of normal phase silica gel column, and finally obtaining products.
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BACKGROUND OF THE INVENTION
I. Field of the Invention
The present invention relates generally to clips and hanger devices for attachment to suspended ceilings. More particularly, the present invention relates to resilient, plastic clips designed to be snap-fitted to suspended ceiling rails for supporting miscellaneous objects, and it relates to a method and apparatus for installing such clips. Pertinent prior art clips germane to the invention can be found in United States Patent Class 248, Subclasses 228.1, 228.3, 228.4, 228.7, 317, 318, 339 and 340.
II. Description of the Prior Art
Suspended ceilings are in widespread use, particularly in commercial environments including retail stores, business offices and the like. Typical suspended ceilings comprise an elevated array of grid-like, metal support rails that are suspended from adjacent ceiling structure. Typical ceiling support rails have an inverted, “T-shaped” vertical cross section. They comprise a planar, perpendicular portion disposed vertically with respect to ground, and an integral, horizontal flange portion forming the bottom. Typical suspended ceilings comprise multiple panels or ceiling tiles that are captivated between and supported upon the adjacent, spaced apart rails forming the superstructure. Some of the tiles or ceiling panels may mount various air-conditioning vents or louvers. Usually a plurality of light fixtures also supported by the rails are interspersed between various tiles. The tiles and light fixtures rest upon the horizontal “flanges” on the supporting rails, and they are horizontally restrained by abutment with the integral vertical portions. The mutually orthogonal edges of the spaced apart support rails form a regular, grid-like pattern, visually dividing the suspended ceiling into a plurality of rectangles or squares.
In many retail sales establishments, such as discount stores, grocery stores and the like, it is advantageous to prominently display various signs, flags, banners, advertisements, markers, placards, or the like. Frequently, diverse ornamental or utilitarian items such as toys, novelty displays, mobiles, stuffed animals, or Christmas decorations are also mounted to the ceiling structure for maximum visibility. In addition, flower pots or baskets are commonly suspended for aesthetic purposes. Items that are mounted as high as possible are more likely to be readily observed by customers. Obviously, mounting from the ceiling maximizes potential visibility. Another advantage with ceiling mounting is that the suspended item is positioned out-of-the way, and inadvertent or unwanted physical human contact is avoided.
A variety of hanging devices have been previously proposed for suspending various items from ceiling structures. Items are typically suspended from ceilings with easily releasable fasteners using magnets or quick-installing clips. Typical prior art clips usually comprise some form of jaw structure or engaging the horizontal flange portion of the metal rails.
For example, U.S. Pat. No. 3,743,228, comprises a hanger clip for suspended ceilings that has a pair of spring biased jaws. The jaws are normally biased together by a coiled spring. Each jaw has a horizontal portion that grasps the ceiling rail, and when manually deflected apart they can be forced into a captivating position to attach themselves to a rail. Various items may thus be hung from a ceiling with the clip. However, manual installation and removal are required, usually with the use of ladder. This can be time-consuming and dangerous for the workman. In addition, this clip comprises several working parts that complicate the design and increase its cost.
U.S. Pat. No. 6,027,091 comprises an integral, extruded clip that similarly comprises a pair of oppositely disposed, jaw-like channels. Installation is preceded by manually compressing the clip, to leverage the channels apart. Upon release, they retract to grab and thus captivate the ceiling rail flange.
U.S. Pat. No. 4,223,488 discloses a metal hanger with an integral, U-shaped end portion that initially grabs a portion of the ceiling rail. A separate retaining clip is required for completing installation. The clip fastens to the opposite side of the hanger, in engagement with the exposed edge of the ceiling rail.
U.S. Pat. No. 4,221,355 discloses a metal clip with a central body forming a center. A pair of integral flanges are radially spaced-apart relative to the center. The flanges are adapted to be rotated into a grasping position, whereby edge portions of a suspended ceiling rail are captivated by the clip flanges. The design necessitates a number of separate fasteners.
U.S. Pat. No. 4,323,215 provides a clip that is functionally similar to that described in U.S. Pat. No. 4,221,355 discussed above. A pair of radially spaced-apart flanges on opposite edges of the clip body are rotated into a captivating, gripping position upon installation.
U.S. Pat. No. 4,315,611 comprises a ceiling hanger with a central metal plate equipped with integral, cooperating flanges. The spaced-apart flanges snap into engagement across the ceiling rail.
U.S. Pat. No. 4,065,090 shows a resilient plastic clip that may be snap-fitted to a rail. The resilient walls of the generally V-shaped structure are deformable. They are integral with an apertured body from which a variety of items may be suspended.
U.S. Pat. No. 3,952,985 comprises a metallic hanger clip having a single edge portion that is frictionally forced into contact with the horizontal flange of a ceiling rail. An integral bent portion of the clip stabilizes the arrangement by frictional contact with the exposed underside of the ceiling rail.
Other diverse clips of possible relevance are seen in U.S. Utility Pat. Nos. 3,463,432, 3,561,718, 3,936,913, 4,073,458, 4,041,668, 5,490,651, and 5,806,823. Design patents D289,251 and D364,799 also disclose analogous ceiling attachment clips.
Prior art ceiling clips are deficient for several reasons. Prior art metal versions comprising compound parts are simply too expensive. Many clips fail to adequately grasp the ceiling rail. Some ceiling clips can twist or drop off if item being supported by the clip is bumped or twisted. Many clips are difficult to install, and some require special tools. In addition, it is often difficult and time-consuming to install or remove known suspended ceiling clips. Installation difficulties are further compounded when installing clips in congested areas.
Installation often requires the use of ladders, scaffolding, or power lifts that can elevate at least one workman into an accessible position. Successful, timely installation projects often requires several workmen. Often stepladders or ladders have to be used while one person holds the sign and the other person attaches wires or hangers to an overhead support. Also, to avoid customers inconvenience, signs or displays are often installed or removed when the store is closed for business, thereby increasing labor costs. Not surprisingly, hand tools with elongated handles that facilitate installation from the ground or floor have previously been developed.
For example, U.S. Pat. No. 5,247,725 discloses an elongated, pliers-like tool that can compress and elevate a ceiling clip for installation. The handles may be compressed manually, or a draw string may be deployed in hard-to-reach situations.
U.S. Pat. No. 5,632,519 discloses a retractable pole for attaching items to previously-installed ceiling clips. It can be telescoped between elongated deployed positions and retracted, storage orientations.
Similar elongated tools for mounting ceiling clips or items to be suspend from such clips are seen in U.S. Pat. Nos. 4,135,692, 5,052,733, 5,188,332, 5,267,764, 5,938,255, 6,048,010.
Known installation tools have several disadvantages. Conventional tools are cumbersome and complex. They require substantial manual dexterity and hand-eye coordination. For example, the tool disclosed in U.S. Pat. No. 5,188,332 has pivoting jaws which require substantial force. This makes it difficult to grab or release an object at the same time the jaws are being operated. Further, prior art tools are often incomplete, in that the installer-user must have a set of hand tools in addition to the clip-installation tool for successful use and installation.
Thus a rapidly deployable clip that can be easily and safely installed from the ground by a single person would be highly desirable. Such a clip must be inexpensive and lightweight, and at the same time, strong and dependable. Further, would be advantageous to avoid complex metallic tools with compound parts. A resilient plastic clip that accomplishes these goals, and a apparatus and a method for installing such a clip are proposed.
SUMMARY OF THE INVENTION
Our invention comprises a unique system for hanging diverse objects from conventional suspended ceilings. Resilient, injection-molded plastic clips described herein are adapted to be snap-fitted to the conventional, exposed rails in a typical suspended ceiling. Installation is conveniently done from the ground, without ladders or lifting equipment. A new barrel-like installation tool releasably captivates our clips, and holds them in a convenient installation position. The barrel tool threadably couples to conventional wooden poles and handles with ACME threads, so the assembly can be easily elevated into position adjacent a ceiling rail. Once the hook to be installed is appropriately positioned, it may be snap-fitted to the rail by pushing the pole. When the hook engages the ceiling rail, the pole and the barrel tool may be conveniently withdrawn, and the clip slides out of the tool.
We have proposed a pair of clips, one of which is J-shaped, and the other of which is U-shaped. Each of our new clips comprises a resilient plastic body comprising an upper clasp, an integral, lower hook portion for hanging an item from the ceiling, and an integral, midportion connecting the clasp and the hook. Each hook comprises a pair of halves that are resiliently coupled together.
The hook clasps comprise a opposed jaws that may be yieldably deflected apart during installation. Each generally C-shaped jaw comprises opposed, upper flanges that forcibly grip the ceiling rails. When pushed towards the ceiling rails the jaws snap apart and surmount the horizontal rail portion. When released, the jaws retract, with their flanges firmly gripping the rail.
The clip midportions are specially configured to engage the barrel-like installation tool. The preferred installation tool comprises a generally cylindrical body resembling a barrel. A pair of special receptacles formed on the body. The body comprises an internal, threaded bore having ACME threads adapted to be mated to the installation pole. Each clip midportion comprises a flat, gradually narrowing, trapezoidal section that is adapted to be inserted within a special gap in the tool's special receptacles, that function as docking stations for removably receiving clips to be mounted. Each tool receptacle comprises a pair of generally planar retaining arms that face one another over a transverse captivation slot. The midportions of the clips slidably fit within the captivation slots to enable the barrel tool to remotely manipulate the clips when elevated by the installation pole.
A method of installing ceiling clips comprises the steps of providing resilient clips and barrel installation tools constructed as aforesaid. A suitable threaded pole is threadably coupled to the installation tool to provide access to the required height. The midportions of the clips are slidably mated to the installation tool's docking stations, being temporarily confined within the captivation slots. After clips to be installed are thereby temporarily secured to the mounting tool, the user may press the clips upwardly into engagement with the ceiling rails. When appropriately elevated and aligned, the assembly may be thrust towards the rails, and the clips snap-fit over the horizontal rail bottom. Afterwards the desired item or items to be hung are merely suspended from the clips.
Thus, our invention provides a unique solution for quickly hanging miscellaneous objects upon exposed ceiling support rails.
A basic object is to provide clips and an installation method and apparatus for quickly suspending miscellaneous objects from ceilings with said clips.
A related object is to provide resilient plastic clips that can be quickly attached to exposed suspended ceiling rails for hanging or mounting a variety of utilitarian and aesthetic items.
A similar object is to provide a simple, multi-piece clip assembly that is easily installed with minimal tools.
A related object is to provide resilient suspension ceiling clip that can be safely installed from the ground.
Another object of our invention is to provide a tool that enables a single person to install suspended ceiling clips of the character described.
Another object is to provide a safe method of attaching clips to ceilings or to suspended ceiling frame rails from the ground, without ladders, stools, lifting equipment, scaffolding or similar elevating structure.
Another simple object of the present invention is to provide a clip for installation upon a suspended ceiling rail, and a convenient, easily operated system for installing the clips.
A further object of our invention is to provide a manipulating tool of the character described that can be employed with common household or office poles bearing standard threads.
It is yet a further object of our invention to provide a ceiling clip installation tool system that may be readily operated by a single individual from a relatively safe position on the ground or floor.
Another important object is to avoid the requirement of complex special tools or equipment utilizing compound parts or heavy metal components.
Conversely, an important object is to provide a simple plastic tool for aiding in the installation of ceiling-mounted suspension clips.
A related object is to provide a clip for suspension ceiling mounting that is inexpensive.
A still further object of our invention is to provide a clip of the character described that is strong, lightweight, and dependable.
These and other objects and advantages of the present invention, along with features of novelty appurtenant thereto, will appear or become apparent in the course of the following descriptive sections.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following drawings, which form a part of the specification and which are to be construed in conjunction therewith, and in which like reference numerals have been employed throughout wherever possible to indicate like parts in the various views:
FIG. 1 is a fragmentary isometric view showing portions of a conventional suspended ceiling, showing a plurality of preferred clips installed upon the ceiling rails, and showing an installation tool and method for installation;
FIG. 2 is a fragmentary, isometric view of the underside of the suspended ceiling of FIG. 1;
FIG. 3 is an enlarged isometric view of a preferred suspension clip constructed in accordance with the best mode of the invention;
FIG. 4 is a side elevational view of the preferred clip;
FIG. 5 is a left end view of the preferred clip, taken from a position generally to the left of FIG. 4;
FIG. 6 is a right end view of the preferred clip, taken from a position generally to the right of FIG. 4;
FIG. 7 is a bottom plan view of the preferred clip, taken from a position generally beneath FIG. 4 and looking upwardly;
FIG. 8 is a top view of the preferred clip, taken from a position generally above FIG. 4 and looking downwardly;
FIG. 9 is an enlarged sectional view taken generally along line 9 — 9 of FIG. 4;
FIG. 10 is an enlarged, bottom isometric view of the ceiling clip installer;
FIG. 11 is an enlarged frontal isometric view of the ceiling clip installer,
FIG. 12 is a fragmentary sectional view of the preferred installation tool taken generally along line 12 — 12 of FIG. 11;
FIG. 13 is a side elevational view of the preferred installation tool;
FIG. 14 is a left end view of the preferred tool, taken from a position generally to the left of FIG. 13;
FIG. 15 is a bottom plan view of the preferred tool, taken from a position generally beneath FIG. 13 and looking upwardly;
FIG. 16 is a top plan view of the preferred tool taken generally from a position generally above FIG. 13 and looking downwardly;
FIG. 17 is a right end view of the preferred tool, taken from a position generally to the right of FIG. 13;
FIG. 18 is a side elevational view of the preferred clip coupled to the preferred tool for subsequent installation;
FIG. 19 is a left side elevational view taken from a position generally to the left of FIG. 18;
FIG. 20 is a bottom plan view, taken from a position generally beneath FIG. 18 and looking upwardly;
FIG. 21 is a top plan view taken from a position generally above FIG. 18 and looking downwardly;
FIG. 22 is a right end view, taken from a position generally to the right of FIG. 18;
FIG. 23 is an enlarged isometric view of the preferred clip coupled to the preferred tool for subsequent installation;
FIG. 24 is an enlarged, bottom isometric view of the preferred clip coupled to the preferred tool that is similar to FIG. 23;
FIG. 25 is an enlarged, rear isometric view of the preferred clip coupled to the preferred tool that is similar to FIGS. 23 and 24;
FIG. 26 is an enlarged, frontal isometric view of the preferred clip coupled to the preferred tool that is similar to FIGS. 23-25;
FIG. 27 is an enlarged isometric view of an alternative clip coupled to the preferred tool for subsequent installation;
FIG. 28 is an enlarged, side elevational view of an alternative clip;
FIG. 29 is a left side elevational view of the alternative clip, taken from a position generally to the left of FIG. 28 and looking towards the right;
FIG. 30 is an enlarged isometric view of an alternative clip coupled to the preferred tool for subsequent installation;
FIG. 31 enlarged, left side elevational view of the alternative clip, taken generally from a position to the left of FIG. 27;
FIG. 32 is an enlarged bottom plan view of an alternative installation tool, showing an optional recess and a through-passage for an optional hex-bolt used to temporality hang items from the barrel; and,
FIG. 33 is a fragmentary sectional view taken generally along line 33 — 33 in FIG. 32 .
DETAILED DESCRIPTION
Turning initially to FIGS. 1 and 2 of to the appended drawings, a suspended ceiling 50 is illustrated. The ceiling comprises a plurality of regularly spaced apart rails 52 that are arranged in orderly grids. As will be readily appreciated by those skilled in the art, the ceiling comprises an array or mutually orthogonal rails, including rails (not shown) that intersect rails 52 and divide the ceiling area into an orderly arrangement of regularly arranged rectangles. Typical rails 52 have a cross section generally in the form of an “inverted T,” comprising a narrow and flat, horizontal bottom 56 and an integral, upwardly projecting vertical portion 58 (FIG. 2 ). Normally a plurality of ceiling tiles, not shown, will extend between and be supported by the rails 52 , resting upon horizontal rail bottoms 56 .
Several of our preferred clips, generally designated by the reference numeral 60 , are shown in spaced apart relation mounted upon the rails 52 . However, clip 61 (FIGS. 1, 2 ) is illustrated in an intermediate position being installed upon a ceiling rail. Clips are installed with the aid of a barrel-like installation tool 66 , which is hand-manipulated by a user (not shown) with a conventional elongated, wooden pole 65 . (An alternative installation tool is discussed later in conjunction with FIGS. 32 - 33 ). The barrel tool 66 is releasably, threadably engaged by pole 65 , which can be manipulated from the floor or ground and functions as a temporary installation handle. Typical poles useable for this job may comprise handles for rakes or other garden or lawn implements, commode plunger poles, mop handles, paint-roller poles, or conventional threaded handles for brooms, mops or the like. Preferably, the barrel tool 66 has a standard ACME thread to match that used on many common poles. Once a clip 60 to be installed is fitted to the barrel tool 66 , as hereinafter described in detail, the user may elevate the assembly into appropriate position proximate the suspended ceiling and then press-fit the clip onto the desired rail. By first aiming appropriately, and then gently pushing pole 65 to snap-fit the clip over the target rail, installation is readily insured.
With emphasis now directed concurrently to FIGS. 3-9, the preferred ceiling clip 60 is generally “J”-shaped. As detailed hereinafter, an alternative ceiling clip to be described hereinafter is generally “U”-shaped (i.e., FIGS. 28 - 30 ). Clip 60 is preferably injection molded from resilient plastic. Each clip comprises an upper clasp 64 adapted to be coupled to the ceiling rails, a lower portion in the form of a hook 68 that can support the item to be suspended, and an integral, intermediate midportion 67 connecting clasp 64 and hook 68 . It will be appreciated that the clip comprises two very similar halves that are resiliently coupled together.
Clasp 64 comprises a pair of opposed jaws 70 , 72 that face each other across a void 74 . Each jaw 70 , 72 is generally C-shaped in cross section, and with hook 68 they aesthetically contribute to the overall, generally J-shaped appearance of the clip 60 . Jaws 70 , 72 respectively comprise opposed, upper flanges 76 , 76 A that face each other across void 74 . The gripping flanges 76 , 76 A on the top of each jaw are integral with lower, horizontal projections 77 , 77 A and the arcuate midsections 78 , 78 A. The jaws are adapted to grasp the rails of the suspended ceiling to mount the clips. They are displaced apart somewhat (as described in detail later) and then pushed into place surmounting the horizontal rail bottom 56 (FIG. 1 ). When released, the jaw flange portions 76 , 76 A contract and firmly grasp the rail.
The jaws are integral with the midportion 67 , forming a ninety degree intersection therewith. Midportion 67 comprises a flat, intermediate panel 80 on the left side and a companion, spaced apart intermediate panel 80 A that is curved slightly as indicated. Intermediate panels 80 , 80 A are of substantially uniform width and thickness, and they are respectively integrally joined with lower intermediate panels 82 , 82 A that are on non-uniform width (FIGS. 5, 6 ). Panels 82 , 82 A are thus shaped somewhat like trapezoids, with their width gradually and smoothly decreasing towards the lower hook 68 . Preferably, an interior reinforcing web 84 (FIGS. 3, 4 ) integrally, transversely extends between panels 80 , 82 A at the juncture with hook 68 . Panels 80 and 82 are converged as aforesaid so that they functionally fit to the barrel tool 66 during installation, as hereinafter described.
Hook 68 comprises a pair of arcuate, spaced apart walls 90 , 92 that are integral with panels 82 , 82 A respectively. These complimentary curved walls 90 , 92 (FIG. 3) meet at a foot 94 forming a retaining end of the arcuate hook 68 . At each side of the hook 68 there is a hollow void 97 (i.e., FIGS. 3, 23 ) between walls 90 , 92 . Preferably, an interior reinforcement web 96 (FIG. 9) transversely runs between walls 90 , 92 to reinforce the clip and especially hook 68 . Web 96 extends between foot 94 and the previously discussed transverse web 84 (FIG. 3 ). The web 84 forms a flexure point for the opposed jaws 70 , 72 to be yieldably and temporarily displaced apart.
Turning now to FIGS. 10-15, a preferred installation tool 66 is shown in detail. Each tool 66 is preferably injection molded from resilient plastic. The tool comprises a generally cylindrical, barrel-like body 89 whose periphery comprises a pair of opposed, faceted sides 91 , 91 A and a pair of receptacles 93 , 93 A (FIGS. 10, 11 , 14 , 17 ). The body 89 of tool 66 is preferably provided with a threaded, internal bore 87 (i.e., FIG. 24) that defines a tubular interior. Preferably, ACME threads 95 (FIG. 12) are used, so that bore 87 threadably mates with common household poles 65 (FIG. 1) that are readily available to the user. The top 94 of the barrel tool 66 is closed. Over-tightening of the pole is prevented by an internal, circular ridge lock 98 (FIG. 12) that is spaced apart upwardly within the bore 87 above the threads 95 .
Importantly, receptacles 93 and 93 A (FIGS. 10, 11 ) function as docking stations for removably and temporarily receiving and controlling the clips 60 , 61 to be mounted. These twin, integral receptacles are very similar, but they are dimensioned somewhat differently to fit clips of different sizes and configurations. The receptacle 93 A (FIGS. 11, 16 , 17 ) preferably comprises a pair of opposed, generally planar retaining arms 100 , 102 that face one another across a central gap 104 (FIG. 17 ). Each retaining arm 100 , 102 is offset from an inner, generally rectangular barrel edge surface 106 . An elongated, transverse captivation slot 110 (FIGS. 11, 15 , 16 ) is defined between the arms 100 , 102 and the inner edge surface 106 of the barrel tool (FIGS. 11, 15 ). The captivation slot 110 is generally in the form of a rectangular parallelepiped. Similarly, receptacle 93 (FIG. 10) comprises a pair of opposed, planar arms 114 , 116 (FIG. 10) separated by a gap 117 . Arms 114 , 116 are offset from generally rectangular barrel edge 119 . A captivation slot 122 is defined between edge 119 (FIG. 10) and offset arms 114 , 116 .
With additional reference now directed to FIGS. 18-23, the receptacles 93 and 93 A enable the clips 60 , 61 to be removably coupled to the barrel tool 66 . The clip midportions previously described slidably fit within these captivation slots. The clips are temporarily secured by the arms 100 , 102 that engage the midportion sections. Referring again to FIGS. 3 and 5, the intermediate clip panels 80 and 82 are specially dimensioned as aforesaid. The clip 60 may be fitted to the barrel tool 66 by grasping the clip firmly, and placing intermediate panel 82 between gap 104 and into captivation slot 110 . By sliding the clip downwardly, the midportion's panel 82 will be positioned within slot 110 , with panel 80 positioned just above it (FIG. 18 ). Thus, the temporarily captivated clip 60 will be firmly grasped by and between the retaining arms 100 , 102 , which will project into void 74 (FIG. 4) and contact the inner surface 81 (FIG. 4) of panel 80 .
To install the clip, an adequate pole 65 (FIG. 1) is coupled to the barrel tool 66 . As the pole is threaded (i.e., with ACME threads) it is threadably mated to the threaded barrel tool 66 . After a clip 60 to be installed is temporarily, slidably coupled to a receptacle 93 or 93 A on the barrel tool 66 , the user may elevate the assembly by thrusting the pole 65 upwardly into the immediate proximity of the ceiling rail. The previously described clip jaws will then snap-fit over the horizontal rail bottom section. Afterwards, various diverse items may be easily hung from the hook 68 of the J-shaped clip 60 or 61 (FIG. 1 ). For example, by way of illustration only, FIG. 1 illustrates a miscellaneous item 57 hung from the ceiling rail. Item 57 is connected via loop or wire 59 to the hook portion of the clip.
Turning now to FIGS. 27-31, an alternative suspended ceiling clip 160 is generally “U”-shaped. The injection molded clip 160 comprises an upper clasp 164 , a lower, loop-like hook 169 that can support the item to be suspended, and an integral, intermediate midportion 167 extending between clasp 164 and hook 169 . Clip 160 is symmetrical, with each half comprising a mirror image of the opposite half. Unlike the “open” hook 68 of clip 60 , hook 169 of clip 160 is “closed” (i.e., FIG. 28 ).
Upper clasp section 164 comprises opposed jaws 170 , 172 that are separated by a gap 174 . As before, each jaw 170 , 172 is generally C-shaped in cross section. The opposed, upper flanges 176 , 176 A face each other across gap 174 (FIG. 28 ). The gripping flanges 176 , 176 A on the top of each jaw are integral with lower, horizontal projections 177 , 177 A (FIG. 28 ). The jaws can be deflected apart and then released to grasp the horizontal rail bottoms 56 (FIG. 1) of the suspended ceiling to mount clips 160 . The clip's jaw flanges 176 , 176 A firmly grasp the rail horizontal bottom 56 (FIG. 1 ).
The jaws are integral with midportion 167 , that is in the form of a trapezoid. An intermediate panel 180 (FIG. 29) is somewhat rectangular, but the lower, adjacent portion 182 decreases in width until it smoothly meets the hook portion 169 at a boundary junction 171 . Portion 182 is the same in width as the width 183 (FIG. 29) of the hook 169 .
The preferred installation tool 166 (FIG. 27) is identical to that previously described. As before, receptacles 193 identical with those previously discussed are integrally formed on its body. The tool 166 is threaded as before to receive a threaded mounting pole 65 (FIG. 1 ). Receptacle 193 (FIG. 27) comprises a pair of opposed, generally planar retaining arms 200 , 202 spaced across gap 204 (FIG. 27 ). The retaining arms 200 , 202 are offset from barrel tool edge 206 . An elongated, transverse captivation slot 210 is defined between the arms 200 , 202 and edge 206 .
The U-shaped clip 160 slidably fits to barrel tool 166 . Capture occurs as the clip's trapezoidal midportion is fitted within and to the captivation slots 210 . When inserted edgewise, integral hook 169 fits neatly within and between barrel tool gap 204 . By thereafter sliding the clip downwardly, its trapezoidal midportion 167 mates within captivation slot 210 , and the clip is temporarily secured by arms 200 , 202 (FIG. 27 ). Installation proceeds as previously discussed.
Finally, with reference to FIGS. 32 and 33, a modified installation tool 220 has been shown in detail. Tool 220 comprises a generally cylindrical, barrel-like body 222 having peripheral, faceted sides 224 , 226 , and a pair of radially spaced apart receptacles 228 , 229 similar to those described earlier. Clip midportions are mated to the receptacles as before. The body has an internally-threaded bore 230 , preferably equipped with ACME threads 232 . Bore 230 threadably receives the installation pole in the manner described earlier. Unlike the closed top 94 previously described, top 238 (FIG. 33) is not completely closed.
Instead, as depicted in FIG. 33, the top 238 has a central orifice 240 defined in it, which is coaxial with the body 222 . The orifice 240 is also coaxial with respect to an inner, hexagonal recess 247 (FIG. 32) defined in the underside 238 A (FIG. 32) of the installation tool's top 238 . An optional hex nut or bolt can be conveniently seated within this hexagonal recess 247 . When a hex bolt, for example, is positioned with its head flushly seated within recess 247 , it's elongated shank will project out of top 238 through orifice 240 , where it will be exposed for rapid interconnection with miscellaneous desired items. For example, once a clip or multiple clips is/are installed, the tool can be lowered for subsequently, temporarily grasping an item to be thereafter suspended from the previously-installed clip. Numerous items to be suspended from the clips as aforesaid can be temporarily supported by suitable conventional hex bolts penetrating orifice 240 .
From the foregoing, it will be seen that this invention is one well adapted to obtain all the ends and objects herein set forth, together with other advantages which are inherent to the structure.
It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.
As many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.
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A system for hanging objects from conventional suspended ceilings comprises resilient clips snap-fitted to ceiling rails, an installation tool for controlling the clips, and an elongated pole that threadably couples to the tool, enabling clip manipulation. Each clip comprises an upper clasp, an integral, lower hook, and a midportion. Clasp jaws that yieldably deflect apart comprise opposed flanges that forcibly grip the ceiling rails. The installation tool comprises receptacles for temporarily receiving the clips, and an internal, threaded bore mated to the installation pole. Each receptacle comprises a pair of generally planar retaining arms that partially block a captivation slot. The midportions of the clips slidably fit within the installation tool captivation slots. When pushed towards the ceiling rails the jaws snap apart and surmount the horizontal rail portion. When released, the jaws retract, with their flanges firmly gripping the rail.
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FIELD OF THE INVENTION
[0001] The present invention is the field of fish reproduction and specifically related to peptidomimetics which are active as neurokinin B (NKB) and neurokinin F (NKF) antagonists and their use in inhibiting or delaying fish maturation of reproductive system.
BACKGROUND OF THE INVENTION
[0002] Reproductive function is tightly regulated by a complex network of central and peripheral factors, where the most important is GnRH. Recently, the neuropeptides kisspeptin (encoded by Kiss1) and neurokinin B (NKB, encoded by Tac3) have been placed as crucial at different stages of reproduction (Navarro V M. Front Endocrinol. 2012; 3:48.). Studies in humans have revealed that loss-of-function mutations in the genes encoding NKB or neurokinin 3 receptor (NK3R) lead to hypogonadotropic hypogonadism and infertility.
[0003] Neurokinin B (NKB) is a member of the tachykinin family of peptides. Inactivating mutations in the tachykinin 3 (tac3) or tac3 receptor (NKBR) gene are associated with pubertal failure and congenital hypogonadotrophic hypogonadism in humans. This suggests that NKB may have a critical role in human reproduction.
[0004] NKBs have direct action through receptors on the pituitary and indirect through receptors on gonadotropin-releasing-hormone (GnRH) neurons. NKBs bind to their cognate receptors, they stimulate their activity, which in turn provides an obligatory signal for gonadotropin secretion-thus gating down-stream events supporting reproduction. NKB is an important regulator of the hypothalamic-pituitary-gonadal axis and is the target of a range of regulators, such as steroid hormone feedback, nutritional and metabolic regulation.
[0005] Energy homeostasis and reproduction are the most important processes in an animal's life and are intimately related. Proper regulation of energy homeostasis and reproduction is fundamental for fitness and survival. Reproduction is an energy-intensive process, and precise interaction of regulators for energy balance and reproduction allows coordinated regulation of these two processes. In most fish species studied, seasonal variations in gonadal size are negatively correlated with serum growth hormone (GH) concentrations—e.g. when luteinizing hormone (LH) concentrations are high, due to gonadal size increase, GH concentrations are low, accompanied by very slow somatic growth.
[0006] Fish possess a large diversity of reproduction strategies, can be found in different environmental niches and use different timing regimes of sexual maturation. When compared with other vertebrates, fish have several unique characteristics. In contrast to tetrapod, where the cells in the pituitary are mixed, in fish there is a unique organization of specific calls in certain areas. Fish possesses a dual mode of gonadotrope regulation by GnRH, that combines both neuroglandular and neurovascular components. Moreover, different nerve terminals that secrete different neuropeptides innervate the pituitary. However, it is still unknown whether NKB or NKF neurons project to the pituitary in fish.
[0007] To date, a large number of tachykinins have been identified in a wide range of species from invertebrates to mammals Tac1 encodes both substance P (SP) and NKA through alternative splicing. Tac2/Tac3 produces the peptide NKB, and Tac4 encodes hemokinin-1.
[0008] Three classes of mammalian tachykinin receptors (NK1, NK2, and NK3) have been identified, and these have preferential binding affinities for SP, NKA, and NKB, respectively. The mammalian TAC1 and TAC4 give rise to 2 active neuropeptides, whereas the TAC3 is the only TAC that give rise to only 1 neuropeptide, namely NKB.
[0009] Tachykinin (tac) and tac receptor genes were recently identified from many fish species (Biran 2012, PNAS 109:10269-10274). Phylogenetic analysis showed that piscine Tac3s and mammalian neurokinin genes arise from one lineage. High identity was found among different fish species in the region encoding the NKB; all shared the common C-terminal sequence. Although the piscine Tac3 gene encodes for two putative tachykinin peptides, the mammalian orthologue encodes for only one. The second fish putative peptide, referred to as neurokinin F (NKF), is unique and found to be conserved among all tested fish species.
[0010] Zebrafish tac3a mRNA levels gradually increased during the first few weeks of life and peaked at pubescence. In the brain of zebrafish, tac3a and tac3b mRNA was observed in specific brain areas that are related to reproduction (Biran et al., 2008, Biol Reprod 79:776-786). Furthermore, a single ip injection of NKBa or NKF significantly increased LH levels in mature female zebrafish, and the tac3a and both tac3r genes were upregulated by estrogen (Biran et al., 2012, ibid), suggesting that the NKB/NKBR system may participate in neuroendocrine control of fish reproduction and that the role of the NKB system in the neuroendocrine control of reproduction is evolutionarily conserved in vertebrates.
[0011] Tilapia have become one of the most commercially important cultured freshwater fish, due to their high growth potential, short generation time, ease of spawning, and disease resistance.
[0012] It was shown (Biran et al., 2014, Endocrinology 155, 4831-42) that the recently identified neuropeptides denoted Neurokinin B (NKB) and Neurokinin F (NKF), that are secreted by the fish brain and involved in reproduction, can stimulate the release of follicle stimulating factor (FSH) and LH by direct (through activation of specific receptors at the pituitary level) or indirect (through the brain) mechanisms.
[0013] WO 2013/018097, to some of the inventor of the present invention, discloses NKB and NKF agonists for hormonal regulation in fish and specifically for advancing the onset of puberty, regulating the timing and amount of ovulation and spawning, synchronization or stimulation of reproduction, enhancing the development of gammets, enhancing vitellogenesis, induction of GnRH, induction of Kisspeptine, increase in the levels of hypothalamic neurohormones, increasing the level of LH or FSH and induction of oocyte maturation.
[0014] G. Drapeau et al., (Regul. Peptides, 31, 125, 1990) discloses the compound SR142801 (Trp 7 , β-Ala 8 -Neurokinin A, 4-10) as a potent antagonist of the tachykinin NK3 receptor in mammalians.
[0015] O'Harte, F. (J. Neurochem. 57 (6), 2086-2091, 1991) discloses the peptide analog denoted Ranakinin, an NK1 tachykinin receptor agonist isolated with neurokinin B from the brain of the frog Rana ridibunda.
[0016] Several small molecule, non-peptidic NKB antagonists are known in mammals, for example: SB-222200 (Sarau et al., 2000, J Pharmacol Exp Ther 295:373-381); Osanetant (SR-142,801) and talnetant (SB 223412) (Sarau et al 1997, J Pharmacol Exp Ther 281:1303-1311).
[0017] While previous publications disclosed fish NKB peptide agonists for enhancing fertilization and shortening the time for maturation or mammalian NK-3 antagonists, none of the prior publications disclose NKB antagonists in fish. There is an unmet need for such antagonists for use in delaying maturation and controlling reproductive parameters in fish.
SUMMARY OF THE INVENTION
[0018] The present invention is based on the finding that inhibition of tac-3 receptor activity in fish by NKB antagonists can delay or inhibit maturation and reproduction. It was surprisingly found that alteration of specific amino acid residues in the sequence of NKB and NKF peptides result in change in their activity from agonistic to antagonistic toward maturation of fish reproductive system. Method for inhibiting fish maturation and for treating hormone-dependent problems or processes in fish, using NKB and NKF antagonists are also provided as well as use of NKB and NKF antagonists in pharmaceutical or food compositions. Peripherally active peptide-based NKB and NKF antagonists (herein denoted peptidomimetics) or other antagonists, that inhibit or eliminate the reproduction of fish can lead, among other processes, to increased growth rates and alteration in sex determination.
[0019] The present invention provides, according to one aspect a peptidomimetic according to Formula I:
[0000] X 1 -NMeVal-X 4 -Leu-Met-Z (Formula I)
[0000] wherein:
the peptidomimetic consists of 5-10 amino acids; X 1 is a stretch of 1-6 natural or non-natural amino acid residues and optionally an N-terminal capping moiety or modification; NMeVal is an N-methyl-Valine residue or N-methyl-D-Valine residue; X 4 is —NH(CH 2 ) n —CO— wherein n is 2-6; and Z represents the C-terminus of the peptide which may be amidated, acylated, reduced or esterified. Each possibility represents a separate embodiment of the present invention.
[0025] According to some embodiments X 1 comprises at least one aromatic amino acid residue in L or D configuration.
[0026] According to other embodiments, X 1 comprised a D-Trp residue.
[0027] According to some embodiments X 1 comprises at least one negatively charged (acidic) amino acid residue.
[0028] According to some embodiments, the C-terminus is amidated.
[0029] According to some embodiments, X 1 consists of 2 or 3 amino acids and a capped N-terminus. Each possibility represents a separate embodiment of the present invention.
[0030] According to some embodiments, X 1 consists of 2 or 3 amino acid residues comprising an aromatic residue, a negatively charged (acidic) residue and an N-terminus capping moiety. Each possibility represents a separate embodiment of the present invention.
[0031] According to some embodiments, the X 1 comprises a residue selected from an aliphatic amino acid residue and a polar, uncharged residue. Each possibility represents a separate embodiment of the present invention.
[0032] According to some embodiments, the aliphatic residue is selected from the group consisting of: Ala, Ile, Leu. Each possibility represents a separate embodiment of the present invention.
[0033] According to some embodiments, the polar, uncharged residue is selected from Ser and Thr. Each possibility represents a separate embodiment of the present invention.
[0034] According to some embodiments, X 1 comprises an aromatic residue selected from the group consisting of Phe, DPhe, Trp and DTrp; a negatively charged (acidic) residue selected from Glu and Asp; and a succinyl (Succ) N-terminus capping moiety. Each possibility represents a separate embodiment of the present invention.
[0035] According to yet other embodiments, X 1 comprises an aromatic residue selected from Phe, and DTrp; an Asp residue; a succinyl (Succ) N-terminus capping moiety, and optionally a residue selected from Ile and Ser. Each possibility represents a separate embodiment of the present invention.
[0036] According to some embodiments, the peptidomimetic is according to Formula II:
[0000] X 1 -NMeVal-βAla-Leu-Met-NH 2 (Formula II)
[0000] wherein, X 1 is selected from the group consisting of: Succ-Asp-Phe; Succ-Asp-DPhe; Succ-Asp-Trp; Succ-Asp-DTrp; Succ-Asp-Ile-Phe; Succ-Asp-Ile-DPhe; Succ-Asp-Ile-Trp; Succ-Asp-Ile-DTrp; Succ-Asp-Ser-Phe; Succ-Asp-Ser-DPhe; Succ-Asp-Ser-Trp; Succ-Asp-Ser-DTrp, Succ-Glu-Phe; Succ-Glu-DPhe; Succ-Glu-Trp; Succ-Glu-DTrp; Succ-Glu-Ile-Phe; Succ-Glu-Ile-DPhe; Succ-Glu-Ile-Trp; Succ-Glu-Ile-DTrp; Succ-Glu-Ser-Phe; Succ-Glu-Ser-DPhe; Succ-Glu-Ser-Trp; and Succ-Glu-Ser-DTrp. Each possibility represents a separate embodiment of the present invention.
[0037] According to some embodiments, a peptidomimetic is provided consisting of 5-10 amino acid residues comprising a sequence set forth in SEQ ID NO: 7:
[0000] NMeVal-βAla-Leu-Met (SEQ ID NO: 7).
[0038] According to some embodiment the peptidomimetic comprises a sequence of SEQ ID NO: 7, at least one aromatic amino acid residue and at least one negatively charged amino acid residue.
[0039] According to some embodiments, the peptidomimetic comprises a sequence of SEQ ID NO: 7, at least one aromatic amino acid residue, at least one negatively charged amino acid residue and at least one residue selected from an aliphatic amino acid residue and a polar, uncharged residue. Each possibility represents a separate embodiment of the present invention.
[0040] According to some embodiments, the peptidomimetic comprises a capped N-terminus.
[0041] According to some embodiments the peptidomimetic comprises an amidated C-terminus.
[0042] According to some embodiments the peptidomimetic consist of 5, 6, 7, 8, 9 or 10 amino acid residues and an optional N-terminal capping group. Each possibility represents a separate embodiment of the present invention.
[0043] According to some embodiments, the peptidomimetic consists of 5-10 amino acid residues, an amidated C-terminus and an N-terminal capping moiety. Each possibility represents a separate embodiment of the present invention.
[0044] According to some embodiments, the peptidomimetic consists of 6-7 amino acid residues comprising the sequence of SEQ ID NO: 7, and a sequence selected from the group consisting of: Succ-Asp-Phe; Succ-Asp-DPhe; Succ-Asp-Trp; Succ-Asp-DTrp; Succ-Asp-Ile-Phe; Succ-Asp-Ile-DPhe; Succ-Asp-Ile-Trp; Succ-Asp-Ile-DTrp; Succ-Asp-Ser-Phe; Succ-Asp-Ser-DPhe; Succ-Asp-Ser-Trp; Succ-Asp-Ser-DTrp, Succ-Glu-Phe; Succ-Glu-DPhe; Succ-Glu-Trp; Succ-Glu-DTrp; Succ-Glu-Ile-Phe; Succ-Glu-Ile-DPhe; Succ-Glu-Ile-Trp; Succ-Glu-Ile-DTrp; Succ-Glu-Ser-Phe; Succ-Glu-Ser-DPhe; Succ-Glu-Ser-Trp; and Succ-Glu-Ser-DTrp.
[0045] According to some embodiments the at least one N-terminal capping moiety is a dicarboxylic acid residue. According to some embodiments the at least one N-terminal capping moiety is selected from the group consisting of: succinyl, oxalyl, malonyl, glutaryl, adipoyl, pimaloyl, suberoyl, and acetyl. Each possibility represents a separate embodiment of the present invention.
[0046] According to some specific embodiments the peptidomimetic is selected from the group consisting of:
[0000] (SEQ ID NO: 1, Ant-1) Succ-Asp-Ile-Phe-N(Me)Val-βAla-Leu-Met-NH 2 ; (SEQ ID NO: 2, Ant-2) Succ-Asp-Phe-N(Me)Val-βAla-Leu-Met-NH 2 ; (SEQ ID NO: 3, Ant-3) Succ-Asp-Ser-Phe-N(Me)Val-βAla-Leu-Met-NH 2 ; (SEQ ID NO: 4, Ant-4) Succ-Asp-Ile-D-Trp-N(Me)Val-βAla-Leu-Met-NH 2 ; (SEQ ID NO: 5, Ant-5) Succ-Asp-D-Trp-N(Me)Val-βAla-Leu-Met-NH 2 ; and (SEQ ID NO: 6, Ant-6) Succ-Asp-Ser-D-Trp-N(Me)Val-βAla-Leu-Met-NH 2 ;
wherein Succ denotes a succinyl.
[0047] It is to be explicitly understood that previously known peptides are excluded from the present invention.
[0048] According to some embodiments, the peptidomimetic further comprises a permeability-enhancing moiety. Any moiety known in the art to facilitate actively or passively or enhance permeability of the compound into cells may be used in the peptidomimetics according to the present invention. The permeability-enhancing moiety may be connected to any position in the peptide moiety, directly or through a spacer or linker.
[0049] The present invention provides, according to another aspect, a composition comprising a peptidomimetic of formula I.
[0050] According to some embodiments, the composition comprising a peptidomimetic according to Formula I is selected from a pharmaceutical composition and a food composition.
[0051] According to some embodiments the composition comprises a peptidomimetic according to Formula I wherein X 1 comprises at least one aromatic amino acid residue in L or D configuration.
[0052] According to some embodiments the composition comprises a peptidomimetic according to Formula I wherein X 1 comprised a D-Trp residue.
[0053] According to some embodiments the composition comprises a peptidomimetic according to Formula I wherein X 1 comprises at least one negatively charged (acidic) amino acid residue.
[0054] According to some embodiments the composition comprises a peptidomimetic according to Formula I wherein the C-terminus is amidated.
[0055] According to some embodiments the composition comprises a peptidomimetic according to Formula I wherein X 1 consists of 2 or 3 amino acids and a capped N-terminus. Each possibility represents a separate embodiment of the present invention.
[0056] According to some embodiments the composition comprises a peptidomimetic according to Formula I wherein X 1 consists of 2 or 3 amino acid residues comprising an aromatic residue, a negatively charged (acidic) residue, an amidated C-terminus and an N-terminus capping moiety. Each possibility represents a separate embodiment of the present invention.
[0057] According to some embodiments the composition comprises a peptidomimetic according to Formula I wherein X 1 comprises a residue selected from an aliphatic amino acid residue and a polar, uncharged residue. Each possibility represents a separate embodiment of the present invention.
[0058] According to some embodiments the composition comprises a peptidomimetic according to Formula I wherein the aliphatic residue is selected from the group consisting of: Ala, Ile, and Leu. Each possibility represents a separate embodiment of the present invention.
[0059] According to some embodiments the composition comprises a peptidomimetic according to Formula I wherein the polar, uncharged residue is selected from Ser and Thr. Each possibility represents a separate embodiment of the present invention.
[0060] According to some embodiments the composition comprises a peptidomimetic according to Formula I wherein X 1 comprises an aromatic residue selected from the group consisting of Phe, DPhe, Trp and DTrp; a negatively charged (acidic) residue selected from Glu and Asp; and a succinyl (Succ) N-terminus capping moiety. Each possibility represents a separate embodiment of the present invention.
[0061] According to some embodiments the composition comprises a peptidomimetic according to Formula I wherein X 1 comprises an aromatic residue selected from Phe, and DTrp; an Asp residue; a succinyl (Succ) N-terminus capping moiety, and optionally a residue selected from Ile and Ser. Each possibility represents a separate embodiment of the present invention.
[0062] According to some embodiments, the composition comprises a peptidomimetic according to formula II:
[0000] X 1 -NMeVal-βAla-Leu-Met-NH 2 (Formula II);
[0000] wherein, X 1 is selected from the group consisting of: Succ-Asp-Phe; Succ-Asp-DPhe; Succ-Asp-Trp; Succ-Asp-DTrp; Succ-Asp-Ile-Phe; Succ-Asp-Ile-DPhe; Succ-Asp-Ile-Trp; Succ-Asp-Ile-DTrp; Succ-Asp-Ser-Phe; Succ-Asp-Ser-DPhe; Succ-Asp-Ser-Trp; Succ-Asp-Ser-DTrp, Succ-Glu-Phe; Succ-Glu-DPhe; Succ-Glu-Trp; Succ-Glu-DTrp; Succ-Glu-Ile-Phe; Succ-Glu-Ile-DPhe; Succ-Glu-Ile-Trp; Succ-Glu-Ile-DTrp; Succ-Glu-Ser-Phe; Succ-Glu-Ser-DPhe; Succ-Glu-Ser-Trp; and Succ-Glu-Ser-DTrp. Each possibility represents a separate embodiment of the present invention.
[0063] According to some embodiments the composition comprises a peptidomimetic consisting of 5-10 amino acid residues comprising the sequence NMeVal-εAla-Leu-Met (SEQ ID NO: 7).
[0064] According to some embodiment the composition comprises a peptidomimetic comprising a sequence of SEQ ID NO: 7, at least one aromatic amino acid residue and at least one negatively charged amino acid residue.
[0065] According to some embodiments, the composition comprises a peptidomimetic comprising a sequence of SEQ ID NO: 7, at least one aromatic amino acid residue, at least one negatively charged amino acid residue and at least one residue selected from an aliphatic amino acid residue and a polar, uncharged residue. Each possibility represents a separate embodiment of the present invention.
[0066] According to some embodiments, the composition comprises a peptidomimetic comprising a capped N-terminus.
[0067] According to some embodiments the composition comprises a peptidomimetic comprising an amidated C-terminus.
[0068] According to some embodiments the composition comprises a peptidomimetic consisting of 5, 6, 7, 8, 9 or 10 amino acid residues and an optional N-terminal capping group. Each possibility represents a separate embodiment of the present invention.
[0069] According to some embodiments, the composition comprises a peptidomimetic consisting of 5-10 amino acid residues, an amidated C-terminus and an N-terminal capping moiety. Each possibility represents a separate embodiment of the present invention.
[0070] According to some embodiments, the composition comprises a peptidomimetic consisting of 6-7 amino acid residues comprising the sequence of SEQ ID NO: 7, and a sequence selected from the group consisting of: Succ-Asp-Phe; Succ-Asp-DPhe; Succ-Asp-Trp; Succ-Asp-DTrp; Succ-Asp-Ile-Phe; Succ-Asp-Ile-DPhe; Succ-Asp-Ile-Trp; Succ-Asp-Ile-DTrp; Succ-Asp-Ser-Phe; Succ-Asp-Ser-DPhe; Succ-Asp-Ser-Trp; Succ-Asp-Ser-DTrp, Succ-Glu-Phe; Succ-Glu-DPhe; Succ-Glu-Trp; Succ-Glu-DTrp; Succ-Glu-Ile-Phe; Succ-Glu-Ile-DPhe; Succ-Glu-Ile-Trp; Succ-Glu-Ile-DTrp; Succ-Glu-Ser-Phe; Succ-Glu-Ser-DPhe; Succ-Glu-Ser-Trp; and Succ-Glu-Ser-DTrp.
[0071] According to some embodiments the at least one N-terminal capping moiety is selected from the group consisting of: succinyl, oxalyl, malonyl, glutaryl, adipoyl, pimaloyl, suberoyl, acetyl, and other dicarboxylic acid residues. Each possibility represents a separate embodiment of the present invention.
[0072] According to some specific embodiments the composition comprises a peptidomimetic selected from the group consisting of:
[0000] (SEQ ID NO: 1, Ant-1) Succ-Asp-Ile-Phe-N(Me)Val-βAla-Leu-Met-NH 2 ; (SEQ ID NO: 2, Ant-2) Succ-Asp-Phe-N(Me)Val-βAla-Leu-Met-NH 2 ; (SEQ ID NO: 3, Ant-3) Succ-Asp-Ser-Phe-N(Me)Val-βAla-Leu-Met-NH 2 ; (SEQ ID NO: 4, Ant-4) Succ-Asp-Ile-D-Trp-N(Me)Val-βAla-Leu-Met-NH 2 ; (SEQ ID NO: 5, Ant-5) Succ-Asp-D-Trp-N(Me)Val-βAla-Leu-Met-NH 2 ; and (SEQ ID NO: 6, Ant-6) Succ-Asp-Ser-D-Trp-N(Me)Val-βAla-Leu-Met-NH 2 ;
wherein Succ denotes a succinyl.
Each possibility represents a separate embodiment of the present invention.
[0073] A pharmaceutical composition according to the invention comprises an NKB or NKF antagonist peptidomimetic as defined above and an optional acceptable carrier, diluent, salt or excipient.
[0074] A food composition according to the present invention comprises an NKB antagonist peptidomimetic as defined above and an optional food additive. Any food additive known in the art may be used in a food composition according to the invention. This includes but is not limited to color additives, taste additives etc. Nutrients, including but not limited to proteins, carbohydrates, fats minerals, vitamins etc., may be also included in the food compositions of the present invention. A food composition according to the invention may comprise nutrients and food additives in addition to at least one active NKB or NKF antagonist.
[0075] According to some embodiments, the food composition comprises food pellets which are coated with at least one NKB or NKF antagonist.
[0076] A pharmaceutical or food composition as defined above, for use as an NKB antagonist is also within the scope of the present invention.
[0077] A composition comprising a peptidomimetic according to the invention may be administered to fish by any manner or route known in the art including parenteral administration and enteral administration. According to some embodiments, parenteral administration includes but is not limited to any type of injection. According to some embodiments, enteral administration includes but is not limited to oral administration, including administration as additive to the food, administration by immersion, including administration as additive to the drinking water, and intragastric administration via gavage.
[0078] According to some embodiments the composition is administered to fish as part of regular food or water consumption.
[0079] According to some embodiments, the composition is administered to fish in a volume of water to be taken up by the gills.
[0080] The invention also provides according to another aspect a composition comprising an NKB antagonist for use in inhibiting at least one parameter of fish reproduction or maturation.
[0081] An NKB antagonist according to the invention is a compound capable of binding to a piscine tachykinin 3 (tac3) receptor and inhibiting its activity. NKF antagonists are also within the definition of NKB antagonists.
[0082] According to some embodiments, the composition for use in inhibiting at least one parameter of fish reproduction or maturation comprises a peptidomimetic selected from the group consisting of: a peptidomimetic of Formula I, as defined above; a peptidomimetic of Formula II, as defined above; and a peptidomimetic of 5-10 amino acid residues comprising the sequence of SEQ ID NO: 7.
[0083] According to some embodiments, the composition for use in inhibiting at least one parameter of fish reproduction or maturation comprises a peptidomimetic selected from the group consisting of:
[0000] (SEQ ID NO: 1, Ant-1) Succ-Asp-Ile-Phe-N(Me)Val-βAla-Leu-Met-NH 2 ; (SEQ ID NO: 2, Ant-2) Succ-Asp-Phe-N(Me)Val-βAla-Leu-Met-NH 2 ; (SEQ ID NO: 3, Ant-3) Succ-Asp-Ser-Phe-N(Me)Val-βAla-Leu-Met-NH 2 ; (SEQ ID NO: 4, Ant-4) Succ-Asp-Ile-D-Trp-N(Me)Val-βAla-Leu-Met-NH 2 ; (SEQ ID NO: 5, Ant-5) Succ-Asp-D-Trp-N(Me)Val-βAla-Leu-Met-NH 2 ; and (SEQ ID NO: 6, Ant-6) Succ-Asp-Ser-D-Trp-N(Me)Val-βAla-Leu-Met-NH 2 ;
wherein Succ denotes a succinyl. Each possibility represents a separate embodiment of the present invention.
[0084] According to other embodiments, the composition for use in inhibiting at least one parameter of fish reproduction or maturation comprises a non-peptidic NKB antagonist.
[0085] According to some specific embodiments, the composition for use in inhibiting at least one parameter of fish reproduction or maturation comprises a non-peptidic NKB antagonist selected from the group consisting of: (S)-(2)-N-(a-ethylbenzyl)-3-methyl-2-phenylquinoline-4-carboxamide (also denoted SB-222200); (S)-(1)-N-{{3-[1-benzoyl-3-(3,4-dichlorophenyl)piperidin-3-yl]prop-1-yl}-4-phenylpiperidin-4-yl}-N-methylacetamide (also denoted Osanetant and SR-142,801), and (S)-(2)-N-(a-ethylbenzyl)-3-hydroxy-2-phenylquinoline-4-carboxamide (also denoted talnetant and SB 223412). Each possibility represents a separate embodiment of the present invention.
[0086] The present invention provides according to yet another aspect, a method of inhibiting at least one parameter of fish reproduction or maturation, the method comprising administering to fish a composition comprising an NKB antagonist.
[0087] According to some embodiments, the composition is selected from the group consisting of a pharmaceutical composition and a food composition.
[0088] Any NKB antagonist compound capable of binding to a piscine tac3 receptor and inhibiting its activity may be used according to this aspect.
[0089] According to some embodiments, the method comprises administering to fish a composition comprising a peptidomimetic selected from the group consisting of: a peptidomimetic of Formula I, as defined above; a peptidomimetic of Formula II, as defined above; and a peptidomimetic of 5-10 amino acid residues comprising the sequence of SEQ ID NO: 7.
[0090] According to some embodiments, the composition comprises a peptidomimetic selected from the group consisting of:
[0000] (SEQ ID NO: 1, Ant-1) Succ-Asp-Ile-Phe-N(Me)Val-βAla-Leu-Met-NH 2 ; (SEQ ID NO: 2, Ant-2) Succ-Asp-Phe-N(Me)Val-βAla-Leu-Met-NH 2 ; (SEQ ID NO: 3, Ant-3) Succ-Asp-Ser-Phe-N(Me)Val-βAla-Leu-Met-NH 2 ; (SEQ ID NO: 4, Ant-4) Succ-Asp-Ile-D-Trp-N(Me)Val-βAla-Leu-Met-NH 2 ; (SEQ ID NO: 5, Ant-5) Succ-Asp-D-Trp-N(Me)Val-βAla-Leu-Met-NH 2 ; and (SEQ ID NO: 6, Ant-6) Succ-Asp-Ser-D-Trp-N(Me)Val-βAla-Leu-Met-NH 2 ;
wherein Succ denotes a succinyl.
Each possibility represents a separate embodiment of the present invention.
[0091] According to other embodiments, the composition comprises a non-peptidic NKB antagonist.
[0092] According to some specific embodiments, the composition comprises a non-peptidic NKB antagonist selected from the group consisting of:
[0000] (S)-(2)-N-(a-ethylbenzyl)-3-methyl-2-phenylquinoline-4-carboxamide (also denoted SB-222200); (S)-(1)-N-{{3-[1-benzoyl-3-(3,4-dichlorophenyl)piperidin-3-yl]prop-1-yl}-4-phenylpiperidin-4-yl}-N-methylacetamide (also denoted Osanetant and SR-142,801), and (S)-(2)-N-(a-ethylbenzyl)-3-hydroxy-2-phenylquinoline-4-carboxamide (also denoted talnetant and SB 223412). Each possibility represents a separate embodiment of the present invention.
[0093] A pharmaceutical composition according to the invention administered in a method of inhibiting at least one parameter of fish reproduction or maturation, comprises an NKB antagonist and an optional acceptable carrier, diluent, salt or excipient.
[0094] A food composition according to the present invention administered in a method of inhibiting at least one parameter of fish reproduction or maturation, comprises an NKB antagonist and an optional food additive. A food composition according to the invention may also include nutrients and food additives, including but not limited to proteins, carbohydrates, fats, minerals, vitamins etc., may be also included in the food compositions of the present invention.
[0095] Inhibition of at least one parameter of piscine reproduction or maturation includes but it not limited to: delaying or eliminating puberty in general or precocious puberty in particular; regulating sex (gender) determination and differentiation (the process of gonad development after sex has been determined) and spawning (discharge of eggs and sperm). Also included within the scope is treatment of hormone-dependent problems or processes in fish which are connected to reproduction.
[0096] According to some embodiments, inhibition of piscine reproduction or maturation results in increased weight of the treated fish.
[0097] Fish according to the invention include any type of fish from any class, subclass, order, family or genus including farmed fish, edible fish and ornamental fish. According to some non-limitative embodiments, the fish is selected from the group consisting of: tilapia, carp, salmon, bass, catfish and mullet.
[0098] Administration of the NKB antagonists to fish according to the methods of the present invention can be performed by any manner known in the art including but not limited to parenteral administration, oral administration and administration by immersion.
[0099] According to some embodiments the NKB antagonists are administered to fish as part of food or water consumption.
[0100] According to some embodiments, the compounds are administered to fish in a volume of water to be taken up by the gills.
[0101] Further embodiments and the full scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE FIGURES
[0102] FIGS. 1A and 1B shows the effect of six peptidomimetics in inhibiting signal transduction ( FIG. 1A CRE activation, FIG. 1B SRE activation) in tilapia. Each antagonist was added at different concentration concomitantly with NKB at 1*10 −8 M (=0.1 nM). Tilapia NKB increased the luciferase activity by 1.8 fold and the reduction of the response by the various polypeptides is shown. FIG. 1C demonstrates in comparison, agonist activity of various NKB and NKF analogs in the CRE activation model.
[0103] FIGS. 2A and 2B shows the effect of six peptidomimetics in inhibiting signal transduction in zebrafish ( FIG. 2A CRE activation, FIG. 2B SRE activation). Zebrafish NKB increased the signal transduction activity by more than 3 fold. The effect of the peptidomimetics was tested when each antagonist was added at different concentration concomitantly with NKB at 1*10 −8 M (=0.1 nM).
[0104] FIGS. 3A and 3B demonstrate the effect of the NKB antagonist SB222200 on CRE-Luc in COS-7 cells transfected with tilapia tac3r, using the human receptor and ligand as positive control. FIG. 3A , the effect on luciferase activity, of the non-peptide antagonist alone as compared with hNKB, tilapia NKB or tilapia NKF. FIG. 3B , the effect on luciferase activity of different concentrations of the antagonist added concomitantly with 0.1 nM of the native ligands (NKB or NKF).
[0105] FIGS. 4A and 4B describe the effect of the NKB antagonist Osanetant (SR-142,801) on CRE-Luc in COS-7 cells transfected with tilapia tac3r when the human receptor and ligand serve as positive control. FIG. 4A , the effect of the non-peptide antagonist alone on the luciferase activity in comparison with hNKB, tilapia NKB or tilapia NKF, at 0.1 nM (10 −8 M. FIG. 4B , the effect of different concentrations of the antagonist added concomitantly with 0.1 nM of the native ligands (NKB or NKF).
[0106] FIGS. 5A and 5B depicts the results of in vivo experiments testing the NKB antagonistic activity of SB222200 (at 10, 100 or 500 μg/kg body weight) on FSH ( FIG. 5A ) and LH ( FIG. 5B ) release in tilapia.
[0107] FIG. 6 represents histological observations of gonads from testes of treated fish versus control fish. Fish testes are organized in cysts.
[0108] FIG. 7 semen volume of fish injected with NKB antagonists SB222200, NKB-antagonist Ant-4, or control.
[0109] FIG. 8 11-ketotestosterone (11KT) levels in fish injected with SB222200 or NKB-antagonist Ant-4 for 14 days.
[0110] FIG. 9 growth rates of adult male tilapia in response to injection of SB2222000, or NKB antagonists Ant-6 (500 μg/kg BW every 48 h for 2 weeks, n=25 fish per group).
[0111] FIG. 10 —Gonado-somatic-index (GSI) of fish injected with either SB222200 or NKB-antagonist Ant-6.
[0112] FIG. 11 proliferating cell nuclear antigen (PCNA) expression levels in the testes of injected fish at day 27.
[0113] FIGS. 12A and 12B growth in response to feeding of young fish with antagonists. FIG. 12A fish growth rate (gr) with and without the antagonists. FIG. 12B representative photographs of the fish of FIG. 12A . The three fish on the left are the control fish, and the three fish on the right were fed with the antagonist Ant-6.
[0114] FIG. 13 shows the effect of the NKB antagonist No. 4 and No 6, on CRE-Luc in COS-7 cells transfected with salmon tac3r.
DETAILED DESCRIPTION OF THE INVENTION
[0115] The present invention provides inhibitors of reproduction of fish and methods for controlling their maturation and growth. The invention is based on inhibition of tachykinin 3 receptor (tac-3 receptor) activity by peptide-based or small molecule antagonists of the tac-3 ligands NKB and NKF.
[0116] According to some embodiments of the present invention, the NKB antagonists are peptide-based compounds (peptidomimetics) according to the following formula:
[0000] X 1 -X 2 -X 3 -NMeVal-X 4 -Leu-Met-NH 2
[0000] wherein
X 1 is any amino acid or non-natural amino acid mimetic or alternatively is null (no amino acid); X 2 is any amino acid or non-natural amino acid mimetics or alternatively is null (no amino acid); X 3 is any amino acid, preferably D aromatic amino acid, most preferably D-Trp or alternatively is null (no amino acid); X 4 is spacer of the type —NH(CH 2 ) n —CO— where n=2-6, or alternatively spacer of the type -(Pro) n - where n=1-6.
[0121] The present invention provides peptidomimetics of 5-10 amino acids and an optional N-terminal capping moiety, wherein the peptidomimetic is selected from the group consisting of:
i. a compound of Formula I: X 1 -NMeVal-X 4 -Leu-Met-Z, wherein: X 1 is a stretch of 1-6 natural or non-natural amino acid residues; NMeVal is an N-methyl-Valine residue or N-methyl-D-Valine residue; X 4 is —NH(CH 2 ) n —CO— wherein n is 2-6; and Z represents the C-terminus of the peptide which may be amidated, acylated, reduced or esterified; ii. a compound of formula II: X 1 -NMeVal-X 4 -Leu-Met-NH 2 wherein, X 1 is selected from the group consisting of: Succ-Asp-Phe; Succ-Asp-DPhe; Succ-Asp-Trp; Succ-Asp-DTrp; Succ-Asp-Ile-Phe; Succ-Asp-Ile-DPhe; Succ-Asp-Ile-Trp; Succ-Asp-Ile-DTrp; Succ-Asp-Ser-Phe; Succ-Asp-Ser-DPhe; Succ-Asp-Ser-Trp; Succ-Asp-Ser-DTrp, Succ-Glu-Phe; Succ-Glu-DPhe; Succ-Glu-Trp; Succ-Glu-DTrp; Succ-Glu-Ile-Phe; Succ-Glu-Ile-DPhe; Succ-Glu-Ile-Trp; Succ-Glu-Ile-DTrp; Succ-Glu-Ser-Phe; Succ-Glu-Ser-DPhe; Succ-Glu-Ser-Trp; and Succ-Glu-Ser-DTrp; and X 4 is βAla; and iii. a compound comprising the sequence NMeVal-βAla-Leu-Met (SEQ ID NO: 7).
[0125] Compositions comprising peptidomimetics according to the invention and methods for their use are also provided.
[0126] According to some specific embodiments, the composition of the invention comprises as an active ingredient a compound selected from the group consisting of: Ant-1 to Ant-6
[0000]
(SEQ ID NO: 1, Ant-1)
Succ-Asp-Ile-Phe-N(Me)Val-βAla-Leu-Met-NH 2 ;
(SEQ ID NO: 2, Ant-2)
Succ-Asp-Phe-N(Me)Val-βAla-Leu-Met-NH 2 ;
(SEQ ID NO: 3, Ant-3)
Succ-Asp-Ser-Phe-N(Me)Val-βAla-Leu-Met-NH 2 ;
(SEQ ID NO: 4, Ant-4)
Succ-Asp-Ile-D-Trp-N(Me)Val-βAla-Leu-Met-NH 2 ;
(SEQ ID NO: 5, Ant-5)
Succ-Asp-D-Trp-N(Me)Val-βAla-Leu-Met-NH 2 ;
and
(SEQ ID NO: 6, Ant-6)
Succ-Asp-Ser-D-Trp-N(Me)Val-βAla-Leu-Met-NH 2 ;
[0127] The peptides of the present invention are preferably synthesized using conventional synthesis techniques known in the art, e.g., by chemical synthesis techniques including peptidomimetic methodologies. These methods include exclusive solid phase synthesis, partial solid phase synthesis methods, fragment condensation, classical solution synthesis. Solid phase peptide synthesis procedures are well known in the art. A skilled artesian may synthesize any of the peptides of the present invention by using an automated peptide synthesizer using standard chemistry such as, for example, t-Boc or Fmoc chemistry. Synthetic peptides can be purified by preparative high performance liquid chromatography, and the composition of which can be confirmed via amino acid sequencing. Conjugation of peptidic and permeability moieties may be performed using any methods known in the art, either by solid phase or solution phase chemistry. Some of the preferred compounds of the present invention may conveniently be prepared using solution phase synthesis methods. Other methods known in the art to prepare compounds like those of the present invention can be used and are comprised in the scope of the present invention.
[0128] N-terminal capping or modification according to the present invention denotes alteration of the peptide's sequence by covalently attaching a chemical moiety to the terminal amine resulting in modified charge, activity and/or stability to cleavage by amino peptidases.
[0129] Non-limitative examples of a permeability-enhancing moiety include: hydrophobic moieties such as fatty acids, steroids and bulky aromatic or aliphatic compounds; moieties which may have cell-membrane receptors or carriers, such as steroids, vitamins and sugars, natural and non-natural amino acids and transporter peptides. According to some embodiments, the hydrophobic moiety is a lipid moiety or an amino acid moiety.
[0130] A permeability-enhancing moiety may be connected to any position in the peptide moiety, directly or through a spacer. According to specific embodiments, the cell-permeability moiety is connected to the amino terminus of the peptide moiety. The optional connective spacer may be of varied lengths and conformations comprising any suitable chemistry including but not limited to amine, amide, carbamate, thioether, oxyether, sulfonamide bond and the like. Non-limiting examples for such spacers include amino acids, sulfone amide derivatives, amino thiol derivatives and amino alcohol derivatives.
[0131] The term “peptide” or “peptide-based” as used herein is meant to encompass natural (genetically encoded), non-natural and/or chemically modified amino acid residues, each residue being characterized by having an amino and a carboxy terminus, connected one to the other by peptide or non-peptide bonds. The amino acid residues are represented throughout the specification and claims by either one or three-letter codes, as is commonly known in the art. The peptides and peptidomimetics of the present invention are preferably utilized in a linear form, although it will be appreciated that in cases where cyclization does not severely interfere with peptide characteristics, cyclic forms of the peptide can also be utilized.
[0132] The amino acids used in this invention are those which are available commercially or are available by routine synthetic methods. Certain residues may require special methods for incorporation into the peptide, and sequential, divergent or convergent synthetic approaches to the peptide sequence are useful in this invention. Natural coded amino acids and their derivatives are represented by three-letter codes according to IUPAC conventions. When there is no indication, either the L or D isomers may be used. When a “D”- precedes the amino acid, a D isomer is used.
[0133] Conservative substitution of amino acids as known to those skilled in the art are within the scope of the present invention. Conservative amino acid substitutions includes replacement of one amino acid with another having the same type of functional group or side chain e.g. aliphatic, aromatic, positively charged, negatively charged. These substitutions may enhance oral bioavailability, affinity to the target protein, metabolic stability, penetration into the central nervous system, targeting to specific cell populations and the like. One of skill will recognize that individual substitutions, deletions or additions to peptide, polypeptide, or protein sequence which alters, adds or deletes a single amino acid or a small percentage of amino acids in the encoded sequence is a “conservatively modified variant” where the alteration results in the substitution of an amino acid with a chemically similar amino acid. Conservative substitution tables providing functionally similar amino acids are well known in the art.
[0134] The following is an example of classification of the amino acids into six groups, each contains amino acids that are conservative substitutions for one another:
1) Alanine (A), Serine (S), Threonine (T); 2) Aspartic acid (D), Glutamic acid (E); 3) Asparagine (N), Glutamine (Q); 4) Arginine (R), Lysine (K); 5) Isoleucine (I), Leucine (L), methionine (M), Valine (V); and 6) Phenylalanine (F), Tyrosine (Y), Tryptophan (W).
[0141] Other classifications into somehow different groups (for example, aliphatic, polar, non-polar, hydrophilic, hydrophopic etc.) are also known in the art and can be used for conservative amino acid substitutions according to the present invention.
[0142] Also included within the scope of the invention are salts of the peptides, analogs, and chemical derivatives of the peptides of the invention.
[0143] As used herein the term “salts” refers to both salts of carboxyl groups and to acid addition salts of amino or guanido groups of the peptide molecule. Salts of carboxyl groups may be formed by means known in the art and include inorganic salts, for example sodium, calcium, ammonium, ferric or zinc salts, and the like, and salts with organic bases such as salts formed for example with amines such as triethanolamine, piperidine, procaine, and the like. Acid addition salts include, for example, salts with mineral acids such as, for example, acetic acid or oxalic acid. Salts describe here also ionic components added to the peptide solution to enhance hydrogel formation and/or mineralization of calcium minerals.
[0144] A “chemical derivative” as used herein refers to peptides containing one or more chemical moieties not normally a part of the peptide molecule such as esters and amides of free carboxy groups, acyl and alkyl derivatives of free amino groups, phospho esters and ethers of free hydroxy groups. Such modifications may be introduced into the molecule by reacting targeted amino acid residues of the peptide with an organic derivatizing agent that is capable of reacting with selected side chains or terminal residues. Preferred chemical derivatives include peptides that have been phosphorylated, C-termini amidated or N-termini acetylated.
[0145] “Functional derivatives” of the peptides of the invention as used herein covers derivatives which may be prepared from the functional groups which occur as side chains on the residues or the N- or C-terminal groups, by means known in the art, and are included in the invention as long as they remain pharmaceutically acceptable, i.e., they do not destroy the activity of the peptide, do not confer toxic properties on compositions containing it and do not adversely affect the antigenic properties thereof. These derivatives may, for example, include aliphatic esters of the carboxyl groups, amides of the carboxyl groups produced by reaction with ammonia or with primary or secondary amines, N-acyl derivatives of free amino groups of the amino acid residues formed by reaction with acyl moieties (e.g., alkanoyl or carbocyclic aroyl groups) or O-acyl derivatives of free hydroxyl group (for example that of seryl or threonyl residues) formed by reaction with acyl moieties.
[0146] The term “peptide analog” indicates molecule which has the amino acid sequence according to the invention except for one or more amino acid changes or one or more modification/replacement of an amide bond. Peptide analogs include amino acid substitutions and/or additions with natural or non-natural amino acid residues, and chemical modifications which do not occur in nature. Peptide analogs include peptide mimetics. A peptide mimetic or “peptidomimetic” means that a peptide according to the invention is modified in such a way that it includes at least one non-coded residue or non-peptidic bond. Such modifications include, e.g., alkylation and more specific methylation of one or more residues, insertion of or replacement of natural amino acid by non-natural amino acids, replacement of an amide bond with other covalent bond. A peptidomimetic according to the present invention may optionally comprises at least one bond which is an amide-replacement bond such as urea bond, carbamate bond, sulfonamide bond, hydrazine bond, or any other covalent bond. The design of appropriate “analogs” may be computer assisted. Additional peptide analogs according to the present invention comprise a specific peptide or peptide analog sequence in a reversed order, namely, the amino acids are coupled in the peptide sequence in a reverse order to the amino acids order which appears in the native protein or in a specific peptide or analog identified as active. Whether completely or partially non-peptide, peptidomimetics according to this invention provide a spatial arrangement of chemical moieties that closely resembles the three-dimensional arrangement of groups in the peptide on which the peptidomimetic is based. As a result of this similar active-site structure, the peptidomimetic has effects on biological systems, which are similar to the biological activity of the peptide.
[0147] A modified amino acid residue is an amino acid residue in which any group or bond was modified by deletion, addition, or replacement with a different group or bond, as long as the functionality of the amino acid residue is preserved or if functionality changed (for example replacement of tyrosine with substituted phenylalanine) as long as the modification did not impair the activity of the peptide containing the modified residue.
[0148] “A peptide conjugate” according to the present invention, denotes a molecule comprising a sequence of a blood-vessel promoting peptide to which another moiety, either peptidic or non peptidic, is covalently bound, directly or via a linker.
[0149] The term “linker” denotes a chemical moiety, a direct chemical bond of any type, or a spacer whose purpose is to link, covalently, a cell-permeability moiety and a peptide or peptidomimetic. The spacer may be used to allow distance between the permeability-enhancing moiety and the peptide.
[0150] “Permeability” refers to the ability of an agent or substance to penetrate, pervade, or diffuse through a barrier, membrane, or a skin layer. A “cell permeability” or a “cell-penetration” moiety refers to any molecule known in the art which is able to facilitate or enhance penetration of molecules through membranes. Non-limitative examples include: hydrophobic moieties such as lipids, fatty acids, steroids and bulky aromatic or aliphatic compounds; moieties which may have cell-membrane receptors or carriers, such as steroids, vitamins and sugars, natural and non-natural amino acids, transporter peptides, nanoparticles and liposomes.
[0151] The term “physiologically acceptable carrier” or “diluent” or “excipient” refers to an aqueous or non-aqueous fluid that is well suited for pharmaceutical preparations. Furthermore, the term “a pharmaceutically acceptable carrier or excipient” refers to at least one carrier or excipient and includes mixtures of carriers and or excipients. The term “therapeutic” refers to any pharmaceutical, drug or prophylactic agent which may be used in the treatment (including the prevention, diagnosis, alleviation, or cure) of a malady, affliction, disease or injury in a patient.
Pharmacology
[0152] Apart from other considerations, the fact that the novel active ingredients of the invention are peptides, peptide analogs or peptidomimetics, dictates that the formulation be suitable for delivery of these types of compounds. Although in general peptides are less suitable for oral administration due to susceptibility to digestion by gastric acids or intestinal enzymes novel methods are being used, in order to design and provide metabolically stable and oral bioavailable peptidomimetic analogs.
[0153] The pharmaceutical composition of this invention may be administered by any suitable means, such as orally, topically, intranasally, subcutaneously, intramuscularly, intravenously, intra-arterially, intraarticulary, intralesionally, by inhalation or parenterally, and are specifically formulated for the administration route. The compositions are formulated according to the administration route.
[0154] Pharmaceutical compositions of the present invention may be manufactured by processes well known in the art, e.g., by means of conventional mixing, dissolving, granulating, grinding, pulverizing, dragee-making, levigating, emulsifying, encapsulating, entrapping or lyophilizing processes.
[0155] Pharmaceutical compositions for use in accordance with the present invention thus may be formulated in conventional manner using one or more physiologically acceptable carriers comprising excipients and auxiliaries, which facilitate processing of the active compounds into preparations which, can be used pharmaceutically. Proper formulation is dependent upon the route of administration chosen.
[0156] Pharmaceutical compositions, which can be used orally, include push-fit capsules made of gelatin as well as soft, sealed capsules made of gelatin and a plasticizer, such as glycerol or sorbitol. The push-fit capsules may contain the active ingredients in admixture with filler such as lactose, binders such as starches, lubricants such as talc or magnesium stearate and, optionally, stabilizers. In soft capsules, the active compounds may be dissolved or suspended in suitable liquids, such as fatty oils, liquid paraffin, or liquid polyethylene glycols. In addition, stabilizers may be added.
[0157] For injection, the compounds of the invention may be formulated in aqueous solutions, preferably in physiologically compatible buffers such as Hank's solution, Ringer's solution, or physiological saline buffer. For transmucosal administration, penetrants appropriate to the barrier to be permeated are used in the formulation. Such penetrants for example polyethylene glycol are generally known in the art.
[0158] Dragee cores are provided with suitable coatings. For this purpose, concentrated sugar solutions may be used which may optionally contain gum arabic, talc, polyvinyl pyrrolidone, carbopol gel, polyethylene glycol, titanium dioxide, lacquer solutions and suitable organic solvents or solvent mixtures. Dyestuffs or pigments may be added to the tablets or dragee coatings for identification or to characterize different combinations of active compound doses.
[0159] For buccal administration, the compositions may take the form of tablets or lozenges formulated in conventional manner.
[0160] For administration by inhalation, the variants for use according to the present invention are conveniently delivered in the form of an aerosol spray presentation from a pressurized pack or a nebulizer with the use of a suitable propellant, e.g., dichlorodifluoromethane, trichlorofluoromethane, dichloro-tetrafluoroethane or carbon dioxide. In the case of a pressurized aerosol, the dosage unit may be determined by providing a valve to deliver a metered amount. Capsules and cartridges of, e.g., gelatin for use in an inhaler or insufflator may be formulated containing a powder mix of the peptide and a suitable powder base such as lactose or starch.
[0161] Pharmaceutical compositions for parenteral administration include aqueous solutions of the active ingredients in water-soluble form. Additionally, suspensions of the active compounds may be prepared as appropriate oily injection suspensions. Suitable natural or synthetic carriers are well known in the art (Pillai et al., Curr. Opin. Chem. Biol. 5, 447, 2001). Optionally, the suspension may also contain suitable stabilizers or agents, which increase the solubility of the compounds, to allow for the preparation of highly concentrated solutions. Alternatively, the active ingredient may be in powder form for reconstitution with a suitable vehicle, e.g., sterile, pyrogen-free water, before use.
[0162] Pharmaceutical compositions suitable for use in context of the present invention include compositions wherein the active ingredients are contained in an amount effective to achieve the intended purpose. More specifically, a therapeutically effective amount means an amount of a compound effective to prevent, alleviate or ameliorate symptoms of a disease of the subject being treated. Determination of a therapeutically effective amount is well within the capability of those skilled in the art.
[0163] Toxicity and therapeutic efficacy of the peptides described herein can be determined by standard pharmaceutical procedures in cell cultures or experimental animals, e.g., by determining the IC50 (the concentration which provides 50% inhibition) and the LD50 (lethal dose causing death in 50% of the tested animals) for a subject compound. The data obtained from these cell culture assays and animal studies can be used in formulating a range of dosage for use in human The dosage may vary depending upon the dosage form employed and the route of administration utilized. The exact formulation, route of administration and dosage can be chosen by the individual physician in view of the patient's condition (e.g. Fingl, et al., 1975, in “The Pharmacological Basis of Therapeutics”, Ch. 1 p. 1).
[0164] The doses for administration of such pharmaceutical compositions range according to some embodiments of the present invention from about 0.1 mg/kg to about 50 mg/kg body weight.
[0165] Depending on the severity and responsiveness of the condition to be treated, dosing can also be a single administration of a slow release composition, with course of treatment lasting from several days to several weeks or until cure is effected or diminution of the disease state is achieved. The amount of a composition to be administered will, of course, be dependent on the subject being treated, the severity of the affliction, the manner of administration, the judgment of the prescribing physician, and all other relevant factors.
[0166] In certain embodiments, peptide delivery can be enhanced by the use of protective excipients. This is typically accomplished either by complexing the peptide with a composition to render it resistant to acidic and enzymatic hydrolysis or by packaging the polypeptide in an appropriately resistant carrier such as a liposome. Means of protecting polypeptides for oral delivery are well known in the art (see, e.g., U.S. Pat. No. 5,391,377 describing lipid compositions for oral delivery of therapeutic agents).
[0167] Elevated serum half-life can be maintained by the use of sustained-release protein “packaging” systems. Such sustained release systems are well known to those of skill in the art. In one preferred embodiment, the ProLease biodegradable microsphere delivery system for proteins and peptides (Tracy, 1998, Biotechnol. Prog. 14, 108; Johnson et al., 1996, Nature Med. 2, 795; Herbert et al., 1998, Pharmaceut. Res. 15, 357) a dry powder composed of biodegradable polymeric microspheres containing the protein in a polymer matrix that can be compounded as a dry formulation with or without other agents.
[0168] In certain embodiments, dosage forms of the compositions of the present invention include, but are not limited to, biodegradable injectable depot systems such as, PLGA based injectable depot systems; non-PLGA based injectable depot systems, and injectable biodegradable gels or dispersions. Each possibility represents a separate embodiment of the invention. The term “biodegradable” as used herein refers to a component which erodes or degrades at its surfaces over time due, at least in part, to contact with substances found in the surrounding tissue fluids, or by cellular action. In particular, the biodegradable component is a polymer such as, but not limited to, lactic acid-based polymers such as polylactides e.g. poly (D,L-lactide) i.e. PLA; glycolic acid-based polymers such as polyglycolides (PGA) e.g. Lactel® from Durect; poly (D,L-lactide-co-glycolide) i.e. PLGA, (Resomer® RG-504, Resomer® RG-502, Resomer® RG-504H, Resomer® RG-502H, Resomer® RG-504S, Resomer® RG-502S, from Boehringer, Lactel® from Durect); polycaprolactones such as Poly(e-caprolactone) i.e. PCL (Lactel® from Durect); polyanhydrides; poly(sebacic acid) SA; poly(ricenolic acid) RA; poly(fumaric acid), FA; poly(fatty acid dimmer), FAD; poly(terephthalic acid), TA; poly(isophthalic acid), IPA; poly(p-{carboxyphenoxy}methane), CPM; poly(p-{carboxyphenoxy}propane), CPP; poly(p-{carboxyphenoxy}hexane)s CPH; polyamines, polyurethanes, polyesteramides, polyorthoesters {CHDM: cis/trans-cyclohexyl dimethanol, HD: 1,6-hexanediol. DETOU: (3,9-diethylidene-2,4,8,10-tetraoxaspiro undecane)}; polydioxanones; polyhydroxybutyrates; polyalkylene oxalates; polyamides; polyesteramides; polyurethanes; polyacetals; polyketals; polycarbonates; polyorthocarbonates; polysiloxanes; polyphosphazenes; succinates; hyaluronic acid; poly(malic acid); poly(amino acids); polyhydroxyvalerates; polyalkylene succinates; polyvinylpyrrolidone; polystyrene; synthetic cellulose esters; polyacrylic acids; polybutyric acid; triblock copolymers (PLGA-PEG-PLGA), triblock copolymers (PEG-PLGA-PEG), poly (N-isopropylacrylamide) (PNIPAAm), poly (ethylene oxide)-poly (propylene oxide)-poly (ethylene oxide) tri-block copolymers (PEO-PPO-PEO), poly valeric acid; polyethylene glycol; polyhydroxyalkylcellulose; chitin; chitosan; polyorthoesters and copolymers, terpolymers; lipids such as cholesterol, lecithin; poly(glutamic acid-co-ethyl glutamate) and the like, or mixtures thereof.
[0169] In some embodiments, the compositions of the present invention comprise a biodegradable polymer selected from, but not limited to, PLGA, PLA, PGA, polycaprolactone, polyhydroxybutyrate, polyorthoesters, polyalkaneanhydrides, gelatin, collagen, oxidized cellulose, polyphosphazene and the like. Each possibility represents a separate embodiment.
Fish Food Compositions
[0170] The food compositions of the present invention may be part of, or mixed with conventional of special fish food. Fish food normally consists of a feed used for the type of fish to be nourished and includes proteins, oils, vitamins and other additives.
[0171] According to some non-limiting examples, the antagonist compositions of the present invention are included in pelletized, solid compositions containing, about 15 to 50 percent protein or protein hydrolysate, about 2 to 5 percent fat, and about 3 to 10 percent crude fiber together with minor amounts of adjuvants, such as minerals, vitamins, and/or trace elements.
[0172] Fish food composition comprising the antagonists of the present invention are prepared using methods known in the art. For example, pellets, typically 0.5-20 millimeters in diameter, are made from the composition and dried prior to storage and use. The coherence of the pellets may be improved by dissolving a small amount of gelatin in the water. If water-soluble whey powder provides much of the protein content, the pellet surfaces are preferably coated with a little oil or fat to prevent premature disintegration of the pellets upon contact with water. Gelatin-bearing compositions may be foamed in a conventional manner to produce cellular pellets whose overall density is similar to that of water. Such pellets float in water and remain accessible to the fish for a relatively long period. Pellets that sink to the bottom are lost to many fish. The antagonists of the invention may also be mixed with commercial fish feed of conventional composition by uniformly distributing the addition in the basis composition and thereafter making pellets from the mixture obtained. According to some embodiments, food pellets are coated with the compounds of the invention and used for feeding the fish.
[0173] Although the present invention has been described with respect to various specific embodiments thereof in order to illustrate it, such specifically disclosed embodiments should not be considered limiting. Many other specific embodiments will occur to those skilled in the art based upon applicants' disclosure herein, and applicants propose to be bound only by the spirit and scope of their invention as defined in the appended claims.
EXAMPLES
[0174] The following examples demonstrate the in-vitro and in-vivo activity of the compounds of the present invention as antagonists of fish NKB.
Example 1
Design and Synthesis of Peptidomimetics
[0175] Some of the peptidomimetic of the present invention were design based on the following considerations:
i) The N-terminus of the peptide was modified by adding a capping moiety such as succinyl (succ) coupled to the Asp residue, such that the peptide lacks the terminal amino group that is susceptible to degradation by amino peptidases. This unexpectedly resulted in ability of shortening of the active peptide from 11 to 7 amino acids; ii) Replacement of a Phe residue by D-Trp prevented tight fitting of the agonist to the NK receptor. This altered the activity of the peptide from agonist into antagonist and also stabilized the peptide to degradation by endopeptidases. iii) The Val residue was N-methylated to impose conformational constrain that stabilize the bioactive conformation thus impose receptor selectivity and metabolic stability, preventing degradation by endopeptidases. iv) The residue Gly was replaced by βAla (betta alanine) resulting in increased conformational flexibility of the bioactive conformation and facilitate the conversion of agonist into antagonist. v) The carboxamide group in the carboxy terminus is essential for binding and receptor activation and prevents degradation by carboxypeptidases.
[0181] The peptidomimetic were synthesized by an automatic solid-phase method applying Fmoc active-ester chemistry. Difficult coupling of hydrophobic amino acids, such as Fmoc-D-Trp-OH to NMe-Val-peptidyl-resin was performed twice using HATU for 5 hours in DMF. The compounds were purified by HPLC to ≧95% purity.
Example 2
In Vitro Tests
[0182] There are two signal transduction pathways, one is relayed trough cAMP/PKA (protein kinase A), and the second is trough Ca2+/PKC. The PKA pathway is activated by CRE (cAMP response element) and the PKC through SRE (steroid response element).
[0183] In order to differentiate between the PKC and PKA signal transduction pathways, a sensitive luciferase (LUC) reporter gene assay was utilized by using the LUC transcriptionally regulated by a serum response element (SRE; Invitrogen) or cyclic AMP (cAMP) response element (CRE; Invitrogen). Tilapia tac3ra and tac3rb (GenBank accession numbers KF471674 and KF471675, respectively) or zebrafish tac3ra and tac3rb (JF317292, and JF317293, respectively) were cloned in pcDNA3.1 expression vector (Zeo-; Invitrogen) under the control of the CMV promoter.
[0184] Transient transfection, cell procedures and stimulation protocols were generally according to (Levavi-Sivan et al., 2005, Mol Cell Endocrinol 236:17-30; Biran et al., 2008, ibid, Biran et al., 2012, ibid, Biran et al., 2014 ibid). Briefly, COS-7 cells were grown in DMEM supplemented with 10% FBS, 1% glutamine, 100 U/ml penicillin, and 100 mg/ml streptomycin (Biological Industries) under 5% CO2 until confluent. Cotransfection of either pc-tac3ra, pc-tac3rb (at 3 μg/plate), a reporter plasmid (at 2 μg/plate), and pCM.
[0185] Transfection was carried out with FuGENE 6.0 reagent (Roche). The cells were serum starved for 36 h, stimulated with vehicle or various concentrations of either human NKB, tilapia NKB, tilapia NKF, zebrafish NKBa, NKBb or zebrafish NKF for 6 h, and then harvested and analyzed.
[0186] Lysates prepared from the harvested cells were assayed for both luciferase activity and β-galactosidase activity, which was used as an internal standard to normalize the luciferase activity directed by the test plasmid, as described previously. Transfection experiments were performed in triplicate with three independently isolated sets.
[0187] The concentrations of ligand used were from 1 nM to 1 μM. Treatments were performed in quadruplicate in three independent experiments.
[0188] Each antagonist was added at different concentrations with a constant concentration of the wild-type NKB or NKF, at a dose of the ligand (10 −8 M) that gave a response close to the ED50. The results were analyzed by Prism software, according to a non-linear regression one-site competition curve.
[0189] The effect of NKB antagonists was tested in tilapia when each antagonist was added at different concentration concomitantly with NKB at 10 −8 M (=0.1 nM). Tilapia NKB increased the luciferase activity by 1.8 fold. The various antagonists reduced this response by approximately 60% ( FIG. 1A ). Similar results were obtained using the SRE response ( FIG. 1B ). In contrast, Tilapia NKB and NKF analogs (disclosed in WO 2013/018097) were shown to have agonistic activity in both assays as demonstrated in FIG. 1C for the CRE assay.
[0190] The zebrafish NKB was more efficient than the tilapia peptide in the induction of the signal transduction activity, and increased the CRE-LUC by more than 3 fold. The effect of NKB antagonists was tested when each antagonist was added at different concentration concomitantly with NKB at 10 −8 M (=0.1 nM). The various antagonists reduced the response by approximately 60% ( FIG. 2A ). Similar results were obtained using the SRE response ( FIG. 2B ), while NKB agonists were not inhibitory but stimulatory and gave results similar to FIG. 1C .
[0191] To conclude, NKB antagonist peptidomimetics according to the present invention are able to inhibit the NKB signal transduction.
Example 3
Non-Peptide Antagonists for NKB
[0192] The effect of known NKB small molecule antagonists was tested in vitro and in vivo. The compounds are: SB-222200 (Sarau et al., 2000 ibid); Osanetant (SR-142,801) and talnetant (SB 223412, (Sarau et al., 1997 ibid).
[0193] The effect of the NKB antagonist SB222200 on CRE-Luc in COS-7 cells transfected with tilapia tac3r was tested when the human receptor and ligand served as a positive control.
[0194] As shown in FIG. 3A , the non-peptide antagonist alone had no effect on the luciferase activity, while hNKB, tilapia NKB or tilapia NKF, at 0.1 nM (=10 −8 M), increased the luciferase activity by 1.7 and 2.3 fold, respectively.
[0195] When different concentrations of the antagonist were added concomitantly with 0.1 nM of the native ligands (NKB or NKF) a typical inhibition curve was achieved, demonstrating the antagonistic potency of SB222200 on the tilapia NKB receptor ( FIG. 3B ).
[0196] The effect of the NKB antagonist Osanetant (SR-142,801) was tested on CRE-Luc in COS-7 cells transfected with tilapia tac3r when the human receptor and ligand served as a positive control. The non-peptide antagonist alone had no effect on the luciferase activity while hNKB, tilapia NKB or tilapia NKF, at 0.1 nM (=10 −8 M), increased the luciferase activity by 2.5 and 1.6 fold, respectively ( FIG. 4A ). However, when different concentrations of the antagonist were added concomitantly with 0.1 nM of the native ligands (NKB or NKF) a typical inhibition curve was achieved, showing the antagonistic potency of Osanetant (SR-142,801) on the tilapia NKB receptor ( FIG. 4B ).
[0197] SB222200 was further tested in vivo for its NKB antagonistic activity on gonadotropin release in tilapia. Sexually mature tilapia females (0.62±0.22%; n=10/treatment) were injected with different doses of the NKB non-peptide antagonist SB222200 (10, 100 or 500 μg/kg body weight) at time 0. 1, 2, 4 and 8 hours after the injection the fish were bled from their caudal vasculature. The levels of the gonadotropins FSH and LH were determined using specific ELISA according to Aizen et al., 2007 (Aizen et al., 2007, Gen Comp Endocrinol, vol. 153, pp 323-332). The results show that while no significant changed were recorded in the control group, a significant gradual decline was recorded in both FSH ( FIG. 5A ) and LH ( FIG. 5B ) levels starting already 1 hour after the injection.
Example 4
In Vivo Experiments
[0198] Selected antagonists that were shown effective in the in-vitro transactivation assay are tested in vivo.
[0199] Adult male Tilapia (BW 90 g) were injected ip with saline and 25% DMSO, SB2222000, or the NKB antagonists Ant-4 (500 μg/kg BW every 48 h for 2 weeks, n=20 fish per group). The fish were bled from the caudal blood vessels into heparinized syringes every 2 days after injection. At days 7 and 14 five fish from each group were bled, striped for sperm volume and gonads were taken for Histology, Plasma was analyzed for LH, FSH and 11KT. Blood samples were collected from the caudal vasculature and centrifuged (3000 rpm for 20 minutes at 4° C.) to obtain plasma samples, which were stored at −20° C. until assayed. ELISAs were performed according to (Aizen et al., 2007, Gen Comp Endocrinol, vol. 153, pp 323-332) for FSH and LH and according to Hurvitz et al., 2005 (Gen Comp Endocrinol 140:61-73) for 11KT (11-ketotestosterone, the main androgen in fish which is involved in spermatogenesis).
[0200] FIG. 6 represents histological observations of gonads from testes of treated fish versus control fish. Fish testes are organized in cysts. As demonstrated in the figure, Fish exposed to NKB-antagonist Ant-4 contained more partially empty cysts with mature spermatozoa (mature sperm). Semen volume of fish injected with NKB antagonists is presented in FIG. 7 . From right to left: semen from fish injected with SB222200; semen from control fish; semen from fish injected with NKB-antagonist #4. 11KT levels in fish injected with SB222200 or NKB-antagonist Ant-4 are shown in FIG. 8 . 11KT is the main androgen in fish and is involved in spermatogenesis. During the treatment period, plasma 11KT levels increased gradually from 0 to 12 days for the control fish, whereas for fish that were injected with SB222200 or NKB-antagonist Ant-4 (#4), this increase was significantly inhibited.
Example 5
In-Vivo Growth of Tilapia
[0201] Adult male tilapia (BW 60 g) were injected ip with saline and 25% DMSO, SB2222000, or NKB antagonists Ant-6 (500 μg/kg BW every 48 h for 2 weeks, n=25 fish per group). Fish were weighed every 7 days. As indicated in FIG. 9 , significant growth was seen at day 21, seven days after the treatment was finished.
[0202] The gonadosomatic index (GSI), is the calculation of the gonad mass as a proportion of the total body mass. The OSI value of the injected fish was also calculated ( FIG. 10 ). At day 27, fish were sacrificed and total RNA was extracted from their testes. Proliferating cell nuclear antigen (PCNA) is a DNA clamp that acts as a factor for DNA polymerase δ in eukaryotic cells and is essential for replication. The gene expression of PCNA was determined in the testes of the injected fish after 27 days ( FIG. 11 ).
Example 6
Feeding of Young Tilapia
[0203] Female tilapia fish at age 105 days were used in this study. Feeding, by fish pellets coated with the peptidomimetics antagonists, was initiated at age of 3 month and 12 days. The diet of NKB antagonists (Ant-2, Ant-3, Ant-6) was applied at 7.5 mg/kg feed (2% to 3% of fish weight). The fish were fed twice daily during the day light hours. Fish growth rate was determined. As indicated in FIGS. 12A and 12B fish that were fed on a diet containing the NKB antagonists grew significantly faster (about 25% increase in body weight) than the control fish. No changes were observed in their internal organs (as determined by photography of the organs).
Example 7
In Vitro Experiments in Salmon
[0204] Similar to the in-vitro experiments performed in Example 2 in Tilapia and Zebrafish, the inhibition of NKB activity was tested in Salmon fish. Salmon tac3 receptor was cloned in pcDNA3.1 expression vector (Zeo-; Invitrogen) under the control of the CMV promoter. Transfection was carried out with FuGENE 6.0 reagent (Roche). The cells were serum starved for 36 h, stimulated with vehicle or various concentrations of either tilapia NKB for 6 h, and then harvested and analyzed. Lysates prepared from the harvested cells were assayed for both luciferase activity and β-galactosidase activity, which was used as an internal standard to normalize the luciferase activity directed by the test plasmid. Transfection experiments were performed in triplicate with three independently isolated sets. The concentrations of ligand used were from 1 nM to 1 μM. Treatments were performed in quadruplicate in three independent experiments. Each antagonist (NKB-ant 4 and NKB-ant 6) was added at different concentrations with a constant concentration of the wild-type NKB (10 −8 M) that gave a response close to the ED50. The results were analyzed by Prism software, according to a non-linear regression one-site competition curve.
[0205] When salmon tac3 was transfected, NKB increased the luciferase activity by 1.8 fold. As demonstrated in FIG. 13 , both antagonists #4 and #6 successfully reduced this response by approximately 60%.
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Provided are Peptide-based neurokinin antagonists of fish reproduction. Compositions including antagonists of fish neurokinin and methods of inhibiting or delaying puberty, fish maturation or reproduction processes using these compounds are also provided.
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RELATED APPLICATIONS
This application claims the benefit of United States Provisional Patent Application Ser. No. 60/828,445 filed in the United States Patent and Trademark Office on Oct. 6, 2006.
BACKGROUND OF INVENTION
As weapons technologies have advanced, so too have the implements used for protection. Various materials have been employed as material technology has moved forward. The cost and weight of these various armoring materials and techniques are generally factors for designers. Additionally, historical armor materials and techniques generally require continuous updating to meet the demands of modern armaments. For instance, while steel has been used in traditional armor applications, it is generally impractical to employ steel in the dimensions needed to completely protect against all projectiles, as any vehicle carrying such armor would be severely hampered due to the excessive weight. Armor and shielding that is undersized or under-strengthened for its purpose is largely useless. In some cases, this scenario may give a false sense of security to the user.
Armor generally must be designed to protect against a wide variety of threats. The angle of attack, the method of threat, munitions used, and the frequency of danger are all factors that designers may consider.
While some armor is able to withstand the force and penetration of a single strike in a particular region, multiple strikes in the same zone generally represent an unprotected threat. Some armors employ explosive charges and “smart armor” techniques that engage an anticipated projectile, however these techniques severely limit the multiple strike capabilities in the same zone. Accordingly, there exists a need to address these and other deficiencies associated with conventional armor techniques.
SUMMARY OF THE INVENTION
In general, methods and devices for protective armor are disclosed; and more particularly, representative and exemplary embodiments of the present invention generally relate to improved methods and systems for ballistic deflection and protection through dynamic armor, and/or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
Representative elements, operational features, applications and/or advantages of the present invention reside in the details of construction and operation as more fully hereafter depicted, described or otherwise identified—reference being made to the accompanying drawings, images, figures, etc. forming a part hereof, wherein like numerals (if any) refer to like parts throughout. Other elements, operational features, applications and/or advantages may be implemented in light of certain exemplary embodiments recited, wherein:
FIG. 1 representatively illustrates a dynamic armor system having embedded shaped bodies in the absorbing filler layer in accordance with an exemplary embodiment of the present invention;
FIG. 2 representatively illustrates a dynamic armor system having dynamic materials located in the absorbing filler layer in accordance with an exemplary embodiment of the present invention;
FIGS. 3A and 3B representatively illustrate dynamic armor systems having segmented dynamic zones before and during a projectile strike in accordance with an exemplary embodiment of the present invention;
FIG. 4 representatively illustrates a dynamic armor system having shaped segmented dynamic zones in accordance with an exemplary embodiment of the present invention;
FIG. 5A representatively illustrates a dynamic armor system having segmented dynamic zones in accordance with an exemplary embodiment of the present invention:
FIGS. 5B and 5C representatively illustrate dynamic armor systems having three (3) segmented and six (6) segments dynamic zones respectively in accordance with an exemplary embodiment of the present invention;
FIG. 6 representatively illustrates a dynamic armor system having embedded segmented dynamic zones in accordance with an exemplary embodiment of the present invention; and
FIG. 7 representatively depicts a flow diagram of a dynamic armor system in accordance with an exemplary embodiment of the present invention.
Elements in the figures, drawings, images, etc. are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of various embodiments of the present invention. Furthermore, the terms ‘first’, ‘second’, and the like, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. Moreover, the terms ‘front’, ‘back’, ‘top’, ‘bottom’, ‘over’, ‘under’, and the like in the disclosure and/or in the claims, are generally employed for descriptive purposes and not necessarily for comprehensively describing exclusive relative position. Any of the preceding terms so used may be interchanged under appropriate circumstances such that various embodiments of the invention, for example, may be capable of operation in other configurations and/or orientations than those explicitly illustrated or otherwise described.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
The following description is intended to provide convenient illustrations for implementing various embodiments of the invention. As will become apparent, changes may be made in the function and/or arrangement of any of the elements described in the disclosed exemplary embodiments without departing from the spirit and scope of the invention.
The present invention may be described herein in terms of conventional armor, strike plates, energy and/or shock absorbing materials and composite layers. It should be appreciated that the armor may comprise any number of conventional materials including, but not limited to ceramics, metals, plastics, fiberglass, glass, electrified materials, surface launchers, imbedded explosives, various other inorganic and organic materials, and/or the like. Furthermore, such armor may comprise various forms, layers, sizes, thicknesses, textures and dimensions. Additionally, the armor may be employed in civilian applications to protect vehicles and passengers in hazardous situations or in space travel, body armor, door and wall structures, maritime and aerospace applications, industrial applications, untamed areas, and/or the like. The armor may be adapted as a generic protective external surface.
The specification and Figures are to be regarded in an illustrative manner, rather than a restrictive one, and all such modifications are intended to be included within the scope of the present invention. Accordingly, the scope of the invention should be determined by the claims and their legal equivalents. For example, the steps recited in any method or process embodiments may be executed in any order and are not limited to the specific order presented in the claims. Additionally, the components and/or elements recited in any apparatus embodiment may be assembled, or otherwise operationally configured, in a variety of permutations to produce substantially the same result as the present invention and are accordingly not limited to the specific configuration recited in the claims.
Referring to FIG. 1 , a system for dynamic armor 100 generally comprises a first surface layer 110 , an absorbing filler layer 120 and a force absorbing material 140 (e.g., a kinetic layer). These layers may be integrated into unitary material or may comprise a plurality of divisional layers. Additionally, these layers may be assembled in various orders with or without duplication between layering.
First surface layer 110 may comprise the external surface of dynamic armor 100 . This surface may be the face of the absorbing filler layer 120 or it may comprise a layer of additional material. First surface layer 110 may be fabricated from any suitable material. For instance, first surface layer 110 may be constructed of composite, steel, steel-composite, ceramic-composite, inorganic composite nanostructures, and/or the like. First surface layer 110 may be suitably configured for any thickness. This material may be similar or dissimilar to other materials used in the dynamic armor 100 system. Similarly, first surface layer 110 , in accordance with a representative embodiment of the present invention, may be implemented to form various shapes or geometries, including but not limited to: squares, rectangles, triangles, cones, ovoids, prolate, and/or oblate spheroids, and/or the like. Further, first surface layer 110 may be segmented into various geometric planes and/or faces, such as, for example: quadrilateral, hexagonal, pentagonal, octagonal, and/or the like. These segments may extrude or extend from any angle with respect to first surface layer 110 , and/or be at least partially integrated into the form of first surface layer 110 . First surface layer 110 may have suitable coatings applied to it for camouflage or other practical reasons.
First surface layer 110 may reduce the velocity and force of projectiles striking the dynamic armor system 100 . It will be appreciated that first surface layer 110 and/or protection materials, as shaped, may form angular deflection implements to redirect projectile trajectories. Additionally, the armor may be shaped or otherwise formed with a curvature to reduce ballistic damage, deflect material, protect against debris, weather, and/or the like. First surface area 110 may comprise multiple materials such as tile products for mosaic armor construction, a panel system, a layering scheme, plates with compound curvature, and/or the like. First surface layer 110 may be coupled to the absorbing filler layer 120 . Additionally, first surface layer 110 may comprise a suitable shape to couple to the surface or objects it is designed to protect, for example, approximating the natural contours of the body in the case of body armor.
In a representative embodiment, referring to FIG. 4 , first surface layer 110 may increase the area that comprises a high degree obliquity, axial inclination and/or the like to decrease ballistic damage and/or deflect shots, debris and/or the like. In one representative embodiment of the present invention, first surface layer 110 may comprise a strike plate 115 for reducing the velocity of a projectile. The strike plate 115 may be formed from any suitable material and/or comprise any suitable dimension. Strike plate 115 may be fashioned in any suitable orientation and/or suitable configuration or shape. Strike plate 115 may be configured to be static or dynamic.
In an alternative embodiment, referring now to FIGS. 5A-5C , first surface layer 110 comprises at least one segment of the dynamic armor system 100 which is configured to move in response to impact with a projectile or shock wave. Such an embodiment may incorporate a strike plate 115 that may be configured to present a planar surface to an impacting projectile, or may be shaped to present an angle of obliquity for an impacting projectile.
Absorbing filler layer 120 may comprise any space between the first surface layer 110 and the force absorbing material 140 . This space may constitute an air gap or may be tilled with material. Absorbing filler layer 120 may comprise any conventional energy and/or shock absorbing materials, whether now known or hereafter described in the art. Such materials may comprise foams, springs, elastic materials, foam barriers, plastics, composite materials, plastics, protection barriers, and/or the like. Absorbing filler layer 120 may be coupled to the force absorbing material 140 .
In one representative embodiment, absorbing filler layer 120 may comprise energy and/or shock absorbing materials placed in between first surface layer 110 and force absorbing material 140 to form dynamic armor. In another representative embodiment, referring now to FIG. 2 , absorbing filler layer 120 may comprise a plurality of materials. This may include a segment of dynamic material coupled to first surface layer 110 , and coupled to an energy absorbing material configured to move when impacted by a projectile. This dynamic material may comprise deflection material 130 . The shape and orientation of this dynamic material may be such that it directs the forces and/or paths of the projectile away from the surface the armor is protecting. Force may be dissipated through at least one of the friction of the dynamic material moving upon impact, the shape and positioning of the dynamic material within the absorbing filler layer 120 , and the compression of the force absorbing material 140 by the dynamic material.
In another representative embodiment, referring to FIGS. 3A and 3B , the absorbing filler layer 120 may be dynamic, wherein the armor is at least partially configured to move and/or recoil upon impact and/or the like. In the case of a dynamic filler layer 120 , the layer may be configured such that it will be able to deform and reform upon impact. This recoiling will facilitate absorbing the force of multiple strikes within the same segment of armor. Sections of the first surface layer 110 may be configured to move against the absorbing filler layer 120 upon projectile strike.
In another embodiment of the present invention, the absorbing filler layer 120 may also comprise embedded shaped bodies 130 for redirection and fragmentation of the projectile. These obliquities may employ oblique strike angles to aid in redirection of the projectile and projectile elements.
Back strike plate 150 may comprise the forward facing plane of the force absorbing material 140 from the perspective of an impacting projectile, or it may comprise an additional layer of material. Back strike plate 150 may be configured to absorb the impact of a projectile. The back strike plate may also be configured to contain the various other layers of the dynamic armor 100 into their respective zones. Back strike plate 150 may act as a spall layer and may be fabricated from any suitable material. Back strike plate 150 may comprise the same material as the strike plate 115 or may be formed from a different suitable material. Back strike plate 150 may be any suitable dimension. Back strike plate 150 may be a dynamic force absorbing material or it may be static. Back strike plate 150 may be configured for catching and/or deflecting projectiles, debris, fragments, and/or the like. Additionally, back strike plate 150 , may comprise a suitable shape to couple to the material or objects it is designed to protect. For example, back strike plate 150 may be shaped to approximate the natural contours of the body in the case of body armor.
It should be appreciated that the energy and/or force absorbing material 140 may comprise any conventional energy and/or force absorbing materials, whether now known or hereafter described in the art. Such materials may comprise foams, foam barriers, plastics, composite materials, protection barriers, and/or the like. These materials may be implemented, according to various aspects of the present invention, to conform to any suitable size, shape weight, texture, form, thickness, density, and/or the like.
In a representative embodiment of the present invention, the energy and/or force absorbing material 140 may be at least partially configured to comprise a layer between the first surface layer 110 and the absorbing filler layer 120 . In another representative embodiment of the present invention, referring to FIG. 6 , the energy and/or force absorbing material 140 may be at least partially configured to absorb at the perimeter of strike plates 115 , ( 150 ) and/or spall layer.
Though the dynamic armor 100 may comprise the external surface of the materials it is designed to protect, the dynamic armor 100 may, in the alternative, be mounted to a second surface. It will be appreciated that representative attachment mechanisms in accordance with representative aspects of the present invention may comprise any conventional mounting devices, such as, for example: rings, frames, plates, bases, screws, nuts, bolts, nails, adhesives, welds, couplers, and/or the like. Additionally, the attachment means of the present invention may comprise any conventional materials, such as ceramics, metals, plastics, composites, fiberglass, various other inorganic and organic materials and/or the like. The parameters of the attachment mechanism, such as, for example: size, shape, form, texture, dimensions, integrity, and/or the like, may comprise any suitable parameters that may be suitably adapted to provide attachment mechanisms in accordance with representative aspects of the present invention.
It will further be appreciated that the mounting devices may be attached to, affixed to, and/or coupled to the protection and armoring materials to substantially form protection and armor devices. In a representative embodiment, the attachment means may comprise welding the dynamic armor 100 to a second surface.
Referring to FIG. 7 , the dynamic armor 100 may be mounted on or comprises the outer surface of the material to be protected. In another embodiment, the first surface layer 110 may be oriented to the exterior of the dynamic armor 100 . This generally comprises the first surface with which a projectile striking the dynamic armor 100 will come in contact. In a representative aspect, the first surface may comprise a strike plate 115 configured to reduce the projectile velocity upon impact. Next, the projectile may be further slowed and its trajectory altered by the energy absorbing filler layer 120 . The projectile may cause a section of the armor to react dynamically to the projectile's impact and cause the force absorbing material 140 to absorb force. Upon impact, the force absorbing material 140 may be configured to flex from a first position dynamically when impacted by a blast, projectile, or projectile fragment. This material may be configured to recoil substantially to a first position after a projectile impact. If the projectile has enough velocity, the projectile will ultimately strike the back strike plate 150 .
In another representative embodiment, referring to FIG. 2 , deflection materials 130 may be located such that a projectile may make contact with them should the projectiles penetrate through the first surface layer 110 . These deflection materials 130 or embedded shaped bodies may redirect the force and/or direction of the projectile away from the surface or materials the armor is protecting. This generally results in force being dissipated and directed away from the protected surface. Post projectile impact, the absorbing filler layer 120 and/or force absorbing material 140 will reform relocating the deflection materials 130 substantially back to their original locations.
In yet another embodiment, referring to FIGS. 3A and 3B , the first surface layer 110 may comprise the forward facing plane of the absorbing filler layer 120 . These segmented protective elements generally react dynamically to projectile impacts. Upon impact, the projectile is slowed by impacting the absorbing filler layer 120 , which then makes contact with deflection material 130 that deflects the projectile and segments the absorbing filler layer 120 . The force absorbing material 140 may be coupled to the absorbing filler layer 120 and compresses due to the force of the segmented absorbing filler layer 120 during impact. The slowed and/or deflected projectile will then be further directed away from the protected surface by the force absorbing material 140 . In the present embodiment, the back strike plate 150 may comprise a spall layer to contain the diverted projectile. The compressed force absorbing material 140 generally reforms and directs the deformed absorbing force layer 120 substantially back to its original pre-impact conformation.
En yet another embodiment, referring to FIG. 4 , the first surface layer 110 may be shaped such that it presents an oblique angle for impacting projectiles. First surface layer 110 may also comprises deflection material 130 . The shape generally helps to redirect and/or dissipate the force of an impacting projectile. The first surface layer 110 may be segmented and compressed upon projectile strike. The absorbing filler layer 120 generally dissipates the force of the impact. Back strike plate 150 serves to contain projectile elements if needed.
In yet a further embodiment, referring now to FIG. 5A thru 5 C, the first surface layer 110 may be compartmentalized into segmented faces. These faces may be built around the surfaces they are configured to protect, as shown, or they may be fabricated over the surface they are designed to protect. These segmented faces individually compress against the force absorbing material 140 upon projectile impact. Additionally, the absorbing filler layer 120 compresses to dissipate the force of the impact. The movement of the segment helps to dissipate and redirect the force of the impact. Post projectile impact, the segment reforms to substantially its original conformation.
In yet another representative embodiment, referring now to FIG. 6 , the dynamic armor 100 system may comprise a first surface layer 110 coupled to an absorbing filler layer 120 . Coupled to this, absorbing filler layer 120 may be a shaped deflection material 130 . These shaped deflection materials 130 generally serve to both dissipate force and redirect the trajectories of projectiles. The deflection materials 130 may be coupled to force absorbing material 140 that deform during projectile impact. This deformation redirects the force of the projectile away from the surfaces that the dynamic armor 100 is designed to protect. Post projectile impact, the deflection material 130 generally reforms to substantially its original conformation.
The dynamic armor 100 may comprise dynamic elements, functions, and/or features. Among other qualities, this generally allows the armor to move and recoil on impact. By decelerating the projectile over a longer stopping distance, the impact force may be reduced with energy absorbed and/or dissipated over a larger area.
The particular implementations shown and described are illustrative of the invention and its best mode and are not intended to otherwise limit the scope of the present invention in any way. For the sake of brevity, conventional manufacturing, connection, preparation, and other functional aspects of the system may not be described in detail. The connecting lines shown in the various figures are intended to represent exemplary functional relationships and/or physical couplings between the various elements. Many alternative or additional functional relationships or physical connections may be present in a practical system.
Benefits, other advantages and solutions to problems have been described above with regard to particular embodiments; however, any benefit, advantage, solution to problems or any element that may cause any particular benefit, advantage or solution to occur or to become more pronounced are not to be construed as critical, required or essential features or components.
As used herein, the terms “comprises”, “comprising”, or any variation thereof, are intended to reference a non-exclusive inclusion, such that a process, method, article, composition or apparatus that comprises a list of elements does not include only those elements recited, but may also include other elements not expressly listed or inherent to such process, method, article, composition or apparatus. Other combinations and/or modifications of the above-described structures, arrangements, applications, proportions, elements, materials or components used in the practice of the present invention, in addition to those not specifically recited, may be varied or otherwise particularly adapted to specific environments, manufacturing specifications, design parameters or other operating requirements without departing from the general principles of the same.
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Methods and apparatus for ballistic shielding and protective armor; and more particularly, representative and exemplary embodiments of the present invention generally relate to improved methods and systems for ballistic deflection and protection through dynamic armor and/or the like.
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This application is a divisional application claiming priority to Ser. No. 11/275,514, filed Jan. 11, 2006.
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to semiconductor transistors, and more particularly, to semiconductor transistors with expanded top portions of gates.
2. Related Art
In the fabrication process of a typical semiconductor device, if a gate is small it is very difficult to form silicide in the top portion of the gate. Therefore, there is a need for a semiconductor transistor with an expanded top portion of a gate (and a method for forming the same).
SUMMARY OF THE INVENTION
The present invention provides a semiconductor structure, comprising (a) a semiconductor region including a channel region, a first source/drain region, and a second source/drain region, wherein the channel region is disposed between the first source/drain region and the second source/drain region; (b) a gate dielectric region in direct physical contact with the channel region; and (c) a gate electrode region including a top portion and a bottom portion, wherein the bottom portion is in direct physical contact with the gate dielectric region, wherein a first width of the top portion is greater than a second width of the bottom portion, wherein the gate electrode region is electrically insulated from the channel region by the gate dielectric region, and wherein a first upper portion and a second upper portion of the first and second source/drain regions, respectively, are compressively strained.
The present invention provides a semiconductor structure, comprising (a) a semiconductor region including a channel region, a first source/drain region, and a second source/drain region, wherein the channel region is disposed between the first source/drain region and the second source/drain region; (b) a gate dielectric region in direct physical contact with the channel region; (c) a gate electrode region including a top portion and a bottom portion, wherein the bottom portion is in direct physical contact with the gate dielectric region, wherein a first width of the top portion is greater than a second width of the bottom portion, and wherein the gate electrode region is electrically insulated from the channel region by the gate dielectric region; and (d) an ion beam incident on the gate electrode region, wherein the ion beam comprises ions of a material selected from the group consisting of germanium and arsenic.
The present invention provides a semiconductor transistor with an expanded top portion of a gate or an expanded top portion of a source or drain.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-10 show a first fabrication process of a semiconductor transistor with an expanded top portion of a gate, in accordance with embodiments of the present invention.
FIGS. 11-20 show a second fabrication process of a vertical semiconductor transistor with an expanded top portion of a gate, in accordance with embodiments of the present invention.
FIGS. 21-30 show a third fabrication of another semiconductor transistor with an expanded top portion of a gate, in accordance with embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1-10 show a first fabrication process for forming a transistor structure 100 , in accordance with embodiments of the present invention, wherein FIGS. 1-10 show cross-section views of the transistor structure 100 .
More specifically, with reference to FIG. 1 , in one embodiment, the first fabrication process starts out with a silicon substrate 110 .
Next, with reference to FIG. 2 , in one embodiment, two trenches 210 and 220 are formed in the silicon substrate 110 . Illustratively, the trenches 210 and 220 are formed using a conventional lithographic and etching process.
Next, with reference to FIG. 3 , in one embodiment, two STI (Shallow Trench Isolation) regions 310 and 320 are formed in the two trenches 210 and 220 ( FIG. 2 ), respectively, using a conventional method. Illustratively, the two STI regions 310 and 320 comprise silicon dioxide.
Next, with reference to FIG. 4 , in one embodiment, a gate dielectric layer 410 is formed on a top surface 111 of the silicon substrate 110 . Illustratively, the gate dielectric layer 410 comprises silicon dioxide. In one embodiment, the gate dielectric layer 410 is formed by thermal oxidation.
Next, with reference to FIG. 5 , in one embodiment, a gate electrode region 510 is formed on the top surface 111 of the silicon substrate 110 . In one embodiment, the gate electrode region 510 is formed by (i) CVD (Chemical Vapor Deposition) of polysilicon everywhere on a top surface 412 of the structure 100 ( FIG. 4 ) to form a polysilicon layer (not shown), and then (ii) a conventional lithographic and etching process to etch the deposited polysilicon layer, resulting in the gate electrode region 510 , as shown in FIG. 5 .
Next, with reference to FIG. 6 , in one embodiment, extension regions 610 and 620 are formed in the silicon substrate 110 . Illustratively, the extension regions 610 and 620 are formed by ion implantation using the gate electrode region 510 as a blocking mask.
Next, with reference to FIG. 7 , in one embodiment, halo regions 710 and 720 are formed in the silicon substrate 110 . Illustratively, the halo regions 710 and 720 are formed by ion implantation using the gate electrode region 510 as a blocking mask.
Next, with reference to FIG. 8 , in one embodiment, dielectric spacers 810 and 820 are formed on side walls of the gate electrode region 510 . Illustratively, the dielectric spacers 810 and 820 are formed by (i) CVD of an insulating material, such as silicon dioxide or silicon nitride, or a composite, everywhere on top of the structure 100 of FIG. 7 , and then (ii) directional etching back until the top surface 111 of the silicon substrate 110 and a top surface 511 of the gate electrode region 510 are exposed to the surrounding ambient.
Next, in one embodiment, source/drain regions 840 and 850 are formed in the silicon substrate 110 . Illustratively, the source/drain regions 840 and 850 are formed by ion implantation using the gate electrode region 510 and the dielectric spacers 810 and 820 as a blocking mask.
Next, in one embodiment, germanium atoms are implanted in a top portion 512 of the gate electrode region 510 by ion implantation in a direction indicated by arrows 830 . Hereafter, the implantation of germanium atoms in the top portion 512 of the gate electrode region 510 of FIG. 8 can be referred to as a germanium implantation step 830 . Illustratively, the germanium implantation step 830 uses germanium atoms at a high dose (10 16 Ge atoms/cm 2 ) and at a low energy. The directions 830 can be vertical or tilted less than 10 degrees from vertical. As a result of the germanium implantation step 830 , the top portion 512 expands laterally, as shown in FIG. 9A .
With reference to FIG. 9A , it can be seen that as a result of the lateral expansion of the top portion 512 , a width 517 of the top portion 512 is greater than a width 516 of the bottom portion 515 . In one embodiment, the top portion 512 of the gate electrode region 510 is expanded laterally at least 20%. In other words, the width 517 is at least 120% of the width 516 .
Next, with reference to FIG. 9B , in one embodiment, a metal (e.g., nickel, etc.) layer 910 is formed on top of the structure 100 of FIG. 9A . Illustratively, the nickel layer 910 is formed by sputtering of nickel everywhere on top of the structure 100 of FIG. 9A .
Next, with reference to FIG. 10 , in one embodiment, silicide regions 512 , 1010 , and 1020 are formed on top of the gate electrode region 510 , the source/drain regions 840 and 850 , respectively. Illustratively, the silicide regions 512 , 1010 and 1020 comprise nickel silicide. In one embodiment, the silicide regions 512 , 1010 and 1020 are formed by first annealing the whole structure 100 of FIG. 9B so that nickel of the nickel layer 910 chemically reacts with silicon of the gate electrode region 510 , the source/drain regions 840 and 850 , resulting in the silicide regions 512 , 1010 and 1020 . Then, in one embodiment, unreacted nickel is removed by a wet etching step, resulting in structure 100 of FIG. 10 . In one embodiment, the entire top portion 512 ( FIG. 9B ) of the gate electrode region 510 chemically reacts with Ni of the Ni layer 910 resulting in the silicide region 512 as sown in FIG. 10 .
As can be seen in FIGS. 8 , 9 B, and 10 , because of the germanium implantation step 830 ( FIG. 8 ), an interfacing surface 514 between the nickel layer 910 and the top portion 512 of the gate electrode region 510 ( FIG. 9B ) is larger than the case in which the implantation step 830 is not performed. Therefore, it is easier for nickel (of the nickel layer 910 ) to react with silicon of the top portion 512 ( FIG. 9B ) than in the case the top portion of the gate electrode region 510 is not expanded. Also as a result of the top portion 512 being expanded laterally, the silicide region 512 ( FIG. 10 ) is more conductive than the case in which the top portion 512 of the gate electrode 510 is not expanded.
FIGS. 11-20 show a second fabrication process for forming a transistor structure 200 , in accordance with embodiments of the present invention.
More specifically, with reference to FIG. 11 , in one embodiment, the second fabrication process starts out with an SOI (Silicon on Insulator) substrate 1110 . Illustratively, the SOI substrate 1110 comprises a silicon layer 1120 , a buried oxide layer 1130 on the silicon layer 1120 , and a silicon layer 1140 on the buried oxide layer 1130 . Illustratively, the SOI substrate 1110 is formed by a conventional method. In one embodiment, the SOI substrate 1110 may comprise an Ultra-Thin SOI wherein the silicon layer 1140 is less than 15 nm in thickness.
Next, in one embodiment, a dielectric hard mask layer 1150 is formed on top of the silicon layer 1140 . Illustratively, the dielectric hard mask layer 1150 is formed by CVD of silicon nitride or silicon dioxide, or a composite of the two, everywhere on top of the silicon layer 1140 .
Next, in one embodiment, a lithographic and etching step is performed to etch the dielectric hard mask layer 1150 and then the silicon layer 1140 so as to form a dielectric cap region 1151 and a fin region 1141 , respectively, as shown in FIG. 12 .
With reference to FIG. 12 (a front view of the structure 200 ), it should be noted that the dielectric cap region 1151 and the fin region 1141 are farther away from the viewer than the silicon layer 1120 and the buried oxide layer 1130 .
Next, with reference to FIG. 13A , in one embodiment, a silicon dioxide layer 1310 is formed on side walls of the fin region 1141 of FIG. 12 . Illustratively, the silicon dioxide layer 1310 is formed by thermal oxidation. FIG. 13A shows a front view of the structure 200 after the silicon dioxide layer 1310 is formed. In alternative embodiments, 1310 may comprise a high-k gate dielectric, such as hafnium silicate, deposited, for example, by means of CVD, MOCVD, ALD.
Next, with reference to FIG. 13B , in one embodiment, a gate electrode region 1320 is formed on top of the dielectric cap region 1151 and on side walls of the silicon dioxide layer 1310 . Illustratively, the gate electrode region 1320 comprises polysilicon. In one embodiment, the gate electrode region 1320 is formed by (i) CVD of polysilicon everywhere on top of the structure 200 of FIG. 13A , and then (ii) a conventional lithographic and etching process. FIG. 13B shows a front view of the structure 200 after the gate electrode region 1320 is formed. So, it should be noted that the silicon dioxide layer 1310 and the dielectric cap region 1151 are farther away from the viewer than the gate electrode region 1320 .
Next, in one embodiment, extension regions 1410 and 1420 and halo regions 1430 and 1440 (not shown in FIG. 13B but can be seen in FIG. 14 ) are formed in the fin region 1141 of FIG. 12 by ion implantation using the gate electrode region 1320 as a blocking mask.
FIG. 14 shows a top down view of the structure 200 of FIG. 13B along a line 14 - 14 after the formation of the extension regions 1410 and 1420 and halo regions 1430 and 1440 .
Next, in one embodiment, germanium atoms are implanted on a top portion 1321 ( FIG. 13B ) of the gate electrode region 1320 by ion implantation. Illustratively, germanium atoms are implanted at a high dose (10 16 Ge atoms/cm 2 ) and at a low energy. As a result of the germanium implantation in the top portion 1321 ( FIG. 13B ) of the gate electrode 1320 , the top portion 1321 expands laterally as shown in FIG. 15 .
With reference to FIG. 15 , it can be seen that as a result of the lateral expansion of the top portion 1321 , a width 1326 of the top portion 1321 is greater than a width 1325 of a bottom portion 1322 . In one embodiment, the top portion 1321 of the gate electrode region 1320 is expanded laterally at least 20%. In other words, the width 1326 is at least 120% of the width 1325 .
Next, with reference to FIG. 16 , in one embodiment, a silicon dioxide layer 1610 is formed on top and side walls of the gate electrode region 1320 . Illustratively, the silicon dioxide layer 1610 is formed by thermal oxidation. Hereafter, expanded top portions 1620 and 1630 of the gate electrode region 1320 are referred to as overhangs 1620 and 1630 . FIG. 16 shows a front view of the structure 200 after the silicon dioxide layer 1610 is formed (except for the silicon dioxide layer 1610 and the gate electrode region 1320 whose cross section view is shown). It should be noted that, the silicon dioxide layer 1310 and the dielectric cap region 1151 are farther away from the viewer than the silicon dioxide layer 1610 and the gate electrode region 1320 .
Next, with reference to FIG. 17 , in one embodiment, dielectric spacers 1710 and 1720 are formed on side walls of the gate electrode region 1320 and under the overhangs 1620 and 1630 . Illustratively, the dielectric spacers 1710 and 1720 are formed by (i) CVD of a dielectric material, such as silicon dioxide, silicon nitride, or a composite of the two, everywhere on top of the structure 200 of FIG. 16 to form a dielectric layer (not shown), and then (ii) directionally etching back the deposited dielectric layer. More specifically, the deposited dielectric layer is over etched so that the dielectric spacers 1710 and 1720 remain on side walls of the gate electrode region 1320 but no dielectric material remains on side walls of the silicon dioxide layer 1310 . FIG. 17 shows a front view of the structure 200 after the dielectric spacers 1710 and 1720 are formed (except for the silicon dioxide layer 1610 , the gate electrode region 1320 and the dielectric spacers 1710 and 1720 whose cross section view is shown).
Next, in one embodiment, source/drain regions 1810 and 1820 (not shown in FIG. 17 but can be seen in FIG. 18 ) are formed in the fin region 1141 of FIG. 18 by ion implantation using the gate electrode region 1320 and the dielectric spacers 1710 and 1720 as a blocking mask.
FIG. 18 shows a top down view of the structure 200 of FIG. 17 along a line 18 - 18 after the formation of the source/drain regions 1810 and 1820 .
Next, with reference to FIG. 19 , in one embodiment, the dielectric cap region 1151 of FIG. 17 is removed by a Reactive Ion Etch (RIE), or a wet etching step, resulting in the structure 200 of FIG. 19 .
Next, with reference to FIG. 20 , in one embodiment, silicide regions 2010 , 2020 , and 2030 are formed on top of the gate electrode region 1320 and the source/drain regions 1810 and 1820 ( FIG. 18 ). Illustratively, the silicide regions 2010 , 2020 , and 2030 comprise silicide nickel. In one embodiment, the silicide regions 2010 , 2020 and 2030 are formed by (i) sputtering of nickel everywhere on top of the structure 200 ( FIG. 19 ) to form a nickel layer (not shown), then (ii) annealing so that nickel of the deposited nickel layer chemically reacts with silicon of the gate electrode region 1320 and the source/drain regions 1810 and 1820 ( FIG. 18 ) resulting in the silicide regions 2010 , 2020 , and 2030 . Then, unreacted nickel is removed by a wet etching step, resulting in structure 200 of FIG. 20 .
Similar to the structure 100 of FIG. 10 , the structure 200 of FIG. 20 has an advantage of the enlarged silicide region 2010 which is more conductive than in the case in which the top portion 1321 of the gate electrode 1320 is not expanded laterally by the germanium implantation. Moreover, because the top portion 1321 of the gate electrode 1320 ( FIG. 19 ) is enlarged, it is easier for nickel of the deposited nickel layer (not shown) to chemically react with silicon of the gate electrode region 1320 to form the silicide 2010 .
FIGS. 21-30 show a third fabrication process for forming a transistor structure 300 , in accordance with embodiments of the present invention, wherein FIGS. 21-30 show cross-section views of the transistor structure 300 .
More specifically, with reference to FIG. 21 , in one embodiment, the third fabrication process starts out with an SOI substrate 2110 . In one embodiment, the SOI substrate 2110 comprises a silicon layer 2120 , a buried oxide layer 2130 on the silicon layer 2120 , and a silicon layer 2140 on the buried oxide layer 2130 . Illustratively, the SOI substrate 2110 is formed by a conventional method.
Next, with reference to FIG. 22 , in one embodiment, a trench 2210 is formed in the silicon layer 2140 . In one embodiment, the trench 2210 is formed by a conventional lithographic and etching process.
Next, with reference to FIG. 23 , in one embodiment, an STI region 2310 is formed in the trench 2210 ( FIG. 22 ) using a conventional method. Illustratively, the STI region 2310 comprises silicon dioxide.
Next, with reference to FIG. 24 , in one embodiment, a gate dielectric layer 2410 is formed on top of the structure 300 ( FIG. 23 ). The gate dielectric layer 2410 may be formed (a) by oxidation and nitridation of a top portion of the silicon layer 2140 , to form a silicon oxinitride dielectric, or (b) by deposition of a high-k material such as hafnium silicate by CVD, MOCVD, or ALD.
Next, with reference to FIG. 25 , in one embodiment, a polysilicon layer 2510 is formed on top of the structure 300 ( FIG. 24 ) by CVD.
Next, in one embodiment, the polysilicon layer 2510 is selectively etched, resulting in a gate electrode region 2511 as shown in FIG. 26 .
Next, with reference to FIG. 26 , in one embodiment, extension regions 2610 and 2620 and halo regions 2630 and 2640 are formed in the silicon layer 2140 . Illustratively, the extension regions 2610 and 2620 and halo regions 2630 and 2640 are formed by ion implantation using the gate electrode region 2511 as a blocking mask. Hereafter, a silicon region of the silicon layer 2140 which is disposed between the extension regions 2610 and 2620 and the halo regions 2630 and 2640 is referred to as a channel region 2140 .
Next, with reference to FIG. 27 , in one embodiment, dielectric spacers 2710 and 2720 are formed on side walls of the gate electrode region 2511 . Illustratively, the dielectric spacers 2710 and 2720 are formed by (i) CVD of a dielectric layer, such as silicon dioxide or silicon nitride, or a composite of both, everywhere on top of the structure 300 of FIG. 26 , and then (ii) directional etching back. Any remaining gate dielectric layer 2410 in the etched-back regions is completely removed by either sufficient over etch, or by and additional etching process, resulting in a gate dielectric region 2411 .
Next, with reference to FIG. 28A , in one embodiment, silicon regions 2810 and 2820 are epitaxially grown on the extension regions 2610 and 2620 , respectively.
It should be noted that the silicon is also epitaxially grown on top of the gate electrode region 2511 . But to make the description simple, this is not shown. Alternatively, in one embodiment, before the formation of the silicon regions 2810 and 2820 by epitaxial growth, a cap region (not shown) can be formed on top of the gate electrode region 2511 . In one embodiment, the cap region (not shown) comprises a silicon dioxide layer and a silicon nitride layer (not shown). More specifically, the silicon dioxide layer and the silicon nitride layer (not shown) can be formed in that order on top of the polysilicon layer 2510 of FIG. 25 . After that, the silicon dioxide layer and the silicon nitride layer (not shown) can be patterned at the same time that the gate electrode region 2511 is formed. As a result, portions of the silicon dioxide layer and the silicon nitride layer (not shown) still remain on top of the gate electrode region 2511 . Therefore, the cap region (not shown) can prevent epitaxial growth of the silicon on top of the gate electrode region 2511 .
Next, in one embodiment, the gate electrode region 2511 and the dielectric spacers 2710 and 2720 are used as a blocking mask to ion implant the silicon regions 2810 and 2820 , the extension regions 2610 and 2620 and the halo regions 2630 and 2640 so as to form source/drain regions 2811 and 2821 (as shown in FIG. 28B ).
Next, in one embodiment, with reference to FIG. 28B , germanium atoms are implanted in a top portion 2512 of the gate electrode region 2511 by ion implantation in a direction indicated by arrows 2830 . Hereafter, the implantation of germanium atoms in the top portion 2512 of the gate electrode region 2511 can be referred to as a germanium implantation step 2830 . Illustratively, the germanium implantation step 2830 uses germanium atoms at a high dose (10 16 Ge atoms/cm 2 ) and at a low energy. As a result of the germanium implantation step 2830 , the top portion 2512 expands laterally, as shown in FIG. 29 .
With reference to FIG. 29 , it can be seen that as a result of the lateral expansion of the top portion 2512 , a width 2519 of the top portion 2512 is greater than a width 2518 of a bottom portion 2514 . In one embodiment, the top portion 2512 of the gate electrode region 2511 is expanded laterally at least 20%. In other words, the width 2519 is at least 120% of the width 2518 . In one embodiment, the germanium implantation step 2830 also implants Germanium atoms in upper portions 2811 a and 2821 a of the source/drain regions 2811 and 2821 , respectively. As a result, the upper portions 2811 a and 2821 a are expanded laterally and compressively strained. Therefore, the channel region 2140 is tensile strained.
Next, with reference to FIG. 30 , in one embodiment, silicide regions 2513 , 2812 and 2822 are formed on top of the gate electrode region 2511 , the source/drain regions 2811 and 2821 , respectively. Illustratively, the silicide regions 2513 , 2812 , and 2822 comprise silicide nickel. In one embodiment, the silicide regions 2513 , 2811 and 2821 are formed by (i) CVD of nickel everywhere on top of the structure 300 ( FIG. 29 ) to form a nickel layer (not shown), then (ii) annealing so that the deposited nickel layer chemically reacts with silicon on top portions of the gate electrode region 2511 , the source/drain regions 2811 and 2821 so as to form the silicide regions 2513 , 2812 and 2822 . Then, unreacted nickel is removed by a wet etching step, resulting in structure 300 of FIG. 30 .
In the embodiments described above, germanium ions/atoms are implanted in the gates so as to expand the top portions of the gates. Alternatively, arsenic can be used instead of germanium. Also, in one embodiment, the germanium and arsenic ion implantations can be carried out at room temperature with the ions being at an energy of 25 KeV such that the ions can reach as deep as 23 nm in the gates.
In one embodiment, as a result of the Ge implantation in the top portion 512 ( FIG. 9A ), the top portion 1321 ( FIG. 13B ), the top portion 2512 ( FIG. 29 ), and in the top portions 2811 a and 2821 a ( FIG. 29 ), each of these portions 512 , 1321 , 2512 , 2811 a , and 2821 a is at least 0.5% compressively strained, meaning the average atom spacing of the resulting Si—Ge lattice is 0.5% less than the average atom spacing of a Si—Ge mixture of the same composition ratio in a relaxed/unstrained condition.
While particular embodiments of the present invention have been described herein for purposes of illustration, many modifications and changes will become apparent to those skilled in the art. Accordingly, the appended claims are intended to encompass all such modifications and changes as fall within the true spirit and scope of this invention.
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A semiconductor transistor with an expanded top portion of a gate and a method for forming the same. The semiconductor transistor with an expanded top portion of a gate includes (a) a semiconductor region which includes a channel region and first and second source/drain regions; the channel region is disposed between the first and second source/drain regions, (b) a gate dielectric region in direct physical contact with the channel region, and (c) a gate electrode region which includes a top portion and a bottom portion. The bottom portion is in direct physical contact with the gate dielectric region. A first width of the top portion is greater than a second width of the bottom portion. The gate electrode region is electrically insulated from the channel region by the gate dielectric region.
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[0001] This applications claims benefit of U.S. Provisional Application Ser. No. 60/098,111, filed Aug. 27, 1998.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to methods for terminating both of the constituent encoders of a turbo code and developing puncturing patterns applicable at a trellis termination stage that ensures the same number of transmitted bits for each trellis stage during the information bit transmission and trellis termination stages.
[0003] The process of forward and reverse link turbo encoding and decoding, specifically for Code Division Multiple Access (CDMA) communications channels, is thoroughly described in copending U.S. patent application Ser. No. 09/248,338 (Attorney Docket No. PD-980024) of Eroz, et al., for SETS OF RATE-COMPATIBLE UNIVERSAL TURBO CODES NEARLY OPTIMIZED OVER VARIOUS RATES AND INTERLEAVER DELAYS, filed Feb. 11, 1999, and copending U.S. patent application Ser. No. 09/235,582, (Attorney Docket No. PD-980163) of Eroz, et al., for FORWARD ERROR CORRECTION SCHEME FOR DATA CHANNELS USING UNIVERSAL TURBO CODE, filed Jan. 22, 1999, both of which are incorporated herein by reference.
[0004] In a convolutional encoding scheme, tail bits are inserted after information bits, to zero out all shift registers of an encoder. For feed forward encoders, tail bits are equal to zero. For feedback encoders the value of tail bits depend on the contents of the shift register current values.
[0005] A turbo encoder consists of a parallel concatenation of two (2) or more recursive (feedback) convolutional encoders. Because each constituent encoder processes the information bits in a different order due to a turbo interleaver, it is not possible to terminate all constituent encoders by the same tail bits.
[0006] A trellis termination method general enough to be used for a set of turbo codes with different code rates as in the third generation CDMA systems is desirable. Included in the desirable general method is a method of puncturing tail bit sequences.
SUMMARY OF THE INVENTION
[0007] The present invention advantageously addresses the needs above as well as other needs by providing a method and apparatus for a general Turbo Code trellis termination which may be employed when a turbo encoder operates within a wide range of turbo code rates when transmitting information bits.
[0008] In its most general form, the invention can be characterized as a method of terminating two or more constituent encoders of a turbo encoder. The method comprises the steps of: generating tail input bits at each of two or more constituent encoders, including the step of deriving the tail input bits from each of the two or more constituent encoders separately from the contents of shift registers within each of the two or more constituent encoders, after an encoding of information bits by the two or more constituent encoders; and puncturing one or more tail output bits such that 1/R tail output bits are transmitted for each of a plurality of trellis stages, wherein R is a turbo code rate employed by the turbo encoder during the information bit transmission.
[0009] In yet another variation, the step of puncturing the one or more tail output bits further comprises the step of: transmitting, during trellis termination, the tail output bits only if they are sent from an output branch of one of the two or more constituent encoders that is used during information bit transmission.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The above and other aspects, features and advantages of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein:
[0011] FIG. 1 is a block diagram of a turbo encoder with interleaved bits entering a second encoder, for use in accordance with one embodiment of the present invention.
[0012] Corresponding reference characters indicate corresponding components throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0013] The following description of the presently contemplated best mode of practicing the invention 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.
[0014] Referring to FIG. 1 , an exemplary turbo code encoder is shown wherein one embodiment of a Turbo Code trellis termination design terminates one encoder 10 (a first encoder) while disabling another encoder 10 ′ (a second encoder) and at a different time terminates the other encoder 10 ′ (second encoder) while disabling the encoder 10 (first encoder).
[0015] The encoders (first and second encoders) 10 , 10 ′ of the turbo code encoder of FIG. 1 are constituent encoders configured in a parallel concatenation. It is well known in the art that a constituent encoder employ a configuration of modular adders 17 , 20 , 26 , 28 , 30 , 24 , and 25 , and shift registers 18 , 21 , 22 , coupled through nodes (such as node 32 ) to produce output bits, including tail output bits, X(t), Y o (t), Y 1 (t), for example, depending upon the encoding scheme. FIG. 1 is just one example of such a parallel concatenation of constituent encoders, wherein an interleaver device (Interleaver) 16 is employed between an input for X(t) and the second encoder 10 ′, and wherein additionally, a puncturer 36 is employed, switchably coupled to respective encoder outputs for each of the encoders (first and second encoders) 10 , 10 ′. As described herein, tail input bits will mean the bits X, and X′ in FIG. 1 , and tail output bits will mean the bits X, X′, Y o , Y o ′, Y 1 or Y 1 ′. In other turbo encoders, there may be more than two constituent encoders. Each of the constituent encoders may utilize a fewer or greater number of shift registers than in FIG. 1 .
[0016] In FIG. 1 , after message bits X(t) are encoded, a switch 12 is moved to a feedback position to allow the generation of three (3) consecutive tail input bits, in this example, generated from the contents of each of three shift registers 18 , 21 , and 22 (also referred to herein as a first shift register 18 , a second shift register 21 , and a third shift register 22 ). In general, a number of tail input bits X(t), X′(t) for terminating a constituent encoder is equal to a number of shift registers in that encoder.
[0017] At the end of each clock cycle, new tail input bits X(t), X′(t) are generated for zeroing out each respective shift register of the three shift registers, 18 , 21 and 22 .
[0018] In one embodiment of the invention the encoders 10 , 10 ′ are terminated simultaneously within three clock cycles, each with its own tail input bit X(t), X′(t). Alternatively, the first encoder 10 is first terminated while the second encoder 10 ′ is disabled, followed by the second encoder 10 ′ being terminated while the first encoder 10 is disabled.
[0019] In the variation with the encoders 10 , 10 ′ terminated at different times the encoders 10 , 10 ′ can be terminated in consecutive clock cycles, wherein six (6) consecutive clock cycle tail input bits X(t), X′(t), consecutively terminate both the encoders 10 , 10 ′.
[0020] As can be seen from FIG. 1 , a second tail input bit sequence 34 ′ for terminating the second encoder 10 ′ is fed back into the second encoder 10 ′ through a switch 12 ′ and circuit 14 ′. Tail input bits X(t), X′(t) are not interleaved by the turbo interleaver 16 . Similarly, a tail input bit sequence 34 for terminating the first encoder 10 is fed back into the first encoder 10 through another switch 12 and another circuit 14 .
[0021] The zeroing of the shift registers 18 , 21 , 22 , prior to implementing a puncturing scheme per an embodiment of the invention, is triggered by a beginning and an ending tail input bit sequence X(t), X′(t), each sequence having a number n of tail input bits X(t), X′(t) equal to the number n of shift registers 18 , 21 , 22 or 18 ′, 21 , 22 coupled to each one of the encoders 10 , 10 ′.
[0022] As with information and coded bits, tail output bits X, Y o , Y 1 , X′, Y o , Y 1 ′ are also punctured by the puncturer 36 .
[0023] Table 1 indicates associated tail output bit puncturing patterns having indicator sequences (e.g., “111 000”) identifying which bits to puncture and which bits to transmit. The indicator sequence, comprising “1”'s or “0”'s is selected in accordance with an encoder rate. In this notation, “1” indicates the tail output bit should be transmitted and “0” indicates that the tail output should be punctured. Certain entries in Table 1 are labeled “repeat”, which means that transmitted bits are transmitted twice.
[0024] The tail input bit sequences 34 , 34 ′, which comprise tail input bits X, and X′, are generated after the encoders 10 , 10 ′ encode the information bits with the switches 12 , 12 ′ ( FIG. 1 ), while the switches 12 , 12 ′ are in an up position. The first n/R tail output bits X 1 , Y o , Y 1 , wherein n is the number of shift registers 18 , 21 , 22 or 18 ′, 21 ′, 22 ′ per constituent encoder (n=3 in FIG. 1 ), and wherein R is a turbo code rate being employed, are generated by clocking the first encoder 10 n times with its switch 12 in the down position while the second encoder 10 ′ is not clocked, and puncturing or repeating the resulting tail output bits X 1 , Y o , Y 1 , X′, Y o ′, Y 1 ′ according to Table 1 below. The last n/R tail output bits X′,Y o ′,Y 1 ′ are generated by clocking the second encoder 10 ′ n timer with its switch 12 ′ in the down position while the first encoder 10 is not clocked, and puncturing or repeating the resulting tail output bits according to Table 1. These final output bits are denoted by X′, Y o ′ or Y 1 ′.
[0025] For rate ½ turbo codes, the tail output bits for each of a first n tail input bit (also referred to herein as “the beginning tail bit sequence X(t)”) are XY 0 , and the tail output bits for each of a last n tail bit periods (also referred to herein as “the ending tail bit sequence X′(t)”) are X′Y 0 ′. For rate ⅓ turbo codes, the tail output bits for each of the first n tail input bits are XXY 0 , and the tail output bits for each of the last n tail bits are X′X′Y 0 ′. For a rate ¼ turbo code, the tail output bits for each of the first n tail input bits are XXY 0 Y 1 and the tail output bits for each of the last n tail input bits periods are X′X′Y 0 ′Y 1 ′.
[0026] Tail inputs bits are not interleaved by the interleaver 16 . They are added after the encoding of the information bits.
TABLE 1 Puncturing Patterns for Tail Output Bits Rate 1/2 1/3 1/4 X(t) 111 000 111 000 111 000 Repeat Repeat Y 0 (t) 111 000 111 000 111 000 Y 1 (t) 000 000 000 000 111 000 X′(t) 000 111 000 111 000 111 Repeat Repeat Y 0 ′(t) 000 111 000 111 000 111 Y 1 ′(t) 000 000 000 000 000 111
[0027] When employing Table 1 to design puncturing patterns for tail output bits, the row designation “Repeat” means that for a rate ⅓ or a rate ¼ turbo code, when transmitted, the bits X and X′ are transmitted twice.
[0028] For a rate ½ turbo code, the puncturing table is read first from top to bottom, and then from left to right. For a rate ⅓ turbo code and a rate ¼ turbo code, the puncturing table is read first from top to bottom, repeating X(t) and X′(t), and then from left to right.
[0029] The puncturing patterns in Table 1 are chosen so that:
[0030] (1) A number of transmitted tail output bits during trellis termination is 1/R for each trellis branch wherein R is the turbo code rate employed during information bit transmission. Advantageously, this condition ensures that the same turbo code rate is used for trellis termination as for information bit transmission.
[0031] (2) Only output branches of the encoders 10 , 10 ′ used during information bit transmission are used for trellis termination. For example, for rate ½ and rate ⅓ turbo coders, only X(t), X′(t), Y 0 (t) and Y′ 0 (t) are transmitted during information bit transmission; Y 1 (t) and Y′ 1 (t) are always punctured. Therefore, only X(t), X′(t), Y 0 (t) and Y′ 0 (t) are transmitted during the trellis termination stage, as well. Advantageously, therefore, if a manufacturer only wanted to implement a rate ½ and encoder, such a manufacturer would only have to implement transmissions of bits from branches X, Y 0 or X′, Y 0 ′.
[0032] (3) In order to meet conditions (1) and (2), it may require repetition of some tail output bits during trellis termination. That is, to both keep the turbo code rate the same, and to only use output branches used in information bit transmission, it may be necessary to repeat one or more of the tail bits for each encoder 10 , 10 ′ in order to keep the turbo code rate the same.
[0033] In the preferred embodiment illustrated by Table 1, X(t) and X′(t) are selected to be repeated in both the turbo code rate ⅓ and rate ¼ cases. Table 1 may also be employed irrespective of whether the encoders 10 , 10 ′ are terminated concurrently or non-concurrently.
[0034] Alternative embodiments are envisioned, in keeping within the spirit of the invention wherein another tail output bit is selected to be repeated, such as, for example that corresponding to Y 0 (t) and Y 0 ′(t).
[0035] Alternatively, where a code rate lower than ¼ is employed it may be necessary to repeat more than one tail output bit per encoder 10 , 10 ′, in which case an additional tail bit besides X(t) may be repeated, such as repeating X(t) and Y 0 (t) or repeating X(t) twice or any combination whatsoever.
[0036] While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims.
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A method of terminating two or more constituent encoders of a turbo encoder employing a turbo code, comprising the step of: generating tail input bits at each of two or more constituent encoders, including deriving the tail input bits from each of the two or more constituent encoders separately from a contents of shift registers within each of the two or more constituent encoders, after an encoding of information bits by the two or more constituent encoders; puncturing one or more tail output bits such that 1/R output tail bits are transmitted for each of a plurality of trellis branches, wherein R is a turbo code rate employed by the turbo encoder during an information bit transmission. In yet another variation, the step of puncturing the tail output bits further comprises the step of: transmitting, during trellis termination, the tail output bits, only if they are sent from an output branch of one of the two or more constituent encoders that are used during information bit transmission.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to offshore structures, and more particularly, to a brace assembly for a truss leg.
[0002] Leg-supported offshore structures are extensively used for mineral exploration and production. Convention truss legs comprise a system of horizontal and diagonal braces. The legs are raised or lowered by an elevating system, for instance a self-elevating jacking system that contains racks and pinions. In a typical system using triangular truss legs, there are a total of nine jacking assemblies, three assemblies per leg, One jacking assembly is mounted at each chord of the leg. Each jacking assembly unit has four to six pinions, which are house and supported on bearings.
[0003] A series of guide plates is installed above and below the jacking mechanism. The guide system consists of upper guide plates, middle guide plates and lower wear plates. Gaps between guide plates and rack are pre-determined to ensure smooth transition in raising and lowering the legs. Initially, when the pinions support the entire weight of the hull unit, the differential loads on the pinions cause a vertical moment couple during the jacking up process. Under environmental loads, the unit tilts and the rack teeth react against the guide plates. The guide plates act as horizontal restraint for the drilling unit as it deflects under harsh environmental conditions. This generates a reaction on the guide plates along the chord and indirectly on the horizontal and diagonal braces. The differential loads in the guide plates cause a horizontal moment couple to be developed.
[0004] As the jacking up process continues, the loads are increasingly transferred from a vertical to a horizontal moment couple. The development of the horizontal couple cause the leg between the upper and lower guide plates to sustain a large bending moment. Thus the braces between the upper and lower guide plates develop compressive and tensile forces. As the truss legs are composed of horizontal and diagonal braces, the braces tend to fail under compressive loads, which is built up due to the horizontal moment couple. High compressive loads are undesirable as they result in buckling of the braces under severe environmental conditions. For example, when a rig suffers a severe punch through situation or when the spud can at the base of the unit slides into old footings. This guide assembly is not efficient, as the generated high compressive loads located mainly between the upper and lower edge plates. This constitutes a local failure within the system. A premature local buckling of the brace assembly eventually occurs.
[0005] The capacity of the drilling unit to maintain stability and strength during working conditions is determined by the extent the braces are subjected to the loads through the guide plates. Due to the constraints in terms of weight and drag, it is not feasible to design the braces with heavy tubular sections. In conventional designs, the braces are strengthened by using a larger diameter tubular or a thick-wall tubular. With such designs, it is difficult and often costly to improve the strength of the braces due to the high cost involved in replacing all brace segments. To replace the brace members, the rig would have to be towed to a shipyard, where the bent section of the leg has to be removed and replaced. The expense associated with work stoppage as well as replacement of the damaged section and retrofitting the leg, plus the required manpower is often very high.
[0006] Since the braces are the weak link in the overall leg structure, the present invention contemplates elimination of drawbacks associated with prior designs and provision of a method of improving the capacity of the braces to handle high buckling loads.
SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to provide an improved design of a brace assembly for a support leg of an offshore structure.
[0008] It is another object of the present invention to provide a method of retrofitting existing brace assemblies in situ.
[0009] These and other objects of the invention are achieved through a provision of a reinforcing sleeve means for positioning over a pre-determined portion of a brace member and for increasing structural resistance of the brace member to horizontal moments. The reinforcing sleeve means is mounted and secured in a surrounding relationship about the exterior of the brace member. The thickness of the reinforcing sleeve means depends on the particular requirements of the load bearing capacity that must be achieved at the particular location of the overall structure.
[0010] The reinforcing sleeve may be made of a plurality of materials, preferably non-corrosive materials. One of the suitable materials is steel, another may be a composite fiber material. In the case of the composite fiber materials, the reinforcing sleeve is adhesively secured in multiple layers over the portion of the brace member where reinforcement is particularly desirable. The reinforcing sleeve may be installed on shore, during construction of the rig, or in situ by a simple retrofit process of existing brace assemblies.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] With reference to the drawings, FIG. 1 is an outboard profile of a jack-up unit of the present invention with truss legs.
[0012] FIG. 2 is a plan view showing position of the legs in relation to the platform layout and schematically illustrating jacking assemblies.
[0013] FIG. 3 is a detail view of segment of a brace assembly of the support leg structure in accordance with the present invention.
[0014] FIG. 4 is a cross-sectional view of a portion of a brace member with a reinforcing sleeve welded to the exterior of a brace member.
[0015] FIG. 5 is a detail view illustrating positioning of the reinforcing sleeve on a tubular of a brace member.
[0016] FIG. 6 is a cross-sectional view of a portion of a brace member wherein the reinforcing sleeve is formed from a composite material.
[0017] FIG. 7 is a detail view illustrating position of the reinforcing sleeve made of a composite material on a tubular of a brace member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] Reference will now be made to the following detailed description, taken in conjunction with the accompanying drawings, wherein like parts are designated by like numerals.
[0019] FIG. 1 shows a self-elevating jack-up unit. The jack-up unit is a mobile offshore structure that is used for mineral exploration and production. A typical jack-up unit is provided with a plurality of truss legs 12 , which extend through openings in a floatable hull 14 of the jack-up unit. Although any number of legs may be used to support the hull 14 , for illustration purposes, the jack-up rig shown in FIG. 1 has three such legs 12 . The legs 12 are formed by a system of horizontal and diagonal braces.
[0020] As the legs 12 are “jacked,” the hull 14 is elevated above an anticipated wave action to support the offshore exploration and/or production operations. Conventional offshore structures, such as the jack-up unit, are equipped with a derrick 16 mounted on the hull 14 . The derrick 16 may be also mounted on a cantilever structure 18 , which extends outwardly from the hull 14 , as shown in FIG. 1 .
[0021] The derrick 16 may be positioned for a limited lateral movement to accommodate well drilling in a plurality of locations without changing the position of the legs 12 . The jack-up unit may be also provided with auxiliary equipment, such as cranes 20 , pipe racks, heliport, crew living quarters, etc.
[0022] Each leg 12 is provided with the jacking assemblies 30 for moving the leg vertically with respect to the hull 14 . The jack assemblies 30 are retained against vertical displacement by the hull 14 . The legs 12 move from a raised position, when the jack-up unit is in transit and the legs 12 are supported by the hull 14 , to a lowered position, when the legs 12 support the hull 14 . The lowered position is illustrated in FIG. 1 . Each leg 12 may be provided with a spud can 34 for bearing against an ocean floor and for supporting the jack-up unit.
[0023] Turning now to FIG. 3 , a portion of a leg truss structure is shown in more detail. A segment of the brace assembly is defined by an upper horizontal brace member 22 , a lower horizontal member 24 , a first vertical chord member 26 and a second vertical chord member 28 . Extending between the horizontal and vertical brace and chord members is a plurality of angular, or diagonal brace members 36 , 38 , 40 and 42 . The first and the second diagonals 36 and 38 extend from the vertical chords 26 and 28 upwardly to the center of the upper horizontal brace member 22 . The second and the fourth diagonals 40 and 42 extend from the vertical chord members 26 and 28 downwardly to meet at the center of the lower horizontal brace member 24 .
[0024] Middle portions of the horizontal and diagonal braces were shown to be prone to bending or buckling. To reinforce the critical areas of the brace members, the present invention provides for the use of reinforcing sleeves that are mounted in an enveloping relationship on the middle portions of the horizontal and diagonal braces. A reinforcing sleeve 52 is mounted about the central portion of the upper horizontal brace member 22 spanning between one clear span, node to node.
[0025] A reinforcing sleeve 54 is mounted about the middle portion of the first diagonal brace member 36 ; a reinforcing sleeve 56 is mounted about the middle portion of the second diagonal brace member 38 ; a reinforcing sleeve 58 is mounted about the middle portion of the third diagonal brace member 40 a reinforcing sleeve 60 is mounted about the middle portion of the fourth diagonal brace member 42 .
[0026] A reinforcing sleeve 62 is mounted about the central portion of the lower horizontal brace member 24 , similarly to the sleeve 52 spanning between one clear span, node to node.
[0027] The reinforcing sleeves 52 , 54 , 56 , 58 , 60 , and 62 may be made from a variety of non-corrosive, structurally strong materials. For instance, rolled steel or composite fiber material may be employed for forming the reinforcing sleeves. FIGS. 4 and 5 illustrate position of a rolled steel sleeve 54 on the first diagonal brace member 36 . As can be seen in the drawings, the sleeve 54 covers a portion of the elongated brace member 36 . The sleeve 54 is made of two semicircular sections 55 , 57 joined together and welded at weld points 66 , 68 . The interior diameter of the sleeve 54 is equal to or slightly greater than the exterior diameter of the brace member 36 . The thickness and length of the sleeve 54 will vary depending on the particular buckling capacity of the respective portion of the truss structure. The physical dimensions of the reinforcing sleeve will also depend on the length over the diameter ratio of the brace member. The same design may be used for the horizontal and diagonal braces.
[0028] Alternatively, the reinforcing sleeve may be made of a composite fiber material. FIGS. 6 and 7 illustrate position of such a sleeve 56 on the brace member 38 . To position the composite material on a section of the brace member 38 , the exterior surface of the brace member is properly prepared as for application of an adhesive. Then the designated length of the brace member 38 is coated with a bonding agent. The material of the sleeve, such as finely woven fabric, is wrapped around the designated area in multiple layers. For most applications, it is believed that 5-10 layers of the material should be sufficient, depending on the strength required.
[0029] The composite material consists of fibers that are laid at different orientation at different layers to obtain the maximum effect of the fiber strength in the bending direction. The bonding material may be a resin that cures in a relatively short period of time. The shrinkage of the resin, when cured ensures that the reinforcing sleeve becomes bonded into the steel surface. The composite material is much lighter than steel and has the added advantage of low drag and thickness. The stiffness at the middle section of the brace members depends on the number of layers applied and can be configured to achieve the required stiffness. Of course, other materials may be successfully used for forming the reinforcing sleeves. Steel and composite fiber are merely examples of suitable compositions that can be used for the purpose of providing enhanced structural strength to the portions of the brace members subject to the most stresses.
[0030] The introduction of the reinforcing sleeves significantly improves the overall efficiency of the rig by strengthening the bracing members of the leg assemblies. The increase in the resistance to buckling reduces the tendency of the brace to fail at the most stressful initial condition. The reinforcing sleeves may be positioned on the brace members during construction of the rig at the shipyard or applied to the existing structure by retrofitting the trusses in situ. The amount of steel used, when steel reinforcing sleeves are contemplated, is much lower than would be required for a full replacement of the bracing members. Additional advantage of retrofitting the existing leg structure in situ is that the normal drilling operations can continue while retrofitting takes place.
[0031] Furthermore, the rig structure configuration remains much the same. Only minor changes are made in the design at relatively low cost of the material and the installation. The increased efficiency and load sharing capacity between the brace members outweigh the added cost of the reinforcing sleeves. The current capacity of the leg can be made more robust by an effective use of the reinforcing sleeves installed at strategic locations to allow the leg to take on a higher buckling load.
[0032] It is envisioned that the reinforcing sleeve and method of its installation may be used for reinforcing other brace members and structural elements subject to horizontal moment tending to bend the brace member. This design may find its application in construction, mechanical engineering and other industries where enhanced structural stability of a component is required.
[0033] Many changes and modifications may be made in the design of the present invention without departing from the spirit thereof. We, therefore, pray that our rights to the present invention be limited only by the scope of the appended claims.
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A brace assembly for truss legs of offshore structures is provided with a reinforcing sleeve mounted on the brace member in the portion of the brace member most prone to buckling under the force of horizontal moment acting on the brace member. The reinforcing sleeve surrounds the critical area of the brace member and provides additional load bearing capacity to the brace member. The reinforcing sleeve is made from a non-corrosive material having physical characteristics suitable to withstand the environmental forces in the location. The reinforcing sleeve may be installed at the shipyard when the offshore structure is manufactured or mounted on the existing rig by an easy retrofit not requiring towing of the offshore structure to the shipyard.
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BACKGROUND OF THE INVENTION
1. Field of the Disclosure
The present invention relates in general to disk drives and, in particular, to a system, method and apparatus for synchronizing writing on bit patterned media.
2. Description of the Related Art
In some disk drives with bit patterned media, there is an offset of a few micrometers between the read head and the write head. The read head provides a timing reference using the patterns on the servoing track. Due to the nature of the pattern generation process between the inner and outer diameters of the disk, the regularity of the patterns is not consistent over the range of the read-write offset. This creates a problem for synchronizing the write signal with the patterns on the write track.
Conventional solutions to this problem include measuring the phase difference between the write and read tracks on the master disk, and storing this information in a look-up table in memory. A similar process determines the optimal write phase with a different method and stores it in memory. Still another solution measures the write phases for track groups and stores the information as a look-up table. The look-up table may be stored in a single, dedicated section of the media. However, in use, the look-up table must first be read into memory. Thus, continued improvements in synchronizing writing on bit patterned media are desirable.
SUMMARY
Embodiments of a method for synchronizing writing on bit patterned media are disclosed. For example, a method for synchronizing writing in a disk drive may comprise providing the disk drive with a disk having bit patterned media, and a slider with a read head and a write head for reading data from and writing data to the disk, respectively. The method may further comprise positioning the read head at a read-write offset with respect to the write head; writing data with the write head onto a data pattern on a write track of the bit patterned media; providing a timing offset between the data pattern on the write track and a data pattern on a servoing track of the bit patterned media with the read head using the data pattern on the servoing track; storing the timing offset in a plurality of sync fields in a plurality of servo sectors on the servoing track; reading back the timing offset stored in the sync fields with the read head; and synchronizing a write signal of the data pattern on the write track with the timing offset read back from the sync fields.
The foregoing and other objects and advantages of these embodiments will be apparent to those of ordinary skill in the art in view of the following detailed description, taken in conjunction with the appended claims and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the features and advantages of the embodiments are attained and can be understood in more detail, a more particular description may be had by reference to the embodiments thereof that are illustrated in the appended drawings. However, the drawings illustrate only some embodiments and therefore are not to be considered limiting in scope as there may be other equally effective embodiments.
FIG. 1 is schematic plan view of an embodiment of a disk drive;
FIG. 2 is an enlarged schematic view of an embodiment of a portion of a disk and slider in a disk drive during operation; and
FIG. 3 is an enlarged schematic view of an embodiment of another portion of a disk in a disk drive.
The use of the same reference symbols in different drawings indicates similar or identical items.
DETAILED DESCRIPTION
Embodiments of a system, method and apparatus for synchronizing writing on bit patterned media are disclosed. FIG. 1 depicts a hard disk drive assembly 100 comprising a housing or enclosure 101 with one or more media disks 111 rotatably mounted thereto. The disk 111 comprises magnetic recording media rotated at high speeds by a spindle motor (not shown) during operation. Concentric magnetic data tracks 113 are formed on either or both of the disk surfaces to receive and store information.
Embodiments of a read/write slider 110 may be moved across the disk surface by an actuator assembly 106 , allowing the slider 110 to read and/or write magnetic data to a particular track 113 . The actuator assembly 106 may pivot on a pivot 114 . The actuator assembly 106 may form part of a closed loop feedback system, known as servo control, which dynamically positions the read/write slider 110 to compensate for thermal expansion of the magnetic recording media 111 as well as vibrations and other disturbances or irregularities. Also involved in the servo control system is a complex computational algorithm executed by a microprocessor, digital signal processor, or analog signal processor 116 that receives data address information from a computer, converts it to a location on the disk 111 , and moves the read/write slider 110 accordingly.
In some embodiments of hard disk drive systems, read/write heads 110 periodically reference servo patterns recorded on the disk to ensure accurate slider 110 positioning. Servo patterns may be used to ensure a read/write slider 110 follows a particular track 113 accurately, and to control and monitor transition of the slider 110 from one track to another. Upon referencing a servo pattern, the read/write slider 110 obtains head position information that enables the control circuitry 116 to subsequently realign the slider 110 to correct any detected error.
Servo patterns or servo sectors may be contained in engineered servo sections 112 that are embedded within a plurality of data tracks 113 to allow frequent sampling of the servo patterns for improved disk drive performance, in some embodiments. In a typical magnetic recording media 111 , embedded servo sections 112 may extend substantially radially from the center of the magnetic recording media 111 , like spokes from the center of a wheel. Unlike spokes however, servo sections 112 form a subtle, arc-shaped path calibrated to substantially match the range of motion of the read/write slider 110 .
In some embodiments, a method for synchronizing writing in a disk drive comprises providing the disk drive with a disk having bit patterned media, and the slider 110 with a read head 131 ( FIG. 2 ) and a write head 133 for reading data from and writing data to the disk, respectively. The method further comprises positioning the read head 131 at a read-write offset 134 with respect to the write head 133 ; writing data with the write head 133 onto a data pattern on a write track 135 of the bit patterned media (the read-write offset 134 may be on the order of, e.g., a few micrometers).
The method further comprises providing a timing offset 139 between the data pattern on the write track 135 and a data pattern on a servoing track 137 of the bit patterned media with the read head 131 using the data pattern on the servoing track 137 . The timing offset may comprise differences in frequency and phase. The method may further comprise storing the timing offset 139 in a plurality of sync fields 141 ( FIG. 3 ) in a plurality of servo sectors 143 on the servoing track; reading back the timing offset 139 stored in the sync fields 141 with the read head 131 ; and synchronizing a write signal of the data pattern on the write track 135 with the timing offset 139 read back from the sync fields 141 . These steps may be performed directly from the sync fields without memory storage.
The method may further comprise adjusting a frequency and phase of a clock of the disk drive with the timing offset stored in the sync fields. In still other embodiments, the method further comprise initially adjusting a clock of the disk drive to synchronize the write signal to a timing of the data pattern on the servoing track, since the slider is skewed relative to the bit patterned media.
As shown in FIG. 3 , the sync fields 141 may be radially positioned with about half-track offsets in circumferentially alternating servo sectors (e.g., in even numbered and odd numbered sectors) to accommodate varying read-write offsets. This allows the timing offset stored in the sync fields to still be read back by the reader that is not positioned at the center of the servoing track, while the writer is positioned at the center of the write track. The read-write offsets vary with the skewed head due to geometric parameters and radial location of the head relative to the disk.
Normally the reader can read back the data stored on the track when the reader is positioned within +/−50% track pitch of the track center. However, for the writer, it needs to be positioned within roughly +/−10-15% track pitch of the track center. The effective read-write offset is usually not an integer-multiple of the track pitch. In addition, the effective read-write offset changes with the skew angle. Thus, when the writer is centered on the write track, the reader is probably not centered on the servoing track. By having the sync fields that are radially positioned by ½ track offset, there will always be a sync fields within ½ track from the reader to successfully read back the data stored in it.
In still other embodiments, the method comprises measuring an optimal timing offset by writing at different timing offsets, each incremented by a step between the servo sectors. The optimal timing offset may be determined by reading back the written data and measuring bit error rates in the written data, such that the timing offset corresponding to the smallest bit error rate is the optimal timing offset. Each servo sector may contain one sync field, and then store the optimal timing offset between the servoing track and the write track of the sync field as described herein. The optimal timing offset may be written in the plurality of sync fields on the plurality of servo sectors in a plurality of servoing tracks.
Embodiments of a disk drive may comprise a disk having bit patterned media, and a slider with a read head and a write head for reading data from and writing data to the disk, respectively; the read head is spaced part from the write head at a read-write offset; a data pattern on a write track of the bit patterned media; a data pattern on a servoing track of the bit patterned media; a timing offset between the data pattern on the write track and the data pattern on the servoing track; a plurality of sync fields in a plurality of servo sectors on the servoing track for storing the timing offset; and a write signal of the data pattern on the write track is synchronized with the timing of the data pattern on the servoing track, adjusted by the timing offset read back from the sync fields.
Advantages include storing phase differences in a field inside the servo sector on the read track. Each servo sector can potentially have a different optimal write phase correction. Thus, no look-up tables are used as the optimal write phase for each servo sector is stored in a field inside that servo sector. In addition, the reference timing may be generated by data islands on the read track. Furthermore, the sync fields may be radially offset by half of a track in alternating servo sectors to accommodate variation in read-write offset and changing skew angle of the slider relative to the tracks.
This written description uses examples to disclose the embodiments, including the best mode, and also to enable those of ordinary skill in the art to make and use the invention. The patentable scope is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
Note that not all of the activities described above in the general description or the examples are required, that a portion of a specific activity may not be required, and that one or more further activities may be performed in addition to those described. Still further, the order in which activities are listed are not necessarily the order in which they are performed.
In the foregoing specification, the concepts have been described with reference to specific embodiments. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of invention.
As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
Also, the use of “a” or “an” are employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.
Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.
After reading the specification, skilled artisans will appreciate that certain features are, for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination. Further, references to values stated in ranges include each and every value within that range.
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A system and method of establishing write timing in a disk drive using bit patterned media and a magnetic head with read-write offset in which servoing and writing occur on different tracks with timing offsets. Initially, the distance between the servoing and writing tracks is determined for each track/head position in accordance with head geometry and skew angle. The relative timing errors are then measured by iteratively writing data at timing offset increments to determine the optimal timing offset for the servoing/writing track pair, and then writing the offset to sync fields on the servoing tracks of the disk.
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This application claims the benefit of Korean Patent Application No. 10-2005-0076785 filed on Aug. 22, 2005, which is hereby incorporated by reference as if fully set forth herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a washing machine.
2. Description of the Related Art
Generally, a drum-type washing machine includes a tub mounted in a vertical direction with respect to a main body and a drum installed in the tub to be capable of reversibly rotating. The laundry is loaded in the drum and washed by chemical reaction by the washing machine and detergent and physical reaction generated by lifting and falling of the laundry. Therefore, the drum-type washing machine has been widely used as it less entangles the laundry as compared with the pulsator-type washing machine.
FIG. 1 shows a conventional washing machine.
A drum-type washing machine includes a top plate 1 , a cabinet 2 defining an outer wall of the washing machine, a control panel 3 provided with a variety of manipulation buttons, a front panel 4 having a laundry input opening, and upper and lower decoration panels 5 and 6 installed on both sides of the control and front panels 3 and 4 .
The top plate 1 and the cabinet 2 define an outer appearance of the drum-type washing machine while protecting a variety of components of the drum-type washing machine. The control panel 3 includes a variety of buttons for inputting a washing mode and other functions and a display unit for displaying a current washing cycle of the drum-type washing machine.
The front panel 4 is formed under the control panel 3 to define the front portion of the drum-type washing machine and a laundry input opening is formed on a central portion of the front panel 4 .
The side decoration panel 6 is installed on both sides of the front panel 4 to improve the outer appearance of the washing machine.
A process for coupling the side decoration panels to the front panel will now be described with reference to FIGS. 2 and 3 .
As shown in FIGS. 2 and 3 , first fixing holes 41 are formed on opposite end portions of the front panel 4 and second fixing holes 42 are formed on a side-rear portion of the front panel 4 . At this point, the first and second fixing holes 41 and 42 are arranged along a vertical length.
First and second hooks 61 and 62 corresponding to the first and second fixing holes 41 and 42 are formed on an inner side of the side decoration panel 6 .
Describing the coupling process of the side decoration panel 6 to the front panel 4 , the first hooks 61 formed on the side decoration panel 6 are first inserted in the first fixing holes 41 to guide the position of the side decoration panel 6 . Next, the second hooks 62 are inserted in the second fixing holes 42 of the front panel 4 to fix the side decoration panel 6 to the front panel 4 . In this process, the second hook 62 is elastically deformed to be forcedly fitted in the second fixing hole 62 .
The above-described coupling process has the following problems.
Referring to FIG. 2 , during the process that the second hooks 62 are forcedly fitted in the second fixing holes 42 while being elastically deformed, the second hooks 62 interfere with the outer circumferential end portion A of the second fixing hole 42 . Therefore, the portion A may be worn and damaged.
As a result, even when the second hooks 62 are coupled to the second holes 62 , the secure assembling cannot be realized between the side decoration panel 6 and the front panel 4 since the coupling force between the second hooks 62 and the second fixing holes 42 are weakened.
In addition, since the second hooks 62 are forcedly fitted in the second fixing holes 42 , the assembling work is complicated and inconvenient.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a washing machine that substantially obviates one or more problems due to limitations and disadvantages of the related art.
An object of the present invention is to provide a washing machine in which a side decoration panel can be securely assembled with a front panel without wearing the assembled portion and generating a gap on the assembled portion by improving the coupling structure between the side decoration panel and the front panel.
Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, there is provided a washing machine including: a front panel defining a front portion of the washing machine; a decoration panel covering a front-outer circumference of the front panel; a coupling projection formed on at least one of the front and decoration panels; and a slot-shaped hole formed on at least one of the front and decoration panels so that the coupling projection can be sliding-coupled thereto.
According to another aspect of the present invention, there is provided a washing machine including: a front panel defining a front portion of the washing machine; a decoration panel covering a front-outer circumference of the front panel; a coupling projection formed on at least one of the front and decoration panels; and a projection coupling hole on at least one of the front and decoration panels so that the coupling projection can be forcedly fitted thereto.
According to still another aspect of the present invention, there is provided a washing machine including: a front panel defining a front portion of the washing machine; a decoration panel covering a front-outer circumference of the front panel; a coupling projection formed on at least one of the front and decoration panels, the coupling projection having a connecting portion having a predetermined length and a bent portion bent from the connecting portion; and a projection coupling hole formed on at least one of the front and decoration panels, the projection coupling hole having a projection insertion hole in which the coupling projection can be inserted and a projection fixing hole along which the inserted coupling projection can slide.
According to the present invention, since the -shaped sliding holes are alternately formed on the front panels and the side decoration panel is provided with the fixing portions having bent ribs, the side decoration panel is slidably fixed on the front panel, thereby preventing the coupling portions from being damaged and improving the assembling convenience.
Therefore, the assembling is uniformly realized, the outer appearance of the product can be improved.
It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings:
FIG. 1 is a perspective view of a conventional drum type washing machine;
FIGS. 2 and 3 are cross-sectional views illustrating a coupling process of a side decoration panel to a front panel and showing problems of the conventional drum type washing machine;
FIG. 4 is an exploded perspective view of a front panel and a side decoration panel according to an embodiment of the present invention;
FIG. 5 is a schematic side view of the side decoration panel and the front panel shown in FIG. 4 before they are coupled to each other; and
FIG. 6 is a schematic side view of the side decoration panel and the front panel shown in FIG. 4 after they are coupled to each other.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
FIG. 4 is an exploded perspective view of a front panel and a side decoration panel according to an embodiment of the present invention.
Referring to FIG. 4 , a front panel includes an outer cover 11 and an inner cover 12 .
The outer cover 11 is provided at a front-central potion with a laundry input opening 11 a through which the laundry is loaded and unloaded. In addition, a door (not shown) may be hingedly coupled to a side of the laundry input opening 11 a to selectively open and close the laundry input opening 11 a.
A plurality of flanges 112 are formed on both sides of the outer cover 11 and spaced apart from each other in a vertical direction. Each of the flanges 112 is provided with first sliding hole 111 having upper and lower holes 11 a and 111 b . The first sliding hole 111 may be formed in a -shape. A size of the upper hole 11 a is greater than that of the lower hole 111 b.
Meanwhile, the inner cover 12 may be installed in rear of the outer cover 11 and have an edge bent inward to provide a bent surface 120 .
A plurality of second sliding holes 121 are formed on both bent surfaces 120 of the inner cover 12 . Like the first sliding holes 111 , the second sliding hole 121 is formed in a -shape having upper and lower holes 121 a and 121 b . The second sliding holes 121 and the first sliding holes 111 are alternately formed along a vertical length. The first sliding holes 111 are formed on the flanges 112 of the outer cover 11 and oriented frontward and the second sliding holes 121 are formed on the bent surface 120 and oriented sideward. That is, the sidling directions of the sliding holes 111 and 121 are perpendicular to each other.
Meanwhile, the side decoration panel 2 has a height same as that of the front panel 1 . First and second fixing portions 21 and 22 corresponding to the first and second sliding holes 111 and 121 are formed on an inner surface of the side decoration panel 2 in the vertical direction.
Here, the first and second fixing portions 21 and 22 have coupling parts 21 a and 22 a and ribs 21 b and 22 b . The ribs 21 b and 22 b are bent from the coupling parts 21 a and 22 a at right angles so that the first and second fixing portions 21 and 22 are not removed from the sliding holes 111 and 121 as the ribs 21 b and 22 b are hooked on the lower holes 111 b and 121 b . The bending directions of the ribs 21 b and 22 b of the first and second fixing portions 21 and 22 are different from each other so that the ribs 21 b and 22 b can be coupled to the sliding holes 111 and 121 extending from the front panel 1 at right angles.
Meanwhile, the side decoration panel 2 may be formed of ABS that is endurable.
The coupling process of the side decoration panel 2 to the front panel 1 will be now be described with reference to FIGS. 5 and 6 .
The front panel 1 includes the outer and inner covers 11 and 12 . At this point, the inner cover 12 is mounted on the rear portion of the outer cover 11 . Here, the first sliding holes 111 of the outer cover 11 is oriented frontward with reference to the front panel 1 and the second sliding holes 121 of the inner cover 12 are oriented sideward with reference to the front panel 1 .
As shown in FIG. 1 , the first fixing portions 22 are inserted in the first sliding holes 11 and the second fixing portions 21 are inserted in the second sliding holes 121 . That is, as the first fixing portions 22 are inserted in the upper hole 111 a of the first sliding holes 111 , the second fixing portions 21 are simultaneously inserted in the upper holes 121 a of the second sliding holes 121 .
Next, as shown in FIG. 6 , the side decoration panel 2 slides downward so that the ribs 21 b and 22 b of the first and second fixing portions 22 and 21 can be interlocked with the lower holes 121 b of the first and second sliding holes 111 and 121 , thereby completing the assembling process of the side decoration panel 2 with the front panel 1 .
During the above process, since the sliding holes 111 and the sliding holes 121 are alternately formed on the outer and inner covers 11 and 12 , respectively, a distance between the adjacent sliding holes 111 and 121 is reduced so that the fixing portions 21 and 22 of the side decoration panel 2 are tightly fixed on the front panel 1 .
According to the present invention, since the -shaped sliding holes are alternately formed on the front panels and the side decoration panel is provided with the fixing portions having bent ribs, the side decoration panel is slidably fixed on the front panel, thereby preventing the coupling portions from being damaged and improving the assembling convenience.
Therefore, the outer appearance and reliability of the products can be improved.
It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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A washing machine is provided. The washing machine includes a front panel defining a front portion of the washing machine, a decoration panel covering a front-outer circumference of the front panel, a coupling projection formed on at least one of the front and decoration panels, and a slot-shaped hole formed on at least one of the front and decoration panels so that the coupling projection can be sliding-coupled thereto.
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BACKGROUND OF THE INVENTION
The present invention relates to a human interactive interface device, in particular, to a mouse device having a functional turntable capable of signaling the associated computer for the execution of various functions.
DESCRIPTION OF RELATED ART
With the advancement and wide accessibility of modern personal computers, the user operating interface has been greatly enhanced by the adaptation of various graphical user interface (GUI). To further accommodate the GUI operating requirements, the mouse device was developed and has now become an essential peripheral device.
A conventional mouse device usually includes a right bottom, a left, and a center wheel, each offers limited operational functions. However, when combined with associated software, a conventional mouse becomes capable of introducing more programmable functions to the limited onboard operating interface. The added functions may allow individual users to define the onboard function keys to fit individual flavor and requirement, thus further enhancing, the operating experience.
Moreover, to some power users, such as those who use computers to process graphics or play games, a mouse having a higher resolution is often demanded. Various specialty computer mice have therefore been developed for those needs. For example, the resolution of a mouse device can be configured on demand.
However, for the user's convenience, the multi-functional mouse may require larger physical size to accommodate the additional function keys, thus negatively affect the operating comfort and convenience. Therefore, there exists a need for an improved multi-functional mouse device.
SUMMARY OF THE INVENTION
In view of the abovementioned drawbacks of the conventional mouse device, the instant disclosure provides a pointing device having a functional turntable for accommodating multiple programmable functions.
In an example of the invention, a turntable is introduced to surrounding the mouse wheel. This turntable is configured to execute the functional parameters of the mouse device according to a turning scale as turning the turntable.
According to one of the embodiments, the mouse device with functional turntable includes a housing unit, an interface circuit, a sensor unit, and a control unit. The housing is disposed with at least one key, a wheel, and a turntable. The turntable particularly surrounds the wheel. The interface circuit is electrically connected to the turntable. A dial signal is generated in response to the turning scale made by the turntable. The sensor unit is disposed at one side of the housing. Further, an opposite displacement is output in response to the housing moving on a contact surface.
The control unit is electrically connected to the interface circuit and the sensor unit. In response to the information of dial signal, the control unit adds configuration of coordinate-axis positioning angle or coordinate vector ratio to the output displacement of the sensor unit.
The instant disclosure is designed so that the functional parameters can be fast reached without any change of operative behavior of mouse device.
These and other various advantages and features of the instant disclosure will become apparent from the following descriptions and claims, in conjunction with the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a block diagram of the mouse device with functional turntable in accordance with the embodiment of the instant disclosure;
FIG. 2 shows a perspective view illustrating the mouse device with functional turntable in accordance with the embodiment of the instant disclosure;
FIG. 3 shows a coordinate-axis positioning angle of the sensor unit in accordance with the embodiment of the instant disclosure; and
FIG. 4 shows a coordinate vector ratio of the sensor unit in accordance with the embodiment of the instant disclosure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
One objective of the present invention is to introduce a functional turntable to a human interactive interface device for flexibly enabling additional functional parameters. The turntable allows users to operate the functions more conveniently since the conventional keys may be substituted by a turning mechanism. This turntable can be implemented by any turning means such as, but not limited to, a mechanical-type, an optical-type or a touch-type turntable. The turning motion may generate various signals.
Reference is made to both FIG. 1 and FIG. 2 , which respectively show a block diagram and a perspective view of the pointing device, the mouse device, with functional turntable in accordance with the embodiment of the present invention. Provided is a mouse device 1 with functional turntable applicable to a computer system 2 . The mouse device is placed on a contact surface (not shown) for user's operation. The mouse device 1 includes a housing 10 , a transmission interface unit 11 , a key module 12 , a turntable 13 , an interface circuit 14 , a sensor unit 15 and a control unit 16 .
The transmission interface unit 11 is in communication with the computer system 2 . According to design, the transmission interface unit 11 is in communication with the computer system 2 via a wire or wireless connection. The transmission interface unit 11 serves as a data transmitting path between the mouse device 1 and the computer system 2 .
The key module 12 has at least one wheel 120 , a left button 121 and a right button 122 . The skilled person in the related art may understand that the wheel 120 and the keys 121 , 122 are preferably disposed on the housing 10 . The wheel 120 and the keys 121 . 122 generally allow the user to perform the operations including forward/backward paging, clicking, and calling shortcut menu. The example may not limit to the description
The turntable 13 is disposed on the housing 10 and independent of the mouse device's left button 121 , right button 122 and wheel 120 . In particular, the turntable 13 in accordance with embodiment has a central perforation. The wheel 120 is particularly disposed at center of the turntable 13 , and on the other words, the turntable 13 surrounds the wheel 120 and allows the user's turning operation.
The interface circuit 14 is electrically connected to the turntable 13 . In particular, the turntable 13 has a turning scale, and correspondingly generates a dial signal. This turning scale is made by turning the turntable 13 based on the specification of turntable 13 . It is noted that the present invention may not be limited to what is indicated by the turning scale.
Sensor unit 15 is disposed on one side of the housing 10 , and preferably at the bottom surface of the mouse device. The operation of the sensor unit 15 generally bases on the detection and measurement of the coordinate-axis positioning angle and the coordinate vector ratio of a reflected optical signal. The technology and operating principle of the mouse sensor unit is generally well developed, and thus need not be thoroughly discussed here. However, depending on specific practical needs and operational requirements, the light source of the mouse sensor unit may be laser or infrared, and the detector of the sensor unit ( 15 ) is selected in accordance with the corresponding light source.
The control unit 16 is electrically connected to the transmission interface unit 11 , the key module 12 , the interface circuit 14 and the sensor unit 15 . In particular, the control unit 16 is configured to generate a key signal based on the user key operation of the mouse wheel 120 , the left key 121 , or the right key 122 . Furthermore, the control unit 16 is configured to regulate the function performed by the mouse device according to the dial signal. The detail of the dial signal will be discussed in the following sections.
The control unit 16 will transfer the key signal and displacement to the computer system 2 via the transmission interface unit 11 . The mouse device 1 accomplishes the various operations of the computer system 2 .
The control unit 16 therefore serves to operate a functional parameter of mouse device 1 according to the dial signal generated by the interface circuit 14 . The described functional parameters may include the adjustments for the coordinate-axis positioning angles and the coordinate vector ratio, or the programming control for a tilting wheel, a switching profile or a shortcut function for a mouse key. The programmable functional parameters of the mouse device will be further elaborated as follows.
The functional parameter with respect to the coordinate-axis positioning angle is referred to FIG. 3 , which shows a schematic diagram of the configuration of coordinate-axis positioning angle of the sensor unit.
A user may set the mouse device to operate at a tilted condition. For example, FIG. 3 shows the mouse being operated at a tilting angle of 45 degrees. The operating reference frame of the coordinate-axis positioning angle of the sensor unit 15 of the mouse device 1 is adjustable according to the dial setting of the turntable. Thus, since the coordinate-axis positioning angle shifts with respect to the tilting angle of the mouse device 1 , the mouse cursor in the computer system 2 will move upper left 45 degrees and lower right 45 degrees if the user moves the mouse device with the used horizontal direction forward and backward.
By means of the dialing function of the turntable 13 , the coordinate-axis positioning angle of sensor unit 15 may be adjusted to suit a user's particular habit and need. For example, the user may adjust the turntable 13 by turning the dial clockwise to a certain degree to regulate the positioning angle of the sensor unit 15 of the mouse device 1 . In the meantime, the coordinate-axis positioning angle may be finely adjusted to 45 degrees in a clockwise dial setting. The positioning angle of the sensor unit 15 is referred to the lower diagram of FIG. 3 . Therefore, the mouse device 1 may be operated normally at a preferred tilting angle. The user therefore manipulates the mouse device 1 at his preferred operating angle.
Next, the relevant functional parameters regarding to the coordinate vector ratio is referred to FIG. 4 , which shows the coordinate vector ratio of the sensor unit. It is worth noting that to configure the coordinate vector ratio is to regulate the resolution of the mouse device 1 . The resolution can be easily understood as the mouse's sensitivity, which is used to calculate a moving distance between the mouse device 1 and the mouse cursor. More specifically, if the default resolution of the mouse device 1 is 400 dpi and the display resolution of the computer system 2 is 1280*1024, the moving distance is around 3.2 inch (about 8 centimeters, 1280/400) if the mouse cursor is moved from a far left to an opposite right on the screen.
The turntable of the instant disclosure is configured to execute the functional parameters to configure the coordinate vector ratio, that is, to regulate the ratio of the coordinates projected on the X-axis and the Y-axis. In particular, the vectors on the X axis and the Y axis may not be proportionally enlarged or shrunk. Thus, the resolution of the X axis increases and the resolution of the Y axis decreases when the turntable 13 is turned clockwise. In contrast, the counterclockwise-turned turntable 13 decreases the resolution of X axis and increases the resolution of Y axis.
In accordance with FIG. 4 , the default resolution of mouse device 1 is 600 dpi, and the coordinate vector ratio of sensor unit 15 is 1:1. This ratio shows both the resolutions of X axis and Y axis are 600 dpi. When the turntable 13 is clockwise turned with a certain turning scale, referring to the lower diagram of FIG. 4 , the X axis becomes 800 dpi as adding up 200 dpi and the Y axis becomes 400 dpi as it decreases 200 dpi. After that, the ratio becomes 2:1 after the configuration. It is noted that the change of ratio is not limited to integer, but depends on the need.
Furthermore, the functional parameters related to the coordinate vector ratio allow the user to adjust resolution of the mouse device 1 based on the screen resolution of the computer system 2 . Therefore, the moving displacement of the mouse device 1 may be in compliance with the required precision for the users when the mouse device 1 is moved up, down or around.
The turntable of the instant disclosure may also be adapted to provide tilting functions of a conventional mouse wheel. With proper software setup, the turntable 13 may be operated clockwise or counterclockwise correspondingly to perform the conventional left/right tilting functions of a conventional mouse wheel. Therefore, the replacement of the traditional tilting mouse wheel with the turntable 13 may reduce the mechanical complexity of a conventional tilting mouse wheel, thus contributing to the reduction of component and manufacture costs.
In regard to the functional parameters profile switching capability, turntable 13 may be used to perform profile switching functions. For example, the keys including wheel 120 , left button 121 and right button 122 of the key module 12 of the mouse device 1 may be re-configured or combined for the various functions to suit the operational convenience of different software. This capability can be especially valuable for computer garners who have never-ending needs for custom configuration to suit their particular habits. Serious garners may even find the need for adapting different control profiles within a single game in response to the various game scenes or scenarios. Accordingly, by operating the turntable 13 , the mouse device of the instant disclosure may be configured to provide fast and convenient control profile switching capability.
Since the turntable 13 merely has a clockwise turning direction and a counterclockwise direction used for the fast switched functions, the user may easily make his preferred configuration for various controls using the two directions.
In one more embodiment, for the turntable 13 of the mouse device 1 is used to perform the various functional parameters, a switching signal for the control unit 16 will be introduced further. The switching signal is configured to switch a turntable function mode of the turntable 13 . Therefore, one corresponding functional parameter is performed according to the current turntable function mode. It is noted that one functional parameter corresponds to the configuration of coordinate-axis positioning angle, the configuration of coordinate vector ratio, the tilting wheel, the switching profile or the shortcut function key. Thus, the invention allows the users to perform any corresponding functional parameter by turning the turntable 13 .
In an exemplary embodiment, the control unit 16 can have a built-in lookup table (not shown). This lookup table has variant fields corresponding to the turntable function modes. Each field particularly records the action information regarding the clockwise and counterclockwise turning directions and the turning scales of the turntable 13 . Further, the control unit 16 also selects the field related to the turntable function mode according to the switching signal. The dial signal corresponds to the action information of the selected field. The design of turntable 13 is capable of performing the various functional parameters.
It is worth noting that there are at least two ways to generate the mentioned switching signal. One is to design one more switching key (not shown in the diagram) in the key module 12 of the mouse device 1 . Therefore, the user may use this switching key to trigger a switching signal. The other one is to introduce software that uses a driver interface (not shown) or any program of the computers system 2 for providing selections for users. The selection may generate a switching signal to perform the parameter. Whatever the design is, the turntable effectively conducts the switching signal for the selection of turntable function mode.
To sum up, a turntable component is particularly introduced into a mouse device. The turntable is featured to perform more functional parameters in addition to the basic functions. The users may perform the functions by smoothly turning the turntable. The turntable, in design, surrounds the conventional wheel of the mouse device. The design may not affect the user's conventional behavior, and further provide fast switching to the functional parameters. As a whole, the invention may not increase much size of the mouse device, but the convenient operation interface. It is noted that the number of keys such as the described left and right buttons is not limited to the present invention.
While the description constitutes the preferred embodiment of the instant disclosure, it should be appreciated that the invention may be modified without departing from the proper scope or fair meaning of the accompanying claims. Various other advantages of the instant disclosure will become apparent to those skilled in the art after having the benefit of studying the foregoing text and drawings taken in conjunction with the following claims.
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Provided is a human interactive interface device having a functional turntable. The interface device includes a housing unit, an interface circuit, a sensor unit, and a control unit. The housing unit has at least a left key, a right key, a mouse wheel, and a turntable. The turntable is disposed around the mouse wheel. The interface circuit is connected electrically to the turntable for generating a dial signal in accordance to a dial position of the turntable. The senor unit is located on the lower surface of the housing, and captures an image signal according to a reflex formed on a contact surface. The control unit is connected electrically to the interface circuit and the sensor unit, and is used for adjusting a coordinate axis positioning angle or a coordinate vector ratio of the sensor unit according to the dial signal, and further calculates a displacement according to the image signal.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of International Application No. PCT/IB2005/003358 filed on Nov. 9, 2005, which claims the benefit of Italian Patent Application No. TO 2004 A 000777 filed Nov. 9, 2004. The disclosures of the above applications are incorporated herein by reference.
FIELD
[0002] The present disclosure relates to a thermostatic mixer comprising a device for the dynamic regulation of the cold water flow supplying the mixer.
BACKGROUND
[0003] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0004] Thermostatic mixers that are suited to handle a large flow rate generally do not function if the flow rate required from them is considerably smaller than the maximum flow rate they are designed for, as occurs, for example, when a thermostatic mixer suited to supply a fixture comprising a plurality of showers is used to supply a single shower. Under these circumstances, the thermostatic mixers lose their stability and start to vibrate so that the water flow drawn from them is subject to constant fluctuations in the ratio between cold water and warm water and therefore sustains temperature fluctuations, which are uncomfortable for the user and may become dangerous. This disadvantage may be corrected by opposing a resistance to the cold water flow fed into the thermostatic mixer when small flow rates of mixed water are supposed to be pumped and by suppressing or reducing this resistance when large flow rates of mixed water are supposed to be pumped. This operation is carried out automatically by devices for dynamic flow regulation, which are designed to reduce the passage cross-section provided to the arriving cold water when the accommodated flow rate is reduced and to restore a larger passage cross-section when an increased flow rate is required.
[0005] Nevertheless, the known devices for dynamic flow regulation are generally associated with various disadvantages. Above all, in light of their design and their dimensions, they must be elements that can be added to the fixture in series connection to the feed pipe of the cold water to the mixer and which cannot be installed in the mixer itself. Therefore, the load of the recuperating spring requires adjustment as a function of the inflow pressure of the cold water for the device to function properly. Consequently, during installation the device must be adapted to the pressure conditions prevailing in the system, and the function of the device is no longer appropriate when considerable fluctuations in the cold water inflow pressure occur.
SUMMARY
[0006] The main object of the present invention is to create a thermostatic mixer comprising a device for the dynamic regulation of the cold feed water, the configuration of which must be so simple that it can be installed in the thermostatic mixer, and the function of which must be largely independent from the inflow pressure, so that the device must not require any adjustments during the course of its installation, and may not function irregularly even when considerable variations in the inflow pressure occur.
[0007] Another object of the present invention relates to the creation of such a thermostatic mixer, which comprises a device for dynamic flow regulation that has a simple design, is economical in comparison with a similar thermostatic mixer, which per se does not have a device for dynamic flow regulation and is equipped with a separate device for dynamic flow regulation, and guarantees great reliability and a long service life.
[0008] These tasks are achieved according to the invention by means of a thermostatic mixer, comprising in one body a feed passage for the cold water, a feed passage for the warm water, and a discharge passage for the mixed water, a slide designed for sliding in axial translation inside the body and for narrowing the feed passages for the warm water and for the cold water in opposite directions in order to change their mixing ratio, an expansion thermocouple connected to the slide for actuation of the same and extending in the discharge passage for the mixed water, a spring acting on the thermocouple and the device body, means for adjusting the idle position of the thermocouple, and a rod connecting the thermocouple and the means for adjusting the position of the same, characterized in that an annular feed chamber is formed in the area of the cold water feed passage inside the slide, that furthermore the mixer has a hollow cylinder disposed inside the slide and provided for displacement in axial translation between a first position, in which it narrows the passage between the annular chamber and the space between the slide and the piston, and a second position, in which the piston does not narrow this passage, that the mixer comprises a second spring acting between the slide and the piston in such a direction that it acts on the piston toward the first position, that the piston is provided with reduced radial passages penetrating it and located in the region of the annular feed chamber when the piston is in its first position, and that the piston has a transversal wall separating the space inside the piston into an intermediate chamber and a discharge chamber and in which an axial limited flow passage is located, which is penetrated by the rod for connection between the thermocouple and the means for adjusting the position of the same.
[0009] In this way, the piston reduces the inflow of the mixer only for cold water when the piston is in its first position (resting) and allows a flow with reduced flow rate which, despite the fact that it is considerably smaller than the one the thermostatic mixer is designed for, due to the presence of the restriction of the cold water inflow, does not cause any functional problems of the thermostatic mixer.
[0010] The pressure created inside the intermediate chamber is defined by the pressure decline experienced by the flow while passing from the feed chamber through the restricted radial passages to the intermediate chamber, and the pressure present inside the discharge chamber is smaller than the pressure mentioned above due to the pressure decline experienced by the flow while passing through the axial limited passage present in the transversal piston wall. The effects exerted on the piston in the axial direction and in the opposite direction, as well as the one exerted by the recuperating spring, substantially depend on the difference of the pressure present inside the intermediate chamber and that present inside the discharge chamber, this pressure difference acting on the transversal section of the piston and tending to overcome the force of the recuperating spring. Adequate dimensioning with respect to the cross-sections of the limited passages provided in the piston shell, the free cross-section of the limited passage provided in the transversal wall of the piston, and the force of the recuperating spring in turn make it possible that the piston is not displaced from its first position into its second position as long as a flow is drawn that is smaller than the maximum flow that can cause instability in the thermostatic mixer.
[0011] However, when a flow that is greater than the one defined above is required from the discharge chamber, the pressure present inside the feed chamber drops due to the pressure decline experienced by this larger flow while passing the axial limited passage provided in the transversal piston wall, and the pressure difference acting on the piston increases and overcomes the force of the recuperating spring; then, the piston is displaced into its second position, as a result of which it releases the flow passage from the feed chamber into the intermediate chamber and then into the discharge chamber.
[0012] Since what controls and/or regulates the displacement of the piston is not the absolute pressure present inside the chambers of the device, but the pressure difference between the intermediate chamber and the discharge chamber, which depends on the flow and the resistance opposed to it, but not on the absolute pressure, the function of the device is largely independent from the inflow pressure, and in turn the device does not require any adaptation during the course of its installation and does not exhibit any irregularities in its function, even if the inflow pressure varies considerably.
[0013] In light of the great simplicity of the above-described device for dynamic flow regulation and its reduced dimensions, the installation in the thermostatic mixer is not associated with any problems and according to the invention enables the production of a thermostatic mixer comprising the device for dynamic flow regulation, which according to the state of the art would have to represent a separate attachment.
[0014] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0015] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
[0016] FIG. 1 shows an axial cross-sectional view of a thermostatic mixer according to the invention, which comprises a device for dynamic flow regulation.
[0017] FIG. 2 shows only the components of the mixer according to FIG. 1 relating to the invention, in the idle state and/or in the state of withdrawal with a reduced flow rate.
[0018] FIG. 3 shows the same components of the mixer according to FIG. 2 , however in the state of withdrawal with an increased flow rate.
[0019] FIGS. 4 and 5 equivalent to FIGS. 2 and 3 show another embodiment of the device according to the invention.
DETAILED DESCRIPTION
[0020] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
[0021] In FIG. 1 , a thermostatic mixer according to the invention is shown in an axial cross-sectional view, which mixer comprises a device for the dynamic regulation of an entering cold water flow, with the function of stabilizing the operation of the thermostatic mixer. The mixer comprises a body 1 , which on top is closed in a plug-like manner by the upper part of the body 2 of a cartridge inserted into the body 1 . The body 1 forms an inflow connector 3 for the cold water, an inflow connector 4 for the warm water and an outflow connector 5 for the mixed water. The inflow connector 3 for the cold water and the inflow connector 4 for the warm water each extend into annular feed passages 6 and 7 inside the body 1 , and the feed passages 8 and/or 9 formed in the cartridge 2 each correspond to these annular passages. On the inside of the cartridge 2 , an axially displaceable slide 10 is mounted, which is designed to narrow the feed passages 8 and 9 in opposite directions in order to modify the flow rates of the cold water and of the warm water entering the slide 10 in opposite directions, thus modifying the mixing ratio and temperature of the mixed water sent to the outflow connector 5 . The slide 10 has a transversal wall 11 penetrated by passages, to which wall an expansion thermocouple 12 is attached, extending toward the outflow connector 5 of the mixed water and expanding depending on the temperature of the mixed water, thus displacing the slide 10 . A spring 13 acts on this configuration, while a control and safety device 26 , which is provided on the opposite side of the spring 13 and is accessible to the user for regulation purposes, defines the idle state of the slide 10 by means of a rod 24 . Suitable gaskets are provided in a common way where water tightness must exist and are not described in further detail. The components described so far represent the conventional design of a thermostatic mixer, wherein this design and its function are known to the person skilled in the art.
[0022] According to the invention, the slide 10 forms an annular feed chamber 19 for the cold water in the region of the feed passages 8 , and an axially displaceable hollow cylinder 14 is mounted on the inside of the slide 10 , which cylinder has a cylindrical shell 15 interspersed with limited passages 16 . The cylinder 14 can be displaced between a first position (according to the drawing shifted upwards), in which the shell 15 narrows the passage from the annular feed chamber 19 into the inside of the slide 10 and the hollow cylinder 14 , and a second position (according to the drawing shifted downwards), in which the shell 15 does not narrow the passage.
[0023] Furthermore, the hollow cylinder 14 has a transversal wall 17 in which an axially limited passage 18 opens, which is interspersed with the rod 24 that connects the thermocouple 12 to the regulating means 26 . A recuperating spring 20 is provided between the transversal wall 17 of the cylinder 14 and the transversal wall 11 of the slide 10 , which spring acts on the cylinder 14 toward the first position, which is the idle state.
[0024] The shell 15 and transversal wall 17 of the cylinder 14 define an intermediate chamber 21 , while a discharge chamber 22 is defined between the transversal wall 17 of the cylinder 14 and the transversal wall 11 of the slide 10 .
[0025] It should be noted that in the idle state the limited radial passages 16 allow limited flow to travel from the feed chamber 19 to the intermediate chamber 21 located inside the piston and to continue through the axial passage 18 and the discharge chamber 22 to the outflow connector 5 , thus passing through the entire device. When such a limited flow is present, the pressure in the feed chamber 19 is the inflow pressure of the cold water, the pressure in the intermediate chamber 21 is smaller than the inflow pressure due to the pressure decline experienced by the flow by passing through the limited passages 16 , and the pressure inside the discharge chamber 22 is further reduced due to the pressure decline experienced by the flow by passing through the axial limited passage 18 . Due to the difference between the pressure present in the intermediate chamber 21 and the reduced pressure present in the discharge chamber 22 , the piston is acted upon such that it is displaced away from the feed chamber 19 and the recuperating spring 20 acts against this process.
[0026] In contrast, the piston 14 is practically not influenced by the feed pressure present in the feed chamber 19 since this pressure acts on the shell 15 of the piston 14 in the radial direction. On the other hand, the pressure declines experienced by the flow depend solely on the intensity of the flow and on the resistances opposed to it and not on the absolute pressure value. In turn, the behavior of the piston 14 is not significantly influenced by the inflow pressure value and its fluctuations.
[0027] The limited radial passages 16 , the limited axial passage 18 and the recuperating spring 20 must be proportioned relative to one another so that the effect of the spring 20 corresponds substantially to the force that tends to displace the piston 14 from the first position into the second position when the maximum flow rate is withdrawn, which may cause instability in a thermostatic mixer. The piston 14 in turn maintains its first position illustrated in FIG. 2 as long as the requested flow rate stays below the afore-mentioned maximum value.
[0028] However, when a flow rate that is larger than the above-defined maximum rate is requested by the outflow connector 5 , the pressure inside the discharge chamber 22 is reduced and the pressure difference acting on the piston 14 exceeds the force of the recuperating spring 22 . Now, the piston 14 is displaced into its second opening position illustrated in FIG. 3 . The shell section 15 stops narrowing the passage between the feed chamber 18 and the intermediate chamber 21 and the flow passage from the feed chamber 18 to the discharge chamber 22 is substantially free.
[0029] If thereafter the requested flow rate is reduced again or completely stopped, the effect of the recuperating spring 22 again exceeds the pressure difference acting on the piston 14 and displaces the piston again into its first closing position according to FIG. 2 .
[0030] In the embodiment described above, the limited radial passages 16 are formed by small recesses provided on the edge of the end of the shell section 15 of the piston 14 . In this case, it is advantageous for the shell section 15 to be thin in order to minimize a reduced and generally negligible component of the inflow pressure, which acts on the piston in the axial direction while affecting the cross-section of the limited radial passages 16 .
[0031] FIGS. 4 and 5 show another embodiment of the device according to the invention. In these figures, parts that are identical to or that correspond to the parts in the first embodiment have been denoted by the same reference numerals.
[0032] The second embodiment according to FIGS. 4 and 5 differs from the previous by the fact that the limited passages between the feed chamber 18 and the intermediate chamber 21 consist of one or more small holes 23 , which are provided in the shell section 15 , and not of small recesses 16 , which are provided on the edge of the end of the shell section 15 of the piston 14 . In this case, the negligible component of the inflow pressure, which in the previous embodiment acts on the piston in the axial direction, is missing, and it is of no meaning that the shell section 15 of the piston 14 should be thin.
[0033] FIGS. 4 and 5 also show that a small intermediate space 25 between the piston 14 and the slide 10 may be provided. This intermediate space forms a limited passage and may interact with the effect of the limited passages 16 or 23 or optionally take over their function completely.
[0034] As is apparent from the above, the invention enables the implementation of a thermostatic mixer comprising a device for the dynamic regulation of cold water inflow, which device is practically not sensitive to the fluctuations of the inflow pressure and stabilizes the function of the thermostatic mixer. It is not necessary to adjust the force of the recuperating spring as a function of the inflow pressure present inside the fixture, and no defect whatsoever can be observed in the functioning of the device even if, for whatever reason, this inflow pressure varies to a larger extent.
[0035] It should be noted that the invention is not limited to the embodiments described and illustrated as examples. A large variety of modifications have been described and more are part of the knowledge of the person skilled in the art. These and further modifications as well as any replacement by technical equivalents may be added to the description and figures, without leaving the scope of protection of the invention and of the present patent.
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The disclosure relates to a thermostatic mixer, including a device for the dynamic regulation of the cold water flow which supplies the mixer. A resistance is generated to the flow of cold water supplied to the thermostatic mixer when small flows of mixed water are required, and said resistance is lifted or reduced when large flows of mixed water are required. Said operation is automatically carried out by devices for dynamic regulation of flow, whereby the flow cross-section provided for the incoming cold water is reduced when the drawn flow is reduced and a larger flow cross-section reestablished when a larger flow is required.
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FIELD OF THE INVENTION
The invention relates to systems and methods for conserving vapor and collecting liquid carbon dioxide for cleaning systems, more particularly to methods and systems for conserving vapor and collecting liquid carbon dioxide for carbon dioxide dry cleaning systems.
BACKGROUND OF THE INVENTION
Dry cleaning systems are known. Additionally, dry cleaning systems that use vapor and liquid carbon dioxide are known. The system employs a washing vessel, in which articles to be washed may be placed. Vapor and liquid carbon dioxide is transferred to the washing vessel. The carbon dioxide is pressurized inside the washing vessel. Pressures inside the vessel may be equal to approximately 700-900 psi. Liquid and vapor carbon dioxide is capable of cleaning the articles. Additives, such as organic solvents, may be supplemented. After washing, the washing vessel is depressurized. Liquid and vapor carbon dioxide are removed from the washing vessel. The clothes may be removed from the washing vessel, after which a new washing cycle may be initiated.
A drawback of the known systems and methods is loss of vapor carbon dioxide. Blow off of vapor carbon dioxide for depressurizing the washing vessel leads to losses of material. Additionally, in other parts of the systems, i.e. in piping systems and connections thereof, losses of carbon dioxide may occur. The loss of this carbon dioxide needs to be replenished in a new washing cycle.
Additionally, the losses of liquid and vapor carbon dioxide are associated with a relatively low thermodynamic efficiency.
SUMMARY OF THE INVENTION
It can therefore be an object of the present invention to provide systems and methods for minimizing the losses of carbon dioxide in a liquid carbon dioxide dry cleaning system.
It can be another object of the present invention to provide systems and methods for improving the thermodynamic efficiency of a liquid carbon dioxide dry cleaning systems.
It can be a further object of the present invention to provide systems and methods for lowering the capital costs associated with a liquid carbon dioxide dry cleaning system.
The present invention provides a dry cleaning system arranged for washing articles employing a cleaning solution. The system comprises a wash tank for washing an article to be washed with a cleaning solution. The wash tank may be arranged for washing the article at an increased pressure compared to atmospheric pressure (hyperatmospheric pressure). The system may comprise a fluid displacement device, such as a pump, connected to the wash tank and arranged for transferring the cleaning solution through the dry cleaning system in a first operational mode. According to the invention, the fluid displacement device may be used to reduce the pressure in the wash tank towards atmospheric pressure in a second operational mode. Instead of blowing off the contents of the wash tank, these contents are kept in the dry cleaning system. Loss of material is thus prevented. Additionally, loss of heat is prevented. The fluid displacement device, being arranged for both transferring cleaning solution, as well as depressurizing the wash tank, ensures that a relatively simple dry cleaning system having a minimal amount of components may be used. The complexity of the system is reduced. Connections between the components (e.g. fluid displacement device and wash tank) may be relatively simple. This reduces the losses of cleaning solution, and more specifically losses of carbon dioxide in the system, for instance losses that occur at connections in the system. The reduced complexity of the system also lowers capital costs.
The washing tank may be arranged for washing articles at a pressure of approximately 700-900 psi, for instance 715 psi or 875 psi. It should be noted however, that higher or lower pressures are thinkable. The cleaning solution may be a densified cleaning solution. The cleaning solution may comprise a vapor and a liquid, such as vapor and liquid carbon dioxide.
In an embodiment, the dry cleaning system may comprise a depressurization unit connected to the wash tank for reducing the pressure in the wash tank towards atmospheric pressure. The depressurization unit may be a valve. The depressurization unit, i.e. the fluid displacement device, may be used to accurately control the pressure inside the wash tank. Preferably, however, the depressurization unit is the fluid displacement device. The contents of the wash tank may be preserved in the dry cleaning system, preventing loss of material.
It is possible that the fluid displacement device is arranged for removing vapor from the wash tank in the second operational mode. After washing, liquid cleaning solution may be removed from the wash tank by means of the fluid displacement device operating in the first operational mode. Vapor cleaning solution will remain in the wash tank. Pressures inside the wash tank will still be elevated compared to atmospheric pressure. The fluid displacement device may be arranged for draining the contents, such as a vapor or a gas, e.g. vapor carbon dioxide, from the wash tank. With this, the pressure inside the wash tank may be reduced towards atmospheric pressure. The contents drained may be re-used in the system. With this, preservation of cleaning solution, e.g. carbon dioxide, may be exerted, minimizing losses of material, and additionally increasing thermodynamic efficiency.
In an embodiment, the fluid displacement device is arranged for compressing vapor removed from the wash tank. The pressure of the vapor removed may be brought to a desired level. For instance, the pressure may be increased to the working pressure of the system. With this, the vapor removed may be brought to a pressure suitable for use in the dry cleaning system, e.g. for use in a new washing cycle. This ensures that the pressure throughout the system, except for the wash tank, may be kept at a uniform level. Pressure losses in the system are reduced. With this, thermodynamic efficiency may be increased. In the wash tank, the pressure may be reduced such that articles that are washed may be removed from the wash tank. The fluid displacement device may be used as a compressor, and may increase the pressure of the vapor removed to approximately, for instance, 715 psi or 875 psi. Other pressures, such as higher or lower pressures, are, of course, also possible.
The fluid displacement device may be a pumping/compressing unit arranged for pumping and compressing the cleaning solution. In a first operating modus, the fluid displacement device may be used for pumping cleaning solution in liquid form throughout the system. In a second operating modus, the displacement device may be used for pumping cleaning solution in vapor form throughout the system. In the second operating modus, the fluid displacement device may additionally be used to increase the pressure of the vapor. The combination of two operating modes in one fluid displacement device may lead to lower capital costs.
In an embodiment, the fluid displacement device is a positive-displacement device. The positive-displacement device may be a reciprocating device or a piston device that uses one or more pistons driven by a crankshaft to pressurize fluid. The use of a positive-displacement device with one or more pistons enables the use of a single fluid displacement device for transferring fluids, such as liquids and vapors, as well as compressing fluids, and more particularly for compressing vapors.
In an embodiment, the fluid displacement device comprises an inlet connected to a pumping chamber, in which a piston is reciprocally movable. The pumping chamber may comprise a pumping chamber inlet opening connected to the inlet. The pumping chamber may also comprise a pumping chamber outlet opening connected to the outlet. The pumping chamber comprises a discharge unit connected to the pumping chamber outlet opening. The discharge unit is arranged for closing the pumping chamber outlet opening when a pressure inside the pumping chamber is less than a pre-set pressure. With this it is possible to compress vapor, and to transfer liquid. The fluid displacement device may thus act as a pumping/compressing unit.
The pumping chamber inlet opening may be provided near one end of the pumping chamber, and the pumping chamber outlet opening may be provided near an opposite end. This way, the piston may be used to close the pumping chamber inlet opening. There is no need for a complicated and expensive system for closing the pumping chamber inlet opening during a compression stroke of the fluid displacement device.
In an embodiment, the discharge unit is a spring-loaded valve. The discharge unit ensures that the fluid, such as a gas or a vapor, may be compressed in order to increase the pressure of the fluid. The fluid displacement device is able to function as a pumping/compressing unit, arranged for both pumping and compressing the cleaning solution.
It is possible that the fluid displacement device comprises additional pumping chambers connected to the inlet and the outlet. The pumping chamber comprises a pumping chamber inlet, a pumping chamber outlet, a piston. An additional discharge valves may be provided. The pumping chambers of the fluid displacement device are used for both pumping and compressing fluid. In other words, the pumping chambers have different functions, in different modi of the fluid displacement device. It is possible that the positive displacement device comprises at least three pumping chambers, connected to a single inlet, and connected to a single outlet. With this, the fluid displacement device may exert effective pumping and compressing.
The dry cleaning system may further comprise a central storage tank for storing the cleaning solution. The central storage tank enables storage of unused cleaning solution. The fluid displacement device may be used to transfer cleaning solution from the central storage tank, to the wash tank, and vice versa.
In an embodiment, the dry cleaning system may comprise a first piping system arranged for bringing the central storage tank into fluid communication with the wash tank. The first piping system may be used to transfer liquid carbon dioxide from the central storage tank to the wash tank. Transfer from the wash tank to the central storage may also be possible. Transfer may be exerted by the fluid displacement device. The fluid displacement device may function as a pump for the first piping system. The system may further comprise a second piping system arranged for bringing the wash tank into vapor communication with the central storage tank. The second piping system may be used to transfer vapor from the wash tank to the central storage tank. Transfer from the central storage tank to the wash tank may also be possible. The system may further comprise a common piping system formed by a coinciding part of the second piping system and the first piping system. This way, the common piping system may be used for separate transfer of both liquids, and vapors, enabling the fluid displacement device to work in two operating modes. Preferably, the fluid displacement device is residing in the common piping system. The common piping system improves thermal efficiency, since losses to the environment are minimized. Also, costs are decreased.
It is possible that the dry cleaning system comprises an intermediate storage tank for temporarily storing the cleaning solution. The intermediate storage tank may be connected to the wash tank. The fluid displacement device may be arranged for transferring the cleaning solution between the cleaning device and the wash tank. The intermediate storage tank allows for already used cleaning solution, which may be re-used again, to be stored for further use. The intermediate storage tank may be used for storing liquid cleaning solution. The intermediate storage tank may be connected to the first piping system. It is possible that used cleaning solution, which is dirty, is used again in the same or any further washing cycle. The intermediate storage ensures that this cleaning solution may be stored for further use, without affecting the cleaning solution in the central storage tank.
It is possible that the dry cleaning system comprises a cleaning device for cleaning the cleaning solution. The cleaning device may be connected to the wash tank. The fluid displacement device may be arranged for transferring the cleaning solution to the cleaning device. Already used cleaning solution may be cleaned using this device. The cleaning solution may, after having been cleaned, be transferred to the central storage tank. The cleaning device may be part of the common piping system, such that both vapor and liquid cleaning solution may be cleaned.
In an embodiment, the fluid displacement device is arranged for compressing vapor cleaning solution, and transferring compressed vapor to the cleaning device.
In an embodiment, the cleaning device is a distillation unit. The distillation unit may be used to distillate the used and relatively dirty cleaning solution. Distillation of the already used cleaning solution ensures that impurities are removed. Distillation is relatively simple. Distillation also has a relatively high efficiency. Distillation ensures that a relatively clean cleaning solution may be obtained, which cleaning solution may be re-used in a further washing cycle.
The system may further comprise a central storage tank for storing the cleaning solution. The central storage tank may be connected to the wash tank. The distillation unit may be connected to the central storage tank for returning cleaned cleaning solution to the central storage tank. The system may comprise a third piping system arranged for bringing the distillation unit into fluid connection with the central storage tank for returning relatively clean cleaning solution to the central storage tank. This way, used cleaning solution may be cleaned and transferred to the central storage tank, after which it may be used in a next washing cycle.
The system may comprise a cooling unit arranged for bringing the cleaned and returned cleaning solution into liquid form. The cooling unit may reside in the third piping system. Preferably, the cleaning solution is returned to the central storage tank in liquid form. During the distillation process, the cleaning solution will evaporate. The vapor cleaning solution may then be transferred through the third piping system, for instance under the influence of buoyancy forces, to the central storage tank. To bring the vapor into liquid form, the vapor may be cooled using the cooling unit.
Preferably, the cleaning solution comprises liquid carbon dioxide. The carbon dioxide, when used in a dry cleaning system, produces satisfactory results. As stated before, additives, such as organic or inorganic solvents, may be present in the cleaning solution.
In an embodiment, a purging unit is provided for cleaning the wash tank. The purging unit may be part of the dry cleaning system. The cleaning of the wash tank is preferably exerted before the start, or at the beginning of a new wash cycle. The purging unit may be arranged for removing nitrogen and oxygen from the wash tank.
The purging unit may comprise a purge tank for storing a purging fluid, wherein the purge tank may be brought into fluid communication with the wash tank, and wherein the purging fluid is arranged for cleaning the wash tank.
In an embodiment, the purging fluid is vapor carbon dioxide. The pressure of the purging fluid may be in between 72 and 230 psi. The purging fluid efficiently removes air, and more specifically nitrogen and oxygen, from the wash tank.
The dry cleaning system may comprise a central storage for storing vapor cleaning solution. The vapor cleaning solution may be vapor carbon dioxide. The central storage may be connected to the wash tank for transferring vapor cleaning solution to the wash tank. The dry cleaning system may further comprise a further piping system arranged for bringing the central storage tank into vapor communication with the wash tank. Preferably, the further piping system may be used to transfer vapor cleaning solution from the central storage tank to the wash tank.
In an embodiment, a central storage for both vapor and liquid cleaning solution is provided.
According to another aspect of the invention, a method for washing an article in a dry cleaning system employing a cleaning solution is provided. The cleaning solution may be a densified cleaning solution. The system comprises a wash tank for washing an article to be washed with the cleaning solution, and a fluid displacement device connected to the wash tank and arranged for transferring the cleaning solution. The method comprises the step of operating the fluid displacement device for transferring the cleaning solution in the dry cleaning system, and operating the same fluid displacement device for depressurizing the wash tank. The fluid displacement device may be used for transferring liquid cleaning solution throughout the dry cleaning system. Additionally, the same fluid displacement device may be used for depressurizing the wash tank after washing. Instead of blowing off the contents of the wash tank, the contents may be re-used. This way, loss of material is prevented. Furthermore, in the method only a single component is used for providing two functions to the dry cleaning system.
The step of operating the same fluid displacement device for depressurizing the wash tank may comprises the step of reducing the pressure in the wash tank towards atmospheric pressure. The pressure in the wash tank may be reduced from approximately 700-800 psi, to approximately 100-200 psi, in a relatively controlled manner. With this, pressure is reduced towards atmospheric pressure. Additionally, a further reduction to approximately 14.7 psi may be exerted.
The step of operating the same fluid displacement device for depressurizing the wash tank may comprise the step of removing vapor from the wash tank. In the wash tank, vapor cleaning solution, such as vapor carbon dioxide, may be present. The vapor may have a pressure of approximately 700-800 psi. Depressurizing of the wash tank may be exerted by the fluid displacement device. This way, the vapor cleaning solution will remain in the dry cleaning system, and it is therefore possible to re-use the vapor cleaning solution. For instance, the vapor may be stored temporarily for further use. It is also possible that the vapor cleaning solution is cleaned. Furthermore, it is possible that the vapor cleaning solution is liquefied.
In an embodiment, the step of operating the same fluid displacement device for depressurizing the wash tank comprises the step of compressing the vapor removed from the wash tank. This way, the pressure of the vapor, which was reduced during the depressurization of the wash tank, may be increased to a desired level. For instance, the pressure may be increased to a relatively constant level. For instance, the pressure may be increased to a constant value in the range of 700-900 psi, e.g. 725 psi, or 875 psi. Intermediate values are also possible. The constant value may be dependent on the value used throughout the rest of the system. Preferably, the pressure is increased to the pressure needed in the wash tank.
The method may comprise the steps of operating the fluid displacement device for pumping the cleaning solution in liquid form; and operating the fluid displacement device for compressing the cleaning solution in vapor form. The fluid displacement device may thus operate as a pump, for pumping liquids. The fluid displacement device may also operate as a compressor, for transferring and pressurizing vapors.
According to another aspect, a fluid displacement device is used in a dry cleaning system for washing articles in a wash tank employing a cleaning solution at a hyperatmospheric pressure, for depressurizing the wash tank. Instead of blowing off the contents of the wash tank, the contents are kept in the system, minimizing losses of material. Furthermore, a single device may be used for transferring fluid to the wash tank, and depressurizing the wash tank. Additionally, the use of such a fluid displacement device enables accurate and controlled depressurization of the wash tank. Furthermore, a relatively simple system is provided, since the fluid displacement device may be used in two operating modes.
According to yet another aspect, a fluid displacement device arranged for displacing and compressing fluids is used, in a dry cleaning system for washing articles employing a cleaning solution at a hyperatmospheric pressure. With this, a relatively simple dry cleaning system is obtained, since the fluid displacement device may be used in two operating modes.
The use of the fluid displacement device may comprise compressing the cleaning solution in vapor form. The fluid displacement device may also operate as a compressor, for transferring and pressurizing vapors. With this, the pressure of the vapor may be increased, whilst the pressure in the wash tank may effectively be decreased. The pressure throughout the rest of the dry cleaning system may remain at a constant level. Therefore, the use ensures that a relatively thermodynamic efficient system is obtained. The pressure may be a working pressure. The working pressure may be a constant value in the range of 700-900 psi, e.g. 725 psi or 875 psi. Different values are of course also possible. The fluid displacement device may be arranged for compressing vapor cleaning solution towards the working pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a dry cleaning system employing a fluid displacement device according to the present invention;
FIG. 2 illustrates a fluid displacement device according to the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention now will be described hereinafter with reference to the accompanying drawings, in which a preferred embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein.
Referring to FIG. 1 , a carbon dioxide dry cleaning system is shown. The system comprises a wash tank 2 in which clothes and the like may be brought for washing, using a liquid/gaseous carbon dioxide cleaning solution. Besides the wash tank 2 , the system comprises additional components that may be used to obtain a satisfactory washing result, as will be described next. The wash tank 2 is connected via lines 101 , 102 to a purge tank 3 , from which clean gaseous carbon dioxide may be brought into the wash tank 2 . The wash tank is furthermore connected to an intermediate storage 4 , in which liquid carbon dioxide cleaning solution may be temporarily stored during a washing cycle. The system further comprises a distillation 6 in which liquid carbon dioxide cleaning solution may be brought for cleaning. The cleaned solution may be transferred via lines 110 , 111 , to a central storage tank 5 for storing liquid carbon dioxide cleaning solution. The storage tank 5 is connected to the wash tank 2 , such that clean liquid carbon dioxide may be brought into the wash tank 2 during a washing cycle. The system further comprises a fluid displacement device 1 for transferring the liquid/gaseous carbon dioxide cleaning solution throughout the system and its various components. The fluid displacement device 1 is arranged for both pumping liquid and vapor, and may also be used to compress the liquid and/or vapor, in order to keep the pressure at the pressure side of the fluid displacement device 1 at a desired level, as will be described later. Several valves 20 - 32 may be used to connect the different components to each other, as will be explained in further detail below.
In general, the wash cycle comprises the following steps: 0) Providing carbon dioxide cleaning solution, for instance to a central storage tank 5 ; 1) placing clothes to be cleaned inside the wash tank 2 ; 2) Charging carbon dioxide vapor into wash tank 2 to pressurize it; 3) transferring liquid cleaning solution, comprising liquid carbon dioxide as a solvent, from a general storage vessel (such as central storage tank 5 ) to the wash tank 2 via fluid displacement unit 1 ; 4) washing clothes in wash tank 2 ; 5) draining liquid cleaning solution from wash tank 2 to a general storage vessel; 6) depressurize the wash tank 2 , e.g. by removing carbon dioxide vapor from the wash tank 2 ; and 7) removing clean clothes from wash tank 2 .
Referring to FIG. 1 , the general wash cycle will be described in more detail. At the beginning of the wash cycle, the wash tank 2 is at atmospheric pressure (14.7 psi). All valves 21 - 32 are in a closed position. Clothes to be cleaned may be placed inside the wash tank 2 .
Next, the wash tank is pressurized. This may be done by connecting the central storage tank 5 to the wash tank 2 . In the central storage tank 5 , relatively clean cleaning solution, such as for example liquid and vapor carbon dioxide is stored at a pressure of approximately 725 psi. Higher pressures, such as 875 psi, are of course also possible. The central storage tank 5 is connected to the wash tank through line 104 . Line 104 is provided in the part of the central storage tank 5 where vapor carbon dioxide accumulates. In this line, valve 23 is placed. By opening valve 23 , an open connection between the storage tank 5 and the wash tank 2 is established. As a result, vapor carbon dioxide will transfer to the wash tank 2 , and the pressure in the wash tank 2 will rise to approximately 725 psi. Of course, higher or lower pressures are possible, if the cleaning solution is stored at higher or lower pressures, respectively, inside the central storage tank 5 . Afterwards, valve 23 is closed again.
In the next step, liquid cleaning solution is transferred to the wash tank 2 . In an embodiment, liquid carbon dioxide is obtained from the central storage tank 5 . The central storage tank 5 is connected to the wash tank 2 via lines 112 and 107 , fluid displacement unit 1 , and lines 108 . Line 112 is connected to a part of the wash tank 2 where liquid carbon dioxide accumulates. In line 112 , valve 28 is placed. In line 108 , valve 25 is placed. By opening valves 28 and 25 , liquid carbon dioxide may be transferred through fluid displacement unit 1 to the wash tank 2 . The fluid displacement unit 1 then functions as a pump. Pressure in the wash tank may remain at approximately 725 psi.
The amount of liquid carbon dioxide transferred to the wash tank may be determined by the time the pumping unit 1 is activated. In an embodiment, the contents in the wash tank may be approximately equal to 50% vapor, and 50% liquid carbon dioxide. Other compositions are of course possible. After having transferred a sufficient amount of liquid carbon dioxide, valves 28 and 25 are closed again.
After bringing an amount of vapor and liquid carbon dioxide into the wash tank 2 , the clothes to be cleaned may be washed. Washing may be exerted by continuously pumping cleaning solution, such as liquid carbon dioxide through the system. A bottom part of the wash tank 2 is connected to fluid displacement unit 1 through lines 106 and 107 . Valve 26 is placed in line 106 . As described before, the pump is connected to the wash tank 2 through line 108 , having valve 25 . By opening valves 26 and 28 , and putting into operation pumping unit 1 , liquid carbon dioxide from the wash tank may be re-circulated through the system. The fluid displacement unit 1 then functions as a pump. The clothes to be cleaned may be thoroughly washed this way. After washing, valves 26 and 28 are closed again.
After washing, the liquid carbon dioxide may be drained from the wash tank 2 . In an embodiment, the liquid carbon dioxide is transferred back to the central storage tank 5 . This way, the carbon dioxide may be re-used again. Preferably, the relatively dirty liquid carbon dioxide that is transferred to the central storage tank 5 is cleaned first. This may be done by transferring the liquid carbon dioxide to a cleaning device, such as distillation 6 . The liquid carbon dioxide may be transferred from the vessel, through lines 106 , 107 , to the fluid displacement unit 1 . From there, it may be transferred to distillation 6 , through line 109 having valve 27 . Transfer may be started by using fluid displacement unit 1 , and opening valves 26 and 29 . The fluid displacement unit 1 then functions as a pump. After transfer, valves 26 and 27 may be closed again. The relatively dirty liquid carbon dioxide will be distillated, and vapor carbon dioxide will transfer from the distillation 6 through lines 110 , 111 to the central storage tank 5 . The distillation 6 ensures that a relatively large part of the used carbon dioxide may be re-used again, by transferring distillated carbon dioxide to the central storage tank 5 . The cleaned carbon dioxide may be a vapor. In an embodiment, a cooling unit 8 may be positioned in between the distillation 6 and the central storage tank 5 . The cooling unit 8 ensures that vapor carbon dioxide is cooled down, such that liquid carbon dioxide is obtained, which then may be introduced into the central storage tank 5 . Sludge obtained from the distillation process may be collected in a sludge collector 7 , that is connected to the distillation 6 through line 118 . Sludge may be removed from the system at point 11 , through lines 119 , 120 , in which a valve 32 may be placed.
After having removed the liquid carbon dioxide, the remaining vapor carbon dioxide in the wash tank 2 may be removed. Pressure inside the wash tank 2 may still be relatively high, such as 725 psi. The wash tank 2 may be depressurized, using the fluid displacement unit 1 . Depressurization may be exerted by transferring vapor carbon dioxide from the wash tank 2 . The transfer of the vapor carbon dioxide will depressurize the wash tank 2 . The vapor carbon dioxide may be transferred, for example, to the distillation 6 where the vapor will be cleaned and returned to the central storage tank 5 . Transfer of the vapor carbon dioxide may be exerted by using fluid displacement unit 1 . Preferably, the pressure of the vapor carbon dioxide is maintained at approximately 725 psi, to reduce pressure losses within the system. To this end, the fluid displacement unit 1 may function as a compressor in this step.
Finally, the wash tank 2 may be depressurized completely to atmospheric pressure, by opening valve 22 and blowing off the remaining gas in the vessel. Blowing off remaining gas in the vessel will lead to losses of gas. To prevent losses of gas, the remaining gas might be compressed as well. However, compressing the remaining gas in the vessel is relatively time consuming, making the process less efficient. Hence, an optimum between time efficiency and material losses is present. After depressurizing the wash tank 2 , the clean clothes may be removed. Additionally, a new washing cycle may be started as described before.
The general washing cycle as described before may be expanded with additional steps to improve the washing result, preservation of carbon dioxide, and/or the energy efficiency. These additional steps will be described below.
To improve the washing result, it is possible that several washing steps are performed. For instance, a series of two washing steps may be used. Cleaning solution, such as liquid carbon dioxide may be brought into the wash tank 2 , and clothes may be washed in a first washing step. After washing, the liquid carbon dioxide may be drained from the wash tank 2 . Then, another (second) washing step may be performed, by further bringing carbon dioxide into the wash tank 2 , washing clothes, and draining the liquid carbon dioxide once again. For the second washing step, liquid carbon dioxide may be obtained from the central storage tank 5 .
The liquid carbon dioxide drained from the first washing step is relatively dirty. Therefore, it is preferred to clean this liquid carbon dioxide by transferring it to the distillation 6 , as described before. However, the liquid carbon dioxide drained from the second washing step is relatively clean, and cleaning this liquid carbon dioxide is relatively energy consuming, as well as time consuming. Therefore, the liquid carbon dioxide drained is preferably transferred to an intermediate storage 4 , where it is temporarily stored for alter use. The intermediate storage 4 is connected to pump 1 through line 113 having valve 29 . Valve 26 in the wash tank-pump line 106 , 107 , is opened, together with valve 29 . Fluid displacement unit 1 is put into operation, pumping liquid carbon dioxide from the wash tank 2 to the intermediate storage 4 . The fluid displacement unit 1 then functions as a pump. The liquid carbon dioxide from the intermediate storage 4 may be used in a new washing cycle, when bringing liquid carbon dioxide into the wash tank 2 . Thus, instead of using liquid carbon dioxide from the central storage tank 5 , liquid carbon dioxide obtained from a previous washing cycle and stored in the intermediate storage 4 is used.
Before the step of pressurizing the wash tank 2 with vapor carbon dioxide, the air in the wash tank may be pre-conditioned. Preferably, nitrogen and oxygen are removed from the wash tank 2 in this pre-conditioning step. To this end, a purge tank 3 is connected to the wash tank 2 via lines 101 , 102 and valve 21 . In the purge tank 3 , vapor carbon dioxide vapor is stored. The vapor carbon dioxide in the purge tank 3 has a pressure of approximately 70-230 psi. The pre-conditioning step is initiated by opening valve 21 , and charging carbon dioxide vapor into the wash tank 2 . The pressure in the wash tank 2 will increase to approximately 70-230 psi. Afterwards, valve 21 is closed again. Subsequently, valve 22 is opened after charging the wash tank 2 with vapor carbon dioxide. Air inside the wash tank 2 is blown off via line 103 to the atmosphere 9 . With this, air, and more specifically nitrogen and oxygen are removed from the wash tank 2 . As a result, the pressure in the wash tank 2 may be reduced to, for example, atmospheric pressure (14.7 psi). After depressurizing the wash tank 2 , valve 22 is closed again. This step may be used to prepare the wash tank 2 for a following washing cycle, by (partially) cleaning the inside of the vessel 2 .
After washing, the liquid carbon dioxide and the vapor carbon dioxide need to be drained from the wash tank 2 . As stated before, the liquid carbon dioxide may be transferred from the wash tank to the intermediate storage, using fluid displacement unit 1 . The vapor carbon dioxide remaining in the wash tank 2 , may be removed in two subsequent steps. In the first step, vapor carbon dioxide is transferred from the wash tank 2 to the distillation 6 , using the fluid displacement unit 1 . The fluid displacement unit decreases the pressure inside the wash tank 2 towards atmospheric pressure. Preferably, the pressure in the wash tank 2 is reduced to approximately 115 psi. The fluid displacement unit 1 used in this step may then function as a compressor. The fluid displacement unit 1 is arranged for keeping the pressure of the medium transferred at approximately 725 psi. Hence, the vapor will enter the fluid displacement unit at a relatively low pressure, but will be transferred to the distillation 6 with a relatively high pressure. This ensures that the pressure side of the system remains at a relatively high pressure (i.e. approximately 725 psi), such that pressure losses and energy losses are prevented.
Once the pressure in the wash tank is reduced to approximately 115 psi, it is possible, in a second step, to transfer the remaining vapor carbon dioxide back to the purge tank 3 . To this end, the fluid displacement unit 1 is connected to the purge tank 3 through lines 114 , 115 , and 101 . In line 114 a valve 30 is placed. By opening valve 30 and 26 , the remaining vapor carbon dioxide may be compressed and transferred towards the purge tank 3 , using fluid displacement unit 1 . The fluid displacement unit 1 thus functions as a compressor in this step. In the embodiment shown, a heat exchanger 12 is brought into contact with the wash tank 2 . The heat exchanger is arranged for transferring heat from the medium (i.e. vapor carbon dioxide) passing through lines 114 , 115 , to the wash tank 2 . Due to the compression action of the fluid displacement unit 1 , the compressed vapor carbon dioxide will be heated, and this heat may be transferred to the wash tank 2 , in order to pre-heat the wash tank 2 for a subsequent washing cycle. This step may be performed until the pressure inside the wash tank 2 is equal to approximately 30 psi. Then, all valves may be closed again. The wash tank 2 may be de-pressurized by blowing off air to the atmosphere by opening valve 22 , as described before.
FIG. 2 a shows an embodiment of the fluid displacement device 201 . The fluid displacement device 201 may be a positive-displacement device. The positive-displacement device may be a reciprocating device or a piston device that uses one or more pistons 205 driven by a crankshaft to pressurize fluid. The fluid displacement device 201 comprises an inlet 202 connected to a pumping chamber 208 , in which a piston 205 is reciprocally movable. The pumping chamber 208 also comprises a discharge unit 206 connected to an outlet 204 . The discharge unit may be a spring-loaded valve. The spring 210 exerts a force in the upstream direction, and ensures that the valve 211 is closed. A force in the opposite direction, i.e. the downstream direction, may open the valve 211 , such that the pumping chamber 208 is in open connection with the outlet 204 . The inlet 202 and discharge unit 206 are positioned at opposite ends of the pumping chamber. It is possible, however, to position the inlet and the discharge unit at one end of a cylindrical pumping chamber.
In FIGS. 2 a to 2 c , different stages in a working cycle of the fluid displacement device are shown. The piston 205 is movable between a first position, in which the volume of the pumping chamber 208 is maximal, towards a second position, in which the volume of the pumping chamber 208 is minimal. In FIG. 2 a , the piston is in or near the first position. In FIG. 2 c , the piston is in, or near the second position. Movement from the first position to the second position is called the compression stroke. Movement from the second position to the first position is called the expansion stroke.
As can be seen in FIG. 2 a , the inlet 202 to the pumping chamber 208 is open when the piston is in the first position. Fluid may enter the pumping chamber 208 through the inlet 202 . Referring to FIG. 2 b , the inlet 202 is closed when the piston 205 moves in the compression stroke. Preferably, the inlet is closed right after the compression stroke has started. Further movement of the piston in the compression stroke pushes the fluid towards the discharge unit 206 . The fluid is compressed during the compression stroke, and subsequently pushed through the discharge unit 206 when the pressure inside the pumping chamber 208 exceeds the pre-set pressure of the discharge unit 206 . Since vapor is easily compressible, the fluid displacement device 201 and the discharge unit 206 , such as a spring-loaded valve, may be used to compress the vapor. Thus, the discharge unit 206 ensures that the fluid, such as a gas or a vapor, may be compressed in order to increase the pressure of the fluid. When liquid is transferred by the piston 205 towards the discharge unit 206 , the force exerted by the liquid is large enough to open the discharge unit 206 , and the liquid may transfer to the outlet 204 . Thus the fluid may be easily pumped by the fluid displacement device. After having completed the compression stroke, the piston starts the expansion stroke. BY moving he piston towards the first position, the pressure inside the pumping chamber 208 will decrease. As a result, the discharge unit 206 is closed. The pumping chamber 208 is now completely closed, such that movement of the piston increases the volume, and subsequently lowers the pressure. When the piston reaches the first position, the pressure in the pumping chamber is lower than the pressure of the fluid near the inlet 202 of the fluid displacement device 201 . Hence, the fluid, either gas or liquid, is sucked inside the pumping chamber 208 , after which another compression stroke may take place. Hence, the fluid displacement device is able to function as a pumping/compressing unit, arranged for both pumping and compressing the cleaning solution.
It is possible that additional pumping chambers are provided to the fluid displacement device, each having a respective piston. Additional discharge valves may be provided.
In another embodiment a further valve, in particular a one-way valve is present upstream from the pumping chamber.
In an embodiment the fluid inlet into the pumping chamber 208 is provided in the piston, in particular through the piston axle.
In an embodiment the one way valve upstream from the pumping chamber 208 is provided in the piston.
In the drawings and specification, there have been disclosed typical preferred embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims.
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A dry cleaning system arranged for washing articles employing a cleaning solution. The dry cleaning system includes a wash tank ( 2 ) for washing an article to be washed with a cleaning solution. The wash tank ( 2 ) is arranged for washing the article at an increased pressure compared to atmospheric pressure. The dry cleaning system includes a fluid displacement device ( 1 ), such as a pump, connected to the wash tank ( 2 ) and is arranged for transferring the cleaning solution through the dry cleaning system in a first operational mode. The fluid displacement device is arranged to reduce the pressure in the wash tank towards atmospheric pressure in a second operational mode.
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BACKGROUND OF THE INVENTION
The invention relates to a rail section in the form of a frog comprising two rail sections and guard rails held apart by liners, where at least the frog is passed through by a sleeve surrounding a connecting element such as a bolt.
Frogs are provided at points or crossovers by intersections of rail tracks. There are single, double and triple frogs, although the single frog is most frequently found in simple points.
In the frog, the guiding surfaces of the intersecting rail tracks are interrupted. The rail tracks continuing on from the tongues are angled in the vicinity of the frog and are called guard rails. The two tracks continuing from the ends of the points converge towards the frog tip. The tip can comprise either normal rails (rail frog), specially constructed rails that are then partially welded (partial block frog), or made in one piece (block frog). The latter are used only rarely by the German Railways (DB).
In the case of frogs made flora rails, these latter are frequently welded. This can however result in drawbacks when hard-to-weld materials are to be connected. A further drawback is that extraneous material is present in the abutting surface. Surface decarburizations are also a drawback. Furthermore, the risk of cracking increases.
If the rail parts are not welded to one another, they are held together by connecting elements such as bolts. The drawback here however is that a relative movement between the rail parts takes place.
Various designs of frogs are shown in DE 548 749, DE 23 18 419, DE 81 05 454 U1 or DD 60 326.
SUMMARY OF THE INVENTION
The object underlying the present invention is to develop a frog of the type described at the outset such that rail parts connected to one another without welding cannot move relative to one another at least vertically to the longitudinal axis of the rail section.
The problem is substantially solved in accordance with the invention in that on the one hand in that the frog comprises unwelded rail sections and in that the sleeve passes without play through the rail sections and at least in some areas the liners are passed through free of play by the sleeve. The problem is further solved in that the frog comprises unwelded frog sections, and in that on the one hand said frog sections and on the other hand the liners arranged on both sides thereof holding apart the associated guard rails positively engage with one another by profiling provided in the longitudinal direction of the frog, said profiling comprising a serration formed by teeth extending from surfaces of the frog sections and the liners in contact with one another and being in play-free contact with their tooth flanks.
By the teachings in accordance with the invention, it is ensured by simple means that a relative movement vertical to the longitudinal axis cannot occur between the rail parts to be connected without welding being necessary in this connection area, in particular in the frog area passed through by the connecting element. In consequence, neither problems with surface decarburizations or crack formation nor problems from the presence of extraneous materials occur in the abutting surfaces. Also, the provision of such frog areas is less expensive.
Unwelded in this case means that in the connection area between guard rails and frog, i.e. in the area in which these elements are connected via the liners by means of a connecting element, the frog sections are not welded to one another. This does not however rule out that the tip, on the tongue side, or the normal rails, on the points end side, are welded on.
When the sleeve disposed without play is used, which rules out relative movement in any direction, this sleeve can be pressed or shrunk into the rail parts or liners.
It is thus possible for the frog sections and liners to be heated so that the sleeve can then be inserted. After cooling, the sleeve is pressed in, thereby ensuring the required absence of play.
Alternatively, it is also for example possible to cool the sleeve, so that it can then be inserted into the associated recesses of the frog sections and liners.
It is furthermore possible for the sleeve to be inserted into the frog sections in the cooled state and for heated liners to be shrunk onto the sleeve after their connection free of play.
A further development of a rail section that is inventive per se in the form of a frog area, where the guard rails each have a guard rail head with guide surfaces facing the frog for a wheel passing the frog area, is characterized in that the respective guide surfaces of the guard rails have a curvature matching the curvature of a wheel passing the frog. A constant curvature difference or a continually changing curvature difference--viewed in a plane vertical to the longitudinal direction of the rail parts--can pertain in relation to the respective contact surface between wheel and guide surface.
The bar-like or block-like liners of known form are preferably composed of a block-like inner section extending from the frog and passed through by the sleeve preferably completely without play, of a first wedge-shaped section of trapezoidal cross-section tapering out in the direction of the guard rails, and of a second wedge-shaped section likewise of trapezoidal cross-section underneath the guard rail head and supporting the latter. The first wedge-shaped section can have on the guard rail head side an outer surface that smoothly merges into the guide surface. In particular, the corresponding outer surface of the first wedge-shaped section can have a curvature that has the characteristics of the guide surface.
Further details, advantages and features of the invention are clear not only from the claims and from the features they describe, singly and/or in combination, but also from the following description of a preferred embodiment shown in the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a section through a first embodiment of a frog area,
FIG. 2 shows a section through a second embodiment of a frog area,
FIG. 3 shows a further section through the frog in accordance with the second embodiment according to FIG. 2, and
FIG. 4 shows an enlarged detail of the area indicated in FIG. 3.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a section through a frog area that comprises a frog (16) comprising two rail sections (12) and (14) and guard rails (18) and (20) running along said frog. The rail sections (12) and (14) can be made of filled-section rails.
To hold the guard rails (18) and (20) apart front the frog (16), i.e. from the facing rail sections (12) and (14), liners (22) and (24) of generally known geometry are provided.
The connections between the guard rails (18) and (20) and the liners (22) and (24), and between the liners (22) and (24) and the rail sections (12) and (14) and their connections with one another are without welding, without however any relative movement being possible between them. This is achieved by a connecting element such as a bolt (26) passing through the unit described above in order to achieve a non-positive or partially positive connection, where a sleeve (28), inside which the bolt (26) extends, passes without play through the liners (22) and (24) partially, and through the rail sections (12) and (14) of the frog (16) completely. The bolt is tightened using intermediate pieces (30) and (32) on the outer web faces of the guard rails (18) and (20), thereby ensuring the required non-positive connection between the guard rails (18), the liners (22) and (24), and the frog (16).
As a result of the fact that the sleeve (28) passes without play through the rail sections (12) and (14) and at least in some areas through the liners (22) and (24), a relative movement between the latter and hence in relation to the guard rails (18) and (20) is ruled out. The latter effect is achieved by the liners (22) and (24), that each have an outer wedge-shaped section (34) and (36) respectively of trapezoidal shape, that match the geometry of the fishplate seating--not described in detail--of the associated guard rails (18) and (20) such that any relative movement is ruled out.
The liners (22) and (24) are each composed of a internal block-like section (38) or (40) resting against the outer web face of the rail section (12) or (24) respectively, of an adjacent first wedge-shaped section (46) or (48) extending in the direction of the guard rail heads (42) or (44) respectively, and the second wedge-shaped section (34) or (36) matching the fishplates of the guard rail (18) or (20) and supporting the guard rail head (42) or (44) in a common plane (35) or (37) respectively.
The sleeve (28) runs without play inside the block-like sections (38) and (40).
A particularly noteworthy feature is that the guard rail heads (42) and (44) have guide surfaces (50) and (52) respectively that each have a curvature matching that of the wheels (54) passing through the frog. A constant curvature difference can apply in the contact surface between the guide surface (50) or (52) and the wheel, or a continually changing curvature difference on succeeding sections, each viewed in a plane vertical to the frog's longitudinal axis. The facing outer surfaces (56) and (58) of the inner wedge-shaped sections (46) and (48) of trapezoidal shape extend in matched form over the guide surfaces (50) and (52).
The fact that the guard rail heads (42) and (44) are supported on their undersides by the second wedge-shaped sections (34) and (36) largely over their full width in the common plane (35) and (37) results in a greater support surface compared with the prior art, and thereby in an increase in the stability of the frog area.
The materials used for the rail sections (12) and (14), the liners (22) and (24) and the sleeve (28) should have equal or almost equal expansion coefficients.
FIGS. 2 and 3 show a further embodiment of a frog area in which the frog (60) associated with the guard rails (62) and (64) comprises two rail sections (66) and (68) not welded together and preferably made from filled-section rails.
Liners (70) and (72) are disposed between the guard rails (62) and (64) and the frog (60) in accordance with FIG. 1. The unit thus formed of guard rails (62) and (64), liners (70) and (72) and frog (60) is passed through with play by a bolt (74) that is tightenable from the outside by intermediate pieces (76) and (78) at the outer web surfaces of the guard rails (62) and (64), in order to achieve the required non-positive connection.
To rule out that the parts forming the frog, in particular the rail sections (66) and (68) of the frog (60) can move relative to one another in the direction of the central axis (80), the contacting surfaces of the rail sections (66) and (68), or the surfaces contacting them of the liners (70) and (72), are profiled. This profiling is formed by teeth extending from the contacting surfaces and running in the direction of the frog, only one of such teeth being shown in each surface and numbered (82), (84), (86), (88), (90) and (92). The respective teeth are shaped here such that tooth flanks of engaging teeth are aligned on one another without play, whereas the associated tooth head (81) and tooth foot (83) are kept separate from one another by teeth extending from opposite surfaces (see also enlarged section in FIG. 3).
Furthermore, the flanks, two of whom in contact with one another are numbered (94) and (96) as examples, describe in relation to the central axis (80) an angle α that is preferably between 65° and 75°, in particular 70°.
In this way, the required positive connection is achievable when the bolt (74) is tightened, so that a relative movement in the direction of the central axis (80) is ruled out. Suitable geometries naturally also apply for the teeth (82), (84) or (90), (92) running between the liners (70) or (72) respectively and the frog (60).
With regard to the rail heads of the guard rails (62) and (64) and to the design of the guide surfaces and geometry of the liners (70) and (72) matching them, reference is made to the embodiment in FIG. 1, with no further explanation being necessary.
It should however further be mentioned that the common planes of the liners (70) or (72) and the guard rail head undersides numbered (98) or (100) respectively describe in relation to the central axis (80) an angle β that is also preferably between 65° and 75°, in particular 70°.
It must also be noted that the sleeve in FIGS. 2 and 3 is not an essential element.
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Rail construction including laterally adjacent frog sections with guard rails outwardly spaced to each side thereof by interposed liners. The components are interconnected by a transverse tightened bolt with vertical misalignment precluded by either nesting projections on adjacent abutting faces of the components or by a rigid, preformed sleeve press-fit within the bore receiving the bolt, the sleeve extending through the frog sections and at least partially through the liners.
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FILED OF THE INVENTION
This invention relates to a method and an apparatus for row-wise separation of rectilinear, plastic porous concrete bodies, which are formed by longitudinal and transverse curing of a rectilinear, plastic porous concrete block.
BACKGROUND OF THE INVENTION
A known apparatus (DE 2 502 866 C2), which is actually provided for curing a still plastic porous concrete block, can also be used to separate the cut porous concrete bodies. The known apparatus has a rectangular base frame with a plurality of horizontal laminae arranged parallel alongside each other and which are movable horizontally in the base frame transverse to their longitudinal direction, a plurality of support pedestals extending upwardly from the laminae and arranged in a row, spaced from one another, on the upper side of each lamina, and a drive device engaging at least at the ends of each lamina, by means of which the laminae can be moved and their mutual spacing be altered. In this known apparatus the laminae extend in the transverse direction of the frame and also in the transverse direction of the rectilinear porous concrete block. After the porous concrete block lying on its base surface has been cut in the transverse direction, so that cut gaps are present, the laminae are pushed together by the drive device, so that the cut gaps are closed up. This is done so that the edges shall not break out in the following longitudinal cutting of the porous concrete block when the cutting wires emerge at each cut gap. After the porous concrete block has also been cut in the longitudinal direction, the laminae are again separated in the longitudinal direction of the frame and also in the longitudinal direction of the porous concrete block, so that the porous concrete bodies are now again separated in the transverse direction of the block also and sticking together of the porous concrete bodies in the hardening is prevented. The separation is only used in this known apparatus when the block, as is only possible in this apparatus, is cut lying down and the cut series of porous concrete bodies are separated in the longitudinal direction of the porous concrete block. The separation is thus effected in a direction in which the porous concrete bodies have a width of 250 mm or a multiple thereof, so that they do not fall over in the separation in the longitudinal direction of the porous concrete block. In the transverse direction of the porous concrete block the porous concrete bodies have a spacing from one another which corresponds to the width of the cutting gap of about 0.8 to 1 mm. This space is indeed enough to prevent sticking together. If however the porous concrete bodies are also to be subjected to a drying operation during steam treatment in the autoclave, as is described in EP 0 133 239 B1 or DE 4 135 119 A1, this spacing is too small to be able to carry out the drying within reasonable time.
In the above-described apparatus, which is also provided for the longitudinal and transverse cutting of the porous concrete block, the porous concrete block is cut lying down, i.e. as it is cast. The length of the wires used for the transverse cutting must then be at least as large as the width of the porous concrete block, which usually amounts to about 1.5 m. Such long cutting wires can deflect to the side in the cutting, so that the accuracy of the cut porous concrete bodies suffers. For this reason it has already been proposed in DE-PS 958 639 to turn the porous concrete block through 90° on to its edge after casting and then to divide it up into porous concrete bodies by cutting wires which are parallel to the shortest edge and are guided vertically and horizontally. This does have the advantage that the cutting accuracy is increased but the cut porous concrete bodies lie on top of one another and can thus stick together in the steam hardening, because of their weight. It is therefore proposed in DE-PS 2 108 300 to turn the cut porous concrete block standing on edge back again through 90° on to its large, wide side (base surface) before it is put in the autoclave. Since however in the longitudinal cutting of the block standing on edge the weight thereof closes up the horizontal cut gaps resulting in the longitudinal cutting and the cut porous concrete slabs are pressed tightly together by the weight, there is also the danger that the porous concrete bodies will stick together even after the turning back again. Moreover the porous concrete bodies lie closely against one another in the transverse direction of the porous concrete block even after the turning back again, so that no hardening steam can get to their facing bounding surfaces. This prolongs the hardening operation and it is also not possible to subject the porous concrete bodies to a drying operation within a reasonable time during the treatment in the autoclave, as is described in EP 0 133 239 B1 or DE 4 135 119 A1.
SUMMARY OF THE INVENTION
The invention is therefore based on the object of providing a method and an apparatus for row-wise separation of rectilinear, plastic porous concrete bodies which are formed by longitudinal and transverse cutting of a rectilinear, plastic porous concrete block, of the kind initially referred to, with which the porous concrete bodies which can have any arbitrary thickness can be separated in the transverse direction of the porous concrete block without problem and without danger of tipping over in the transverse direction of the porous concrete block.
In the method for row-wise separation of rectilinear, plastic porous concrete bodies, which are formed by longitudinal and transverse cutting of a rectilinear, plastic porous concrete block, wherein the cut block is so supported for the separation on a plurality of mutually parallel laminae that each row of porous concrete bodies is supported on at least on lamina, and the porous concrete bodies are then separated row-wise by sequential separation of the laminae, the novelty resides in that the porous concrete block is so supported on the laminae on its largest side face (base surface) that its longest side edge runs parallel to the direction of the laminae, in that a clamping force is exerted before the separation from above on the upper ends of all the porous concrete bodies of the row to be separated and independently thereof from above on the upper ends of all the porous concrete bodies of the stationary row in contact with the row to be separated, and in that the clamping force is maintained during the separation and during the displacement of the lamina in the separating direction, a like directed displacing force is exerted synchronously on the upper ends of the porous concrete bodies carried by the separating lamina.
The apparatus for row-wise separation of rectilinear, plastic porous concrete bodies is characterized according to the invention in that the laminae are arranged in the longitudinal direction of the base frame parallel to the longest side of the porous concrete block, in that a longitudinal support is provided a distance above the base frame, extending horizontally and parallel to the laminae and can be moved in the direction of movement of the laminae, in that two horizontal clamp bars are arranged for vertical movement on the longitudinal support, being parallel to one another and to the longitudinal support, which bars can be pressed from above on to the upper ends of the porous concrete bodies of the two adjacent rows respectively which are to be separated from one another, in that one of the two clamp bars is movable on the longitudinal support in its direction of movement by a second drive means, and in that first drive means for the laminae and the second drive means for the clamp bar are synchronized with one another so that, in the separation of a lamina relative to the adjacent stationary lamina, the clamp bar located vertically above the separating lamina is moved in synchronism therewith and the clamp bar located vertically above the stationary lamina remains fixed in position.
It is possible with the method or apparatus according to the invention to separate porous concrete bodies which are formed by cutting a block preferable standing on edge with no problems and without the danger of tipping over in the transverse direction of the porous concrete block. Even if the porous concrete bodies stick together after the porous concrete block is turned back on to its major side surface, the porous concrete bodies cannot fall over in the separation, because separating forces are exerted simultaneously on their upper and lower ends in the separation. Since the invention proceeds from the concept of separating the porous concrete bodies in the transverse direction of the cut porous concrete block, it is also possible so to separate porous concrete bodies with the apparatus according to the invention which can have any thickness from a minimum thickness of about 50 mm in the transverse direction of the block. In order to support porous concrete bodies of different thicknesses, one or more laminae are used, pushed together in groups, depending on the thickness. Since the transverse beams of the hardening grid with which the porous concrete block is transported to the separating apparatus and taken away therefrom run in the direction of displacement of the laminae, the laminae can be moved arbitrarily to match different thicknesses of porous concrete bodies, without this movement being affected by the transverse beams. Because of the fact that the porous concrete block can preferably be cut standing on edge before the separation, this can be effected with relatively short cutting wires, which are only a little longer that the shortest side edge of the porous concrete block, whereby the porous concrete bodies have high accuracy.
Advantageous arrangements are characterized in the dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in more detail with reference to an embodiment shown in the drawings, in which:
FIG. 1 is a front view of the apparatus in the direction I of FIG. 2,
FIG. 2 is a side view of the same in the direction II of FIG. 1,
FIG. 3 is enlarged scale side view, partially in section, of the apparatus
FIG. 4 is a partial front view of a lamina and of its guide,
FIG. 5 is a section on the line V--V of FIG. 4,
FIG. 6 is a partial section on the line VI--VI in FIG. 2 at the end of a lamina,
FIG. 7 is a top plan view of the gantry of the apparatus,
FIG. 8 is a plan view of the base frame with some laminae.
DETAILED DESCRIPTION
The base frame 1 which is substantially rectangular in plan view has a plurality of cross supports 2, 2', each with a guide rail 3, 3'. Details of such guide rails 3 are shown in FIG. 4. The guide rails 3, 3' serve for movable support of a plurality of laminae 4, 4', which extend in the longitudinal direction of the base frame 1. A still plastic, rectilinear, already cut porous concrete block B can be so placed on these laminae 4 such that its longest side, which can be 6 to 7.5 m long, extends in the longitudinal direction of the laminae 4. Each lamina therefore has a length which corresponds to the length of 6 or 7.5 m of the porous concrete block. The width of the porous concrete block can be 1.5 m for example and its height 625 mm. In order that the laminae 4, 4', as is shown in FIGS. 2, 3 and 5, can be moved close together, the rails 3 are associated with the laminae 4. The guide rails 3' are associated with the laminae 4' lying in between two laminae 4. In the region of a running rail 3 each lamina 4 has a small carriage 5, which is mounted on the corresponding running rail 3 by, in total, four rollers 6. Since the carriage 5 has a greater width in the direction of the running rail 3 than the lamina 4, the adjacent lamina 4' if mounted upon the same running rail 3 could not be pushed up tight enough against the lamina 4. Accordingly the separate guide rails 3' are provided for each second lamina 4', on which the laminae 4' are mounted by means of carriages and rollers, which correspond to the carriages 5 and rollers 6 described above.
Each lamina 4, 4' is provided on its upper side with a plurality of upwardly projecting pedestals 7, 7', arranged in each case in a row at distances from one another. These spaces are necessary in order for the transverse beams 8 of a hardening grid 9, shown in broken lines, which serve to transport the porous concrete block B or the porous concrete bodies, to have space between the support pedestals 7 or 7' of a lamina 4, 4'.
Above the base frame 1, at a distance H which is greater than the maximum height of the porous concrete bodies K there is arranged a horizontal longitudinal support 10, which is a movement support means and which runs parallel to the laminae 4, 4'. This longitudinal support 10 advantageously forms a gantry 12 with standard means, which are standards 11, at the ends of the longitudinal support 10, the gantry being movable in the direction of displacement V of the laminae 4, 4'. To this end, running rails 13 are arranged at the two cross sides of the base frame 1. The two standards 11 are mounted for horizontal movement on these running rails 13 by means of carriage means which are carriages 14.
According to FIG. 6, a first drive means, which includes a coupling device 15, is provided on the carriage 14 and has a coupling bolt 17 which is vertically movable by means of a compressed air cylinder 16. Each lamina 4, 4' is provided at one of its ends with a coupling piece 18, which has a downwardly open recess 19. This recess 19 can be formed as a slot running in the longitudinal direction of the lamina but has a dimension in the direction V of displacement of the laminae which corresponds to the diameter of the coupling bolt 17. Since the smallest thickness of the porous concrete bodies K to be separated from one another amounts to 50 mm, the width b of each individual lamina 4, 4' must be less than 50 mm. If the coupling devices 15 for the horizontal displacement of the laminae 4, 4' only engaged the ends thereof, then the laminae which are more than 6 m long and relatively thin would also bow in the horizontal direction. In order that this shall not occur there are two further coupling devices 15 between the ends of the laminae 4, 4', corresponding to the above described coupling devices 15. Each of these further coupling devices 15 is arranged on a slide 20 which is itself movably mounted on a guide rail 21. The two guide rails 21 extend parallel to the running rails 13. The slides can be driven synchronously with the carriages 14 of the gantry 12. This can advantageously be effected by a common drive motor 22 arranged on the base frame 1, which drives endless toothed belts 24 (see FIG. 6), which are connected to the respective carriage 14 or slide 20 and run parallel to the respective running rails 13 and guide rails 21, through drive shafts 23 arranged parallel to the laminae 4, 4'. Instead of endless toothed belts, endless chains or a spindle drive could also be used.
Important components of the apparatus are two mutually parallel clamp bars 26, 27 which run horizontally and parallel to the laminae 4, 4' and are movable vertically in the direction C. These clamp bars 26, 27 are mounted on the longitudinal support 10. Each of the clamp bars 26, 27 can be constructed in one piece over the length of the longitudinal support 10 or consists of several sections. The clamp bar 26 is connected to a plurality of vertical guide rods 28 which are mounted for vertical sliding directly in the longitudinal support 10, for example through suitable guide bushings 29. A second drive means including support beam 30 is mounted in the longitudinal support 10 so as to be movable horizontally in the direction of movement of the gantry 12, i.e. also in the direction V of displacement of the laminae. A drive motor 31 is provided for moving the support beam 30 in the longitudinal support 10 and drives three slides 33 through horizontal drive shafts 32 and endless toothed belts, not shown. The support beam 30 is mounted for movement by the slides in the longitudinal support 10 in the direction D. The drive motor 31 of the support beam 30 is also coupled to the drive motor 22 of the carriages 14 and the slides 20 so that the movement of the gantry in the direction V and the movement of the support beam 30 in the direction D are synchronised with one another but, but move opposite directions. The movements of the gantry 12 and the support beam 30 thus take place at the same time and through equal displacements, but in opposite directions.
The vertical guide rods 35 are connected to the second clamp bar 27 and are mounted for vertical movement on the support beam 30. A plurality of pneumatic cylinders 36, 37 serve to drive the clamp bars 26, 27 respectively.
The manner of operation of the novel apparatus is as follows:
An approximately rectilinear porous concrete block is first cast in a rectangular casting mould, not shown, the horizontal mould bottom forming the largest surface (base surface) of the porous concrete block. After the porous concrete mass has attained the so-called green strength, the sidewalls of the mould are removed and the block is taken to a cutting machine. In this cutting machine the block is first turned through 90° so that it stands on its longer narrow side and the previously horizontal base surface is arranged vertical. In this position the porous concrete block is firstly cut by horizontally tensioned wires, which are pulled horizontally through the block in the longitudinal direction, and then in the transverse direction by horizontal wires which are moved from below upwardly. Depending on the spacing and number of these cutting wires, there thus result rectilinear porous concrete bodies of greater or smaller size, which are called porous concrete bricks, blocks or slabs, depending on their format. Since the weight of the porous concrete mass above the current cutting gap presses down when cutting in a horizontal direction, the cut gap closes up again after the cutting wire passes. In contrast, the cutting gaps which result in the transverse cutting remain and their width corresponds substantially to the diameter of the cutting wires, which can lie between 0.3 and 0.9 mm. The porous concrete block thus cut in the longitudinal and transverse directions is turned back again through 90°, so that it comes to lie with it base surface, which was vertical during cutting, positioned horizontally again on a hardening grid 9. The hardening grid with the cut block lying thereon can be transported by means of a crane to the apparatus according to the invention.
Since the apparatus for separating porous concrete bodies is intended for entirely different thicknesses of separate concrete bodies measuring between 50 mm and 375 mm, the apparatus must first be matched to the cut thickness of the porous concrete bodies. It is assumed that the 1450 mm wide porous concrete block has been cut into rectilinear porous concrete bodies by cutting in the longitudinal direction, where the two outermost porous concrete bodies K have a thickness d of 100 mm while the intervening porous concrete bodies K' have thickness d' of 50 mm each. In the longitudinal direction of the porous concrete block B, the porous concrete bodies K can be cut on the grid with a width of 250 mm each, where the width B1 in the longitudinal direction can also correspond to a multiple of the grid measurement of 250 mm. The height of the porous concrete bodies K, K' amounts uniformly to 625 mm. When the finished porous concrete bodies are later marketed, sold and used, it is possible that the designations of the various dimensions of the porous concrete bodies will be interchanged, because the longest dimension is usually called the length.
The width b of the support faces 7a of the support pedestals 7, 7' corresponds in the direction V of movement of the laminae 4, 4' to about the smallest thickness d' of 50 mm of the porous concrete bodies. Actually the width b is less than 50 mm, because account has to be taken of the fact that porous concrete residues and other impurities stick on the facing vertical surfaces of the support pedestals, so that the laminae can no longer be pushed together tightly enough. For this reason the coupling pieces 18 are so formed that they also serve at the same time as spacers and, when the laminae 4, 4' are pushed together, so support these relative to one another that the laminae are arranged with an accurate pitch of 50 mm relative to one another. For the sake of simplicity however, it is assumed in the following that the width b of the support faces 7a corresponds to the pitch of 50 min. In order to receive a cut porous concrete block B with a total width of 1450 mm 29 laminae are thus required. The total pack of laminae 4, 4' is normally "parked" at one long side of the frame 1. The movements of the gantry 12 are controlled by a suitable automatic programmed control. When 29 laminae are required, the gantry is moved to the 29th lamina and this is then coupled to the carriage 14 and the slides 20 by the four coupling devices 15 on the carriages 15 and the slides 20, in that the coupling bolts 17 are pushed up into the recesses 19 by means of the pneumatic cylinders 16. The carriages 14 and slides 20 and the lamina No. 29 coupled thereto are pushed away from the rest of the parked laminae by the drive motor 22, until sufficient space is made for the lifting device 40 shown in broken lines in FIG. 2 and the hardening grid 9.
The coupling devices 15 are then uncoupled and the gantry 12 is moved back in correspondence with FIG. 2 to its right, starting position. The hardening grid 9 with the cut porous concrete block thereon can be set down on the laminae 4, 4' by means of the lifting device 40. The porous concrete bodies K, K' come into abutment with the support pedestals 7, 7', the outer, 100 mm thick porous concrete bodies K each resting on two adjacent support pedestals 7, 7', while each only 50 mm thick porous concrete body K' is supported on the halves of two adjacent support pedestals 7 of a lamina 4 or two adjacent support pedestals 7' of a lamina 4', as is apparent from FIGS. 1 and 4. The hardening grid 9 is lowered until the surfaces of its transverse beams 8 lie below the support faces 7a but the transverse beams 8 do not bear on the laminae 4, 4'. The plungers 41 serve to support the hardening grid 9 in this position, being moved up into a suitable position.
The separation can now begin. The gantry 12 is moved for this purpose in the direction V so far to the left (as illustrated in FIG. 2) that the coupling bolts 17 are located under the second lamina from the left. The lamina No. 2 is then coupled to the carriages 14 and the slides 20 by the coupling bolts 17. In this position of the gantry 12, the clamp bar 26 carded directly by the gantry is vertically above the lamina No. 2 and the clamp bar 27 carded by the support beam 30 is vertically over the lamina No. 3 (FIG. 3). By means of the pneumatic cylinders 36, 37 the clamp bars 26, 27 are moved down in the direction C until they bear with sufficient pressure on the upwardly directed ends of the porous concrete bodies K and K' respectively. All porous concrete bodies K, which lie next to each other in the transverse direction of the porous concrete block B, are thus clamped by the clamp bar 26 with the lamina No. 2 lying thereunder, while the porous concrete bodies K' of the neighbouring row bearing thereagainst are clamped by the clamp bar 27 and the lamina No. 3 lying thereunder. When the gantry 12 is now moved to the left, according to FIG. 3, the coupled lamina No. 2 is hereby displaced to the left and pushes the lamina No. 1, on whose support pedestals the first row of porous concrete bodies of the larger thickness d is likewise supported. Since the porous concrete bodies K' are clamped by the pressure of the clamp bar 27 and the clamp bar 26 also moves to the left with the longitudinal support 10 of the gantry 12, the clamp bar 26 is pushed synchronously to the left with the two laminae Nos. 1 and 2. The support beam 30 is however driven at the same speed but in the opposite direction by the drive motor 31, so that it moves relative to the gantry 12 to the right. Since however the speed of the support beam 30 is the same as the speed of travel of the gantry, the support beam 30 and thus the other clamp bar 27 stays fixed in position. The lamina No. 3 lying thereunder also remains fixed in position on account of frictional forces. The row of porous concrete bodies K' clamped between the clamp bar 27 and the lamina No. 3 is held positionally fixed. This ensures that none of the porous concrete bodies K and K' previously adhering to each other fall over during the separation. If the gap which results between two adjoining rows of porous concrete bodies after their separation should amount to 2 mm, the lamina No. 2 is moved to the left by the desired gap width times the number of gaps to be produced by separation, in this case 2 mm times 26 or even a little more.
After this has taken place the coupling devices 15 are uncoupled and the clamp bars 26, 27 are raised. The gantry 12 is driven back to the right until the coupling bolts 17 are located beneath the lamina No. 3. At the same time the support beam 30 is moved to the left relative to the longitudinal support 10 into its starting position. The clamp bar 26 is then located above the lamina No. 3 and the clamp bar 27 over the lamina No. 4. Lamina No. 3 is coupled to the gantry in the way described above and the two clamp bars 26 and 27 are pressed on to porous concrete bodies K' supported by the laminae Nos. 3 and 4 respectively. After the next two rows have been clamped in this way the separating operation is repeated. The path of travel of the gantry 12 is shortened by 2 mm this time relative to the path of travel previously covered, so that a gap of 2 mm now remains between the first separated row of porous concrete bodies K and the second row of porous concrete bodies K' located on the lamina No. 3. After all porous concrete bodies have been separated row-wise from one another in this way, the gantry 12 travels back to its fight starting position in accordance with FIG. 2 and the hardening grid 9 can now be raised again by means of the lift device 40, the porous concrete bodies now separated from one another thus being raised from the support pedestals 7, 7'. The hardening grid is then moved in known manner to an autoclave, where the porous concrete bodies remain on the hardening grid and are steam hardened.
Depending of the thickness of the porous concrete bodies, which can amount to between 50 and 375 mm, the support of a porous concrete block uses more or less laminae lying alongside each other. With the novel apparatus porous concrete bodies can also be separated whose thickness is not a whole multiple of 50 mm. Assuming that the thickness of the porous concrete bodies to be separated from one another amounts to 225 mm, a group of four laminae 4, 4' lying alongside each other is used to support such porous concrete bodies. If the laminae are brought by the gantry from the parked position into their working position at the beginning of each operation, this can be so effected that the required number of laminae 4, 4' are first pushed away from the parked laminae as a pack and that the laminae are brought in groups, similarly as in the separation, to a spacing such that between the groups of four laminae there is a space of 25 mm. After the groups of laminae have been positioned in this manner, the porous concrete block is set on the laminae and the separation is effected in the manner previously described, the last lamina of each group being coupled to the gantry each time before the separation.
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In this method for row-wise separation of rectilinear, plastic porous concrete bodies formed by longitudinal and transverse cutting of a rectilinear plastic porous concrete block preferably standing on edge. After turning back through 90°, the cut block is so placed with its major side surface on a plurality of parallel laminae for the separation and so that its longest side edge runs parallel to the direction of the laminae and that each row of porous concrete bodies is supported on at least one lamina. Before the separation, a clamping force is exerted from above on the upper ends of all the porous concrete bodies of the row to be separated. Independently thereof, a clamping force from above is exerted on the upper ends of all the porous concrete bodies of the stationary row in contact with the row to be separated. This clamping force is maintained during the separation and during the displacement of the lamina in the separating direction, a like directed displacing force is exerted synchronously on the upper ends of the porous concrete bodies carried by the separating lamina.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a rotary hook (in execution with bobbin case) for a lockstitch sewing machine (with one needle thread and one bobbin thread), both for home and industrial use, which comprises means to reduce the noise thereof caused by the plays between the bobbin case and the basket of the hook.
[0002] The invention relates further to a lockstitch sewing machine comprising such a rotary hook comprising means to reduce its noise caused by the plays between bobbin case and basket of the hook.
[0003] The rotary hook can be of the type with a horizontal axis of rotation or of the type with a vertical axis of rotation.
DESCRIPTION OF THE RELATED ART
[0004] Lockstitch sewing machines and the associated rotary hooks are well known and therefore will not be described herein, where it will be merely recalled that the rotary hook, in execution with bobbin case, comprises at least one hook body, which is connected to a shaft from which it receives motion and which comprises a cylindrical cavity of the hook body, a basket free to rotate inside the cylindrical cavity of the hook body and which in turn comprises a well of the basket, a gib which helps to constrain the basket to the hook body and a bobbin case which is placed inside the well of the basket and that helps to constrain the bobbin to the basket.
[0005] The shaft can be integral with the hook body, or housed in a hole present in the center of the cylindrical cavity of the hook body.
[0006] The bobbin case, containing the bobbin with the bobbin thread, is mounted and removed by the sewing machine operator at each change of the bobbin, through an axial translation, where the external diameter of the bobbin case is inserted with radial play inside the inner diameter of the well of the basket and the post of the basket, if present, is inserted with radial play into the center hole of the shaft of the bobbin case (in fact there are some embodiments in which the bobbin case and the basket do not have the central shaft and the post respectively in order to allow the use of bobbins without center hole).
[0007] The angular reference for the correct mounting of the bobbin case in the basket is given by the coupling with angular play between a projection on the inner diameter of the well of the basket and a guide, parallel to the axis of the hook, provided on the external diameter of the bobbin case. The axial constraint of the bobbin case on the basket, to prevent accidental disassembly during sewing, is secured by the latch slide of the bobbin case, which engages on the basket with an axial play. The linkage created by the latch lever on the latch slide allows the operator to release the latch slide, and then the bobbin case, from the axial constraint on the basket, in order to remove the bobbin case.
[0008] The basket is constrained to the hook body by a rib, formed on the outer surface thereof, which engages in a race, formed in the inner wall of the cylindrical cavity of the hook body, which prevents the axial and radial translation of the basket with respect to the hook body, but not the rotation thereof.
[0009] The race of the hook body and the rib of the basket must be interrupted for a certain angular sector to allow the needle thread to pass and the stitch to be formed: these interruptions prevent the use of bearings, making necessary a coupling of the sliding type (that is with a sliding friction) between the race of the hook body and the rib of the basket, originating also, during the rotation of the hook body, a source of noise due to the play existing between the rib of the basket and the race of the hook body and to the fact that habitually they are made of metal materials.
[0010] Said source of noise, well known, and possible means to reduce it have been already subject of studies (see for example Italian patent no. 1.392.162; EPO no. 09176587.5).
[0011] U.S. Pat. No. 5,351,636 Patent deals with the problem of reducing the coefficient of friction between the basket and the hook body without taking absolutely into consideration the problem of the noise generated by the hook. In addition the play between the bobbin case and the basket are not even taken into consideration, as it does not contribute to the friction between the basket and the body hook. For this reason the noise generated by the play between the bobbin case and the basket is not considered nor affected by said patent.
[0012] The Italian patent 1.392.162 (or EPO 09176587.5 or U.S. Pat. No. 8,342,110) describes a rotary hook comprising means to reduce the noise caused by the plays between the basket and the hook body. This object is achieved by means apt to apply on the basket an axial stress that forces the rib of the basket to lean on one of the two flat surfaces of the race present in the circular cavity of the hook body, instead of vibrating freely in said race due to the always present play between said rib and said race. This axial stress has the effect of stabilizing the basket, preventing the vibration and the resonance. This patent, however, does not concern in any way the noise generated by the plays between the bobbin case and the basket of the hook.
[0013] U.S. Pat. No. 7,171,914 (or EP 1640490) Patent describes a hook with a vertical axis in which the basket and the hook body are made of synthetic material (synthetic resins) and the basket is constrained to the hook body by magnetic means inserted in the bottom wall of the basket and on the bottom of the cylindrical cavity of the hook body, allowing the structure of the hook to be simplified (for example, the gib and C-shaped race formed in the inner wall of the cylindrical cavity of the hook body are not provided) and the production costs thereof to be reduced. The magnets described thus serve to constrain to the hook body a basket made of synthetic material, which otherwise would be free to fluctuate, due to the simplification of the hook's structure (“L” shaped race instead of the “C” shaped race and the consequent absence of the gib). This invention does not deal with the problem of the noise issue between basket (inner rotary hook) and bobbin case as in this execution of rotary hook, the bobbin case is not present and the bobbin is housed directly inside the basket.
[0014] U.S. Pat. No. 4,429,649 Patent discloses a hook for home sewing machines where the basket (called “bobbin case holder”) is constrained by a rib, provided on the outer surface of the basket, which engages in a “L” shaped race, provided in the inner wall of the cylindrical cavity of the hook body and delimited by only one plane surface and by a cylindrical surface perpendicular to the plane one, suitable to prevent merely the radial translation of the basket in the cylindrical cavity. Said basket is free to fluctuate in axial direction and a magnet positioned at the bottom of the cylindrical cavity of the hook body provides to adjust the tension of the lower thread. Also this patent, as the previously cited U.S. Pat. No. 7,171,914, refers to a rotary hook in execution without bobbin case.
SUMMARY OF THE INVENTION
[0015] The present invention relates to another source of noise, which is here discovered, mentioned and treated for the first time and the means to reduce the noise generated thereof. This further source of noise is due to the plays (radial, angular and axial) present between the bobbin case and the basket of the hook and to their usual constitution in metallic materials. Such plays, necessary for mounting and removing the bobbin case at each bobbin change, enable, however, also the bobbin case, once mounted, to move itself slightly inside the basket during the rotation of the hook body, such causing an additional noise. Both these noises are enhanced by vibration and resonance phenomena and are worsened by the passage of the needle thread during sewing, which pulls and tends to move the basket from its natural position. In fact such noises are considerably reduced during idling (running without thread) of the sewing machine.
[0016] The present invention deals exclusively with the means to reduce the noise caused by this second source of noise, identified and described for the first time in the present text, namely that due to the plays existing between the bobbin case and the basket of the hook. Merit of the present invention is, therefore, to have identified and separated conceptually this source of noise from other noise sources present in the hook and in the sewing machine, even before having found ways to reduce the noise generated by this source.
[0017] At the current state of the art it is not possible to eliminate such pays that allow easy mounting of the bobbin case in the basket and the causes of noise cannot be eliminated by adopting appropriate geometric shapes and/or imposing more stringent dimensional tolerances, which would increase anyway the manufacturing cost of the rotary hook.
[0018] Purpose of the present invention is therefore to provide a rotary hook comprising means suitable to reduce the noise caused by the plays between the bobbin case and the basket, within the negligible noise limits compared to the noise of the sewing machine
[0019] This purpose has been achieved by means of the rotary hook object of the independent claim 1 .
[0020] Further advantageous features are the subject of the dependent claims . . .
[0021] Substantially, the rotary hook according to the invention comprises at least one means, integral with the basket or integral with the bobbin case, that creates a sufficient friction between the bobbin case and the basket to prevent the bobbin case to move and to vibrate freely within the plays always present between said bobbin case and said basket, when mounted, but allowing an easy mounting/removing of the bobbin case, respectively with a slight additional axial pressure/traction compared to the normal mounting/removing operation (pressure to be obviously exercised after having disengaged the slide, as done with the rotary hooks of the prior art).
[0022] This friction, in a preferred embodiment, is exerted by an elastic means, which is deformed during the mounting of the bobbin case and has the effect of stabilizing the bobbin case, preventing its movement, vibration and resonance. To achieve this effect, the elastic means at rest (i.e. with the bobbin case removed) should occupy a volume such as to create a coupling with interference between the bobbin case and the basket. The mounting of the bobbin case deforms the elastic means just to obtain a correct coupling. Moreover, the presence of the elastic means, irrespective of its deformation, also creates an effect of shock absorber, absorbing the vibrations and reducing the residual noise.
[0023] For each embodiment is it preferable to have the means that create the friction, on the larger diameters (i.e. on the outer diameter of the bobbin case or the inner diameter of well of the basket, rather than on the diameter of the post of the basket or the diameter of the hole in the shaft of the bobbin case), as not only the friction force is important, but also the torque resulting therefrom and which is determined by said force and the arm between the axis of the bobbin case and the point of application of said force. Because of the moment of inertia of the bobbin case containing the bobbin full of thread, and the fact that the bobbin case is linked with play on the post of the basket and/or on inner diameter of the well of the basket, which acts as a pivot, the bobbin case also tends to rotate and vibrate around its own axis, besides having axial and radial movements. For this, a friction force applied near the axis of the bobbin case, even if it may be adequate to eliminate axial movements of the bobbin case, allowing always an easy mounting/removing of the bobbin case, is not suited to create instead a sufficient torque to prevent the movements and vibrations of the bobbin case around its axis; therefore it would improve only very partially the problem of the noise.
[0024] An advantage of the rotary hook object of the present invention consists in the fact that it can be applied to all existing sewing machines without having to modify their stitching members and without requiring any modification to a sewing machine available on the market.
[0025] Furthermore, a rotary hook made according to the invention is completely interchangeable with a rotary hook of the prior art, does not require any modification of the areas destined for the passage of the thread and in itself contains all the constructional features necessary to implement the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The invention will now be described with reference to some embodiments, which are examples, but not limits thereof, which are described in the appended figures, where:
[0027] FIG. 1 shows schematically an exploded view of a rotary hook complete with bobbin case, of the prior art;
[0028] FIG. 2 shows schematically the rotary hook of FIG. 1 assembled and sectioned with a plane passing through its axis of rotation;
[0029] FIGS. 3-7 show schematically different embodiments of the basket of a rotary hook according to the invention, in which elastic means are provided which, when deformed by the mounting of the bobbin case, create a friction on the bobbin case to reduce the noise caused by the plays between the bobbin case and the basket;
[0030] FIG. 8 shows schematically the bobbin case and the basket of the rotary hook of FIG. 1 , of the prior art, disassembled and sectioned with a plane passing through the axis of rotation of the hook;
[0031] FIG. 9 shows schematically another embodiment of the bobbin case and the basket of the rotary hook of FIG. 1 for bobbins without central hole, of the prior art, disassembled and sectioned with a plane passing through the axis of rotation of the hook;
[0032] FIG. 10 shows schematically a different embodiment of the bobbin cases of FIGS. 8 and 9 according to the invention, wherein there is provided a chamfer to facilitate the deformation of the elastic means during the mounting of the bobbin case in the basket, when this means is in correspondence with the inner diameter of the well of the basket;
[0033] FIG. 11 shows schematically a different embodiment of the bobbin case capsule of FIG. 8 according to the invention, wherein there is provided a chamfer to facilitate the deformation of the elastic means during the mounting of the bobbin case in the basket, when this means is in correspondence with the post of the basket;
[0034] FIG. 12 shows schematically a different embodiment of the bobbin case of FIGS. 8 and 9 according to the invention, wherein there is provided a chamfer to facilitate the deformation of the elastic means during the mounting of the bobbin case in the basket, when this means is constituted by the projection on the inner diameter of the well of the basket, which cooperates with the guide, parallel to the axis of the hook, formed on the outer diameter of the bobbin case, for the correct angular reference for the mounting of the bobbin case in the basket;
[0035] FIG. 13 a )- e ) shows in top view some possible embodiments of the elastic means represented in section in FIG. 3 ;
[0036] The pairs of FIGS. 14-15 , 16 - 17 and 18 - 19 respectively show in section and in side view various other embodiments of the bobbin case and the basket of a rotary hook according to the invention, in which are used elastic means that, when deformed during the mounting process of the bobbin case, create a friction on the bobbin case to reduce the noise caused by the plays between the bobbin case and the basket; In particular: FIGS. 14 a , 16 a , 18 a are sectional views of the basket with bobbin case; FIGS. 14 b , 16 b , 18 b are enlargements of details enclosed in a circle in the respective previous Figures, and FIGS. 15 , 17 , 19 are side views of the bobbin case alone taken in the direction of the arrows B, C, D in FIGS. 14 a , 16 a , 18 a respectively.
DETAILED DESCRIPTION OF THE INVENTION
[0037] In the appended figures, corresponding elements will be identified by the same numeral references.
[0038] FIG. 1 shows schematically an exploded view of a rotary hook 1 with a horizontal axis “α” of rotation, of the prior art in which only the elements relevant to the present description have been identified by numeral references:
a hook body 2 , comprising a cylindrical cavity 11 which, in the example shown, has a central hole 17 ( FIG. 2 ) suitable to receive a shaft (omitted for the sake of simplicity of the graphic representation) from which the hook 1 receives motion; in a different embodiment (of which the graphical representation is omitted), the shaft is integral with the hook 1 ; a basket 6 , free to rotate within the cylindrical cavity 11 to which it is constrained by a rib 14 , formed on the outer surface of the basket 6 and comprising: a well 18 of the basket 6 in which is housed the bobbin case 8 complete with bobbin 4 , an inner diameter 19 delimiting said well 18 of the basket 6 in which fits the external diameter 20 of the bobbin case 8 , a projection 21 on the inner diameter 19 of said well 18 of the basket 6 , that coupling with the guide 22 (in the figures are indicated with 22 the edges of said guide) on the outer diameter 20 of the bobbin case 8 allows the angular reference of the bobbin case for the correct mounting of the bobbin case 8 in the basket 6 , a possible post 23 into which the hole 24 of the shaft 25 ( FIG. 2 ) of the bobbin case 8 is inserted; a race 10 , formed in the inside wall of the cylindrical cavity 11 of the hook body 2 and delimited by two plane surfaces parallel with each other and by a cylindrical surface perpendicular to the plane ones, in which the rib 14 of the basket 6 engages to prevent the axial and radial translation of the basket 6 in the cylindrical cavity 11 , but leaving it free to rotate; a bobbin case 8 housed in the well 18 of the basket 6 , complete with latch slide 15 for the axial constraint of the bobbin case 8 on the basket 6 to prevent accidental disassembly during sewing, latch lever 16 that with the leverage created on latch slide 15 allows the operator to release the latch slide 15 , and herewith the bobbin case 8 , from its axial constraint on the basket 6 , allowing the removal of the bobbin case 8 , and with a tension spring 9 to give tension to the bobbin thread (of which the graphical representation is omitted) wound on the bobbin 4 housed inside the bobbin case 8 . There is present also the guide 22 on the outer diameter 20 of the bobbin case 8 and parallel to the axis “α”, which coupling with the projection 21 on the inner diameter 19 of the well 18 of the basket 6 allows the angular reference for the correct mounting of the bobbin case 8 in the basket 6 . The mounting of the bobbin case 8 in the basket 6 occurs trough a free translation along the axis “α” of the bobbin case 8 , at a coupling with play and after that guide 22 on the outer diameter 20 of the bobbin case 8 and parallel to the axis “α”, has been rotated until the angular correspondence with the projection 21 on the inner diameter 19 of the well 18 of the basket 6 ; accidental disassembly is prevented by the axial constraint created by the latch slide 15 that engages on the basket 6 ; a bobbin 4 , on which is wound the bobbin thread (not shown), is housed in the bobbin case 8 and is constrained inside the basket 6 by the mounting of the bobbin case 8 in the basket 6 .
[0044] FIG. 2 shows schematically the rotary hook 1 of FIG. 1 , of the prior art, assembled and sectioned through a plane passing through its axis of rotation “α”; visible in FIG. 2 are the hook body 2 comprising the cylindrical cavity 11 , the rib 14 of the basket 6 , the race 10 of the hook body in which the rib 14 of the basket 6 is engaged, and the central hole 17 of the cylindrical cavity 11 able to accommodate a shaft (omitted for the sake of simplicity of the graphic representation) from which the hook 1 receives motion; in a different embodiment, (not shown), on the other hand, the shaft can be also integral with the hook 1 , further are also shown the bobbin case 8 and the bobbin 4 . The same section used for FIG. 2 , is also used for the other Figures, with the exception of FIGS. 7 , 16 and 18 , which are perpendicular and are made according to the section line A-A of FIG. 2 . Finally, FIG. 15 is made on a section which in horizontal plan is slightly counter-clockwise rotated with respect to the section A-A, to show the elastic means in correspondence with the inner diameter 19 of the well 18 of the basket 6 , where said diameter 19 is developed for its entire height, up to the top edge of the basket.
[0045] The rotary hook 1 object of the present invention comprises means suitable to create a friction between the bobbin case 8 and the basket 6 , such as to annul the plays between bobbin case 8 and basket 6 , preventing the consequent vibration and noisiness.
[0046] In a preferred embodiment of a rotary hook 1 according to the invention, schematically described in FIGS. 3-7 and 13 , the means able to create such friction comprise at least one elastic means integral with the basket 6 of the hook 1 , which can:
[0047] A) Be constituted by an annular elastic means 30 (in its most simple embodiment it is an O-ring) housed in a circular groove 31 formed in the inner diameter 19 of the well 18 of the basket 6 ( FIG. 3 ), which is deformed while mounting the bobbin case 8 by the outer diameter 20 of said bobbin case 8 . That elastic means 30 may have different shapes and be made from different materials. Such variations fall within the modifications of detail within the reach of competence of a person skilled in the art, without departing from the scope of the invention itself. By way of non-limiting example, some examples of realization of said elastic means are depicted in top view ( FIG. 13 ), where the first ( 30 a ) can also be constituted by a well-known O-ring made of rubber, while the followings ( 30 b, 30 c, 30 d, 30 e ) are possible alternative configurations of an elastic metal wire (preferably made of spring steel). Through appropriate form of said elastic means is also possible to realize protrusions ( 32 ) towards the outside , which, matching with appropriate niches on the diameter of the circular groove 31 on the inner diameter 19 of the well 18 of the basket 6 , are constraining angularly said elastic means and prevent it from rotating inside said circular groove 31 .
[0048] B) Be constituted by an annular elastic means 40 (in its most simple embodiment it is an O-ring) housed in a circular groove 41 formed in the post of the basket ( FIG. 4 ) which is deformed while mounting the bobbin case 8 by the inner diameter of the hole 24 of the shaft 25 of said bobbin case 8 .
[0049] C) Be constituted by two or more annular elastic means 50 (in the simplest realization they are O-rings) housed in respective circular grooves 52 formed in the post 23 of the basket 6 ( FIG. 5 ) which are deformed while mounting the bobbin case 8 by the inner diameter of the hole 24 of the shaft 25 of said bobbin case 8 .
[0050] D) Be constituted by one or more means 60 , 61 of material that is elastic to compression and fixed (for example, stuck or glued or affixed as coating) on the inner diameter 19 of the well 18 of the basket 6 , which are deformed while mounting the bobbin case 8 by the outer diameter 20 of said bobbin case. In FIG. 6 are represented, by way of example, but not limiting, respectively two cylindrical means 60 embedded in respective seats formed on the inner diameter 19 of the well 18 of the basket 6 and two means of elastic material of rectangular shape 61 glued on the inner diameter 19 of the well 18 of the basket 6 .
[0051] E) Be constituted by one or more means 70 of material that is elastic to compression and which go to constitute a projection 21 on the inner diameter 19 of the well 18 of the basket 6 for the angular coupling with the guide 22 on the outer diameter 20 of the bobbin case 8 , which are deformed while mounting the bobbin case 8 by the edges of said guide 22 on the outer diameter 20 of the bobbin case 8 . FIG. 7 represents a section A-A (see FIG. 2 ) perpendicular to that used for all other FIGS. 2-6 and 8 - 13 .
[0052] In another preferred embodiment of a rotary hook 1 according to the invention, the means for creating such friction comprise at least one elastic means integral with the bobbin case 8 of the hook 1 . Said at least one elastic means integral with the bobbin case 8 can be constituted by one or more means 60 of material that is elastic to compression and fixed (for example, stuck or glued or affixed as coating) on the outer diameter 20 of the bobbin case 8 , which are deformed while mounting the basket 6 by the inner diameter 19 of the well 18 of the basket 6 . In FIG. 6 is represented, by way of example, but not limiting, a means of elastic material of rectangular shape 61 glued on the outer diameter 20 of the bobbin case 8 (it is the same graphical representation as already previously used, for the fact that the same means can either be glued on the inner diameter 19 of the well 18 of the basket 6 or on the outer diameter 20 of the bobbin case 8 ). In another preferred embodiment of a rotary hook 1 according to the invention, said at least one elastic means integral with the bobbin case 8 can be constituted by a coating of non-metallic material of the entire bobbin case 8 or only the outer diameter 20 of the bobbin case 8 for its entire circumference and throughout its development in height , or even of only a portion of the outer diameter 20 of the bobbin case 8 , formed by the development for the whole circumference of only a portion of the height, preferably comprising the lower edge 80 ( FIG. 8 ). This latter embodiment can be easily obtained by partial immersion of the bobbin case in the coating bath and also brings with it the advantage of covering also part of the inner diameter of the bobbin case 8 in the area where it is coupled with the bobbin 4 , thereby reducing the noise generated also by the play between bobbin case 8 and bobbin 4 .
[0053] In other embodiments FIGS. 14-19 , said at least one elastic means integral with the bobbin case 8 can be constituted by one or more elastic means protruding from the outer diameter 20 of the bobbin case 8 , which are deformed while mounting the bobbin case 8 by the inner diameter 19 of the well 18 of the basket 6 or by a niche formed in said inner diameter 19 .
[0054] FIG. 14 shows in section, by way of example, but not limiting, an elastic means 130 (for example of metal sheet) that is fixed to the bobbin case 8 (for example by a screw 133 ) and protrudes from the outer diameter 20 of the bobbin case 8 and creates a pressure on the inner diameter 19 of the well 18 of the basket 6 or on a niche 131 formed in said inner diameter 19 , and which is facilitated during the mounting operation by a chamfer 132 realized on the top edge of the inner diameter 19 of the well 18 of the basket 6 . FIG. 15 shows the sole bobbin case 8 (without basket 6 ) in the same embodiment in a side view from B, as shown in FIG. 14 .
[0055] In other embodiments, said at least one elastic means integral with the bobbin case 8 can be constituted by one or more elastic means made of a single piece on the outer diameter 20 of the bobbin case, which are possibly equipped with a protrusion from said outer diameter 20 of the bobbin case and which are deformed while mounting the bobbin case 8 by the inner diameter 19 of the well 18 of the basket 6 or by a niche formed in said inner diameter 19 .
[0056] FIG. 16 shows in section, by way of example, but not limiting, an elastic means 140 made of a single piece on the outer diameter 20 of the bobbin case 8 , 8 b, which comprises a protrusion 143 from the outer diameter 20 of the bobbin case 8 , which creates a pressure on the inner diameter 19 of the well 18 of the basket 6 or on a niche 141 that is formed in said inner diameter 19 and is facilitated in the mounting by a chamfer 142 made on the protrusion 143 on the outer diameter 20 of the bobbin case 8 . FIG. 17 shows the sole bobbin case 8 (without basket 6 ) in the same embodiment in a side view from C, as indicated in FIG. 16 .
[0057] FIG. 18 shows in section, by way of examples, but not limiting, more elastic means 150 made in a single piece on the outer diameter 20 of the bobbin case 8 , which create a pressure on a protrusion 151 formed on the inner diameter 19 of the well 18 of the basket 6 and which are facilitated in the mounting by a chamfer 152 made on the outer diameter 20 of the bobbin case 8 and similar to that of FIG. 10 . For simplicity of construction it is possible to realize the protrusion 151 on the inner diameter 19 of the well 18 of the basket 6 in circular form (i.e. for the entire development of the diameter 19 ) and make an relief 153 on the outer diameter 20 of the bobbin case 8 for the whole arc of circumference where the elastic means 150 are not present. FIG. 19 shows the sole bobbin case 8 (without basket 6 ) in the same embodiment in a side view from D, as shown in FIG. 18 .
[0058] FIG. 8 shows schematically the only sub-assembly 5 of the rotary hook 1 of FIG. 1 , of the prior art, sectioned on the same plane passing through the axis of rotation “α” as in FIG. 2 . There are visible:
the basket 6 comprising a well 18 of the basket 6 suited to accommodate the bobbin case 8 complete with bobbin 4 , an inner diameter 19 defining said well 18 of the basket 6 in which fits the outer diameter 20 of the bobbin case 8 , a projection 21 on the inner diameter 19 of the well 18 of the basket 6 , which coupling with the guide 22 on the outer diameter 20 of the bobbin case 8 , allows the reference angle of the bobbin case 8 for the correct mounting of the bobbin case 8 in the basket 6 , a post 23 onto which the hole 24 of the shaft 25 of the bobbin case 8 is inserted; a bobbin case 8 , complete with latch slide 15 and latch lever 16 and comprising an outer diameter 20 with a lower edge 80 , a guide 22 on the outer diameter 20 of the bobbin case 8 and parallel to the axis “α”, that coupling with the projection 21 on the inner diameter 19 of the well 18 of the basket 6 allows the angular reference for the correct mounting of the bobbin case 8 in the basket 6 , two radiuses 82 on the corner between the edges of the guide 22 and the lower edge 80 of the outer diameter 20 of the bobbin case 8 to facilitate the angular coupling, a shaft 25 with a coaxial hole 24 and a lower edge 81 of said hole 24 ; a bobbin 4 , on which is wound the bobbin thread 7 , that must be housed in the bobbin case 8 and is then constrained inside the basket 6 by the mounting of the bobbin case 8 in the basket 6 .
[0062] FIG. 9 , like the previous FIG. 8 , schematically shows only the sub-assembly 5 of the rotary hook 1 of FIG. 1 , but this time in execution, also of the prior art, for bobbins 4 b without central hole, sectioned on the same plane passing through the axis of rotation “α” as in FIG. 2 . These bobbins 4 b of the prior art, are generally composed of only pre-wound and compacted bobbin thread 7 , thus not needing a metallic or synthetic core. The exiting of the bobbin thread 7 from the bobbin 4 b occurs in general axially, rather than tangentially as for traditional bobbins 4 .
[0063] In FIG. 9 are visible:
The basket 6 b comprising a well 18 of the basket 6 b suited to house the bobbin case 8 b complete with bobbin 4 b, an inner diameter 19 delimiting said well 18 of the basket 6 b in which fits the outer diameter 20 of the bobbin case 8 b, a projection 21 on the inner diameter 19 of said well 18 of the basket 6 b, which coupling with the guide 22 on the outer diameter 20 of the bobbin case 8 b allows the angular reference of the bobbin case 8 b for the correct mounting of the bobbin case 8 b in the basket 6 b; a bobbin case 8 b, complete with latch slide 15 and latch lever 16 and comprising an outer diameter 20 with a lower edge 80 , a guide 22 on the outer diameter 20 of the bobbin case 8 b and parallel to the axis “α”, that coupling with the projection 21 on the inner diameter 19 of the well 18 of the basket 6 b allows the angular reference for the correct mounting of the bobbin case 8 b on the basket 6 b, two radiuses 82 on the corner between the edges of the guide 22 and the lower edge 80 of the outer diameter 20 of the bobbin case 8 b to facilitate the angular coupling; a bobbin 4 b, consisting of pre-wound and compacted bobbin thread 7 , thus not needing a metal or synthetic core, which must be housed in the bobbin case 8 b and is then constrained inside the basket 6 b by the mounting of the bobbin case 8 b in the basket 6 b.
[0067] In the case of baskets 6 b and bobbin cases 8 b of the prior art without post 23 and shaft 25 respectively, used to accommodate bobbins 4 b without central hole, the embodiments of the invention described above, which include elastic means placed on the post 23 (see FIGS. 4 and 5 ), which is missing in the basket 6 b, are clearly excluded, but all other embodiments remain valid and applicable, including those of FIGS. 14-19 .
[0068] To facilitate mounting the bobbin case 8 , 8 b in the presence of elastic means ( 30 , 40 , 50 , 51 , 60 , 61 , 70 , 130 , 140 , 150 ) and to facilitate the gradual deformation of said elastic means, different preferred embodiments of a bobbin case 8 , 8 b of a rotary hook 1 according to the invention, schematically described in FIGS. 10-12 and 14 - 19 , comprise at least one chamfer 100 - 110 - 120 and respectively 142 - 152 (already described):
in FIG. 10 , the chamfer 100 is realized on the lower edge 80 of the outer diameter 20 of the bobbin case 8 for the deformation of the elastic means ( 30 , 60 , 61 ) located on the inner diameter 19 of the well 18 of the basket 6 ; in a preferred embodiment, said chamfer is formed by a bevel characterized by an angle β with respect to the generatrix of the outer diameter 20 of the bobbin case 8 and by a cathetus B perpendicular to the generatrix of the outer diameter 20 of the bobbin case 8 . In a preferred embodiment, said angle β of the bevel is between 5° and 20°. In a preferred embodiment, said cathetus B of the bevel is at least greater than 0.2 mm; in FIG. 11 the chamfer 110 is realized on the lower edge 81 of the hole 24 of the shaft 25 of the bobbin case 8 for the deformation of the elastic means ( 40 , 50 , 51 ) located on the post 23 of the basket 6 ; in a form of preferred embodiment, said chamfer is made by a bevel characterized by an angle y with respect to the generatrix of the hole 24 of the bobbin case 8 and a cathetus C perpendicular to the generatrix of the hole 24 of the bobbin case 8 . In a preferred embodiment, said angle y of the bevel is between 5° and 20°. In a preferred embodiment, said cathetus C of the bevel is at least greater than 0.2 mm; In FIG. 12 the chamfer 120 is realized at the place of the radiuses 82 on the corner between the edges of the guide 22 and the lower edge 80 of the outer diameter 20 of the bobbin case 8 for the deformation of the elastic means ( 70 ) of the basket 6 that goes to constitute a projection 21 on the inner diameter 19 of the well 18 of the basket 6 ; in a preferred embodiment, said chamfer is constituted by a bevel or by a bevel rounded at the ends, characterized by an angle g with respect to the edges of the guide 22 of the bobbin case 8 and by a cathetus E perpendicular to the edges of the guide 22 . In a preferred embodiment, said angle g of the bevel is between 5° and 20°. In a preferred embodiment, said cathetus E perpendicular to the edges of the guide is at least greater than 0.5 mm.
[0072] In the case of baskets 6 b and bobbin cases 8 b of the prior art without post 23 and shaft 25 respectively, used to accommodate bobbins 4 b without central hole, the embodiments of the invention described above, which include elastic means placed on the post 23 , which is missing in the basket 6 b, and the relative chamfers on the shaft 25 , which is missing in the bobbin case 8 b, are clearly excluded. In the case of baskets 6 b and bobbin cases 8 b, of the prior art without post 23 and shaft 25 respectively, the preferred embodiments are therefore respectively the one with the chamfer 100 realized on the outer diameter 20 of the bobbin case 8 b for the deformation of the elastic means ( 30 , 60 , 61 ) placed on the inner diameter 19 of the well 18 of the basket 6 b ( FIG. 10 ), the one with the chamfer 120 realized on the corner between the edges of the guide 22 and the lower edge 80 of the outer diameter 20 of the bobbin case 8 b for the deformation of the elastic means ( 70 ) of the basket 6 b which constitute the projection 21 on the inner diameter 19 of the well 18 of the basket 6 b ( FIG. 12 ), the one with the chamfer 132 realized on the top edge of the inner diameter 19 of the well 18 of the basket 6 (or 6 b ) for the deformation of the elastic means ( 130 ) realized on the outer diameter 20 of the bobbin case 8 (or 8 b ) ( FIGS. 14-15 ), the one with the chamfer 142 made on the protrusion 143 on the outer diameter 20 of the capsule 8 (or 8 b ) for the deformation of the elastic means ( 140 ) realized on the outer diameter 20 of the bobbin case 8 (or 8 b ) ( FIGS. 16-17 ) and the one with the chamfer 152 realized on the outer diameter 20 of the bobbin case 8 (or 8 b ) for the deformation of the elastic means ( 150 ) realized on the outer diameter 20 of the bobbin case 8 (or 8 b ) ( FIGS. 18-19 ).
[0073] Naturally, the invention is not limited to the particular embodiments previously described and illustrated in the accompanying figures, but it can be subject to numerous modifications of detail within the reach of a person skilled in the art, without departing from the scope of the invention itself, as defined in the appended claims.
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A rotary hook ( 1 ) of a lockstitch sewing machine composed of at least one hook body ( 2 ) includes a cylindrical cavity ( 11 ) and a basket ( 6, 6 b ) free to rotate in the cylindrical cavity ( 11 ), a bobbin case ( 8, 8 b ) housed in the basket ( 6, 6 b ) and a bobbin ( 4, 4 b ) housed in the bobbin case ( 8, 8 b ), elements ( 30, 40, 50, 60, 61, 70, ) suited to create a friction between the bobbin case ( 8, 8 b ) and the basket ( 6, 6 b ), so as to prevent the bobbin case ( 8, 8 b ) to move freely and to vibrate within the plays present between the bobbin case ( 8, 8 b ) and the basket ( 6, 6 b ) and to consequently reduce the noisiness created during the sewing operation.
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BACKGROUND OF THE INVENTION
(a) Field of the Invention
The invention relates to a method of transforming eukaryotic cells. More particularly, this invention relates to the use of DNA constructs designed to insert a particular DNA fragment more efficiently into host cell's DNA in the goal of transgenesis.
(b) Description of Prior Art
Using recombinant DNA technology, foreign DNA sequences can be inserted into an organism's genome to alter the phenotype of the host's organism. A variety of different procedures have been described and are utilized to produce stably transformed eukaryotic cells. All of these procedures are based on, first introducing the foreign DNA into the eukaryotic cell, and followed by isolation of those cells containing the foreign DNA into the eukaryotic cell's DNA.
Unfortunately, to produce transgenic animal and plant, all current higher eukaryotic cell transformation procedures produce in very low proportions transformed germinal (oocytes, spermatozoa, zygotes, spermatogonia, blastomers, etc.) or stem cells that contain the introduced foreign DNA inserted throughout the genome. Additionally, the random insertion of introduced DNA into the genome of host cells can be lethal if the foreign DNA happens to insert into, and thus mutate, a unique vital native gene in a critical manner.
Introduction of foreign DNA sequence in the mouse and other laboratory animals is now relatively easy to perform and is currently used in transgenesis. At the moment, progress in adapting the technology to higher plants and animals, particularly to commercially exploited animals (e.g. farm animals), has not reached the integration rate of foreign DNA observed in mice. In mice, transgenesis occurs in about six percent of the zygotes injected, whereas it is only 0.6% in pigs, 0.7% in sheep and 0.5% in cattle.
A technique currently exist for selecting cells after homologous recombination (HR) event between an endogenous gene and a DNA construct carrying a copy of the gene (Smitties et al., 1985, Nature, 317:230). This work has been extended for the replacement of a targeted gene or to cause gene deletion as well as introduction of foreign DNA molecules (Thomas et al., 1987, Cell, 51:503). In general, one homologous recombination (HR) event occurs for every 10 2 to 10 5 non-homologous integration events. The HR approach was also tested for mouse transgenesis by microinjecting the DNA construct directly into the fertilized oocytes (Brinster et al., 1989, Proc. Natl. Acad. Sci. USA, 86:7087) The results demonstrated the feasibility of HR to correct a mutant gene which is inactive in fertilized mouse eggs. However, the gene deletion was corrected by HR in one out of five hundred (1/500) transgenic mice that incorporated the injected DNA.
For all the above-mentioned reasons, it would be highly desirable to be provided with a transformation system which would allow integration of a DNA fragment by targeting a repeated site of the host's genome. Preferably, such a system would also provide a means of preventing any insertion into a vital gene or genetic region existing in a single copy.
SUMMARY OF THE INVENTION
One aim of the present invention is to improve the insertion of a length of DNA in the host germinal or embryonic stem cells.
In addition, another aim of the present invention is to provide for a proper selection of the targeted site can minimize position effects, enabling an inserted gene to synthesize an effective amount of its protein product.
Therefore, the present invention allows a much more efficient system of improving the rate of transgenesis in plants and animals than is currently possible.
In accordance with the present invention there is provided a DNA construct for inserting a DNA fragment of interest into eukaryotic host cell, the construct comprising an integration cassette flanked by site-specific recombination sequences in which is inserted the DNA of interest, wherein the DNA fragment of interest is flanked by a nucleotide sequence sharing homology to a nucleotide sequence present in more than one copy in the eukaryotic cell, whereby the integration cassette improve the genomic insertion of the DNA fragment of interest in a site-specific manner.
The DNA sequence of interest may be flanked by nucleotide sequences sharing homology to a repeated nucleotide sequence present in the eukaryotic cell, wherein the flanking nucleotide sequence being linked to only one extremity or to both extremities of a DNA fragment of interest to be integrated into a host cell's genome. Such flanking nucleotide sequences sharing homology with a DNA sequence of the host cell's genome may be selected from the group consisting of a Satellite DNA sequence, corticotropin-β-lipotropin, non-satellite repetitive DNA, histone, ribosomic RNA transfer RNA coding sequences, Pst, Bsu and Alu-like repetitive sequences.
The DNA of interest may be linked to regulatory sequences capable of expressing the said DNA of interest in the eukaryotic cell.
In accordance with the present invention there is also provided a method for improvement of the production of fertile, transgenic eukaryotic organisms wherein the transgenic eukaryotic organisms have a DNA sequence of interest integrated at a predetermined repeated DNA sequence of the organisms, the method comprising the steps of introducing into eukaryotic cells a DNA construct comprising a gene of interest flanked by site-specific recombination sequences, wherein gene of interest is flanked by nucleotide sequences sharing homology to the predetermined nucleotide sequence present in the eukaryotic cell, and the gene of interest is operably linked to regulatory sequences capable of expressing the gene in the eukaryotic cell.
In accordance with the present invention there is also provided a transgenic plant consisting essentially of a plant cell, seed or plant from the in vitro introduction of an exogenous DNA fragment into a plant cell by the method of the present invention.
In accordance with the present invention there is also provided a transgenic animal consisting essentially of an animal cell, gamete, zygote, blastomer, embryonic stem cell or animal from the in vitro introduction of an exogenous DNA fragment into an animal cell by the method of the present invention.
In accordance with the present invention there is also provided a method of directly selecting for insertion of a DNA sequence of interest into a specific sequence of an organism's DNA said method comprising the steps of
a) introducing a DNA construct of the present invention into the cells of said organisms;
b) choosing a pair of primers, wherein one primer recognizes a DNA sequences of the DNA fragment of interest, and the other primer recognizes a DNA sequence of the host cell, where the sequence recognized by the other primer exists outside of the DNA construct as described above;
c) using the pair of primers of step b) to amplify the DNA construct inserted into the host cell's genome by homologous recombination; and
d) selecting those cells having the DNA construct integrated into the DNA of the cell, thus being transgenic cells.
Additional objects, features, and advantages of the invention will become apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments exemplifying the best mode of the invention as presently perceived.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a schematic representation of DNA constructs in accordance with the present invention, respectively with both extremities repeatedly, invertedly or partially homologous, 5' homologous and 3' homologous;
FIG. 2 illustrates the synthesis of the constructs in accordance with the present invention; and
FIG. 3 illustrates the recognition sites of the oligonucleotide primers used in the PCR reactions in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with one preferred embodiment of the present invention, the transformation of eukaryotic cells is improved by the use of DNA sequences that are identical to a repeated predetermined sequence to the eukaryote's DNA. Typically the introduced DNA sequence will constitute entire functional genes.
Here eukaryotic cells includes all manipulated gametes, zygotes, embryos, blastomers or embryonic stem cells used to create a transgenic organism. Eukaryotic cells can also be transformed with other DNA sequences such as gene transcription and translation regulatory sequences. Transcription and translation regulatory sequences are those DNA sequences necessary for efficient expression of a gene product. In general such regulatory elements can be operably linked to any gene to control the gene's expression, the entire unit being referred to as the "expression cassette". An expression cassette is intended to typically contain, in addition to the coding sequence, a promoter region, a translation initiation site and a translation termination sequence. Selected endonuclease restriction sites may also be included at the ends of an expression cassette to allow the cassette to be easily inserted or removed when creating DNA constructs.
The expression of a gene is primarily directed by its own promoter, although other DNA regulatory elements are necessary for efficient expression of a gene product. Promoter sequence elements include the TATA box consensus sequence (TATAAT), which is usually 20 to 30 base pairs (bp) upstream of the transcription start site. In most instances the TATA box is required for accurate transcription initiation.
Promoters can be either constitutive or inducible. A constitutive promoter controls transcription of a gene at a constant rate during the life of a cell, whereas an inducible promoter's activity fluctuates as determined by the presence (or the absence) of a specific inducer. The regulatory elements of an inducible promoter are usually located further upstream of the transcriptional start site than the TATA box. Ideally, for experimental purposes in accordance with the present invention, an inducible promoter should possess each of the following properties: a low to non-existent basal level of expression in the absence of inducer, a high level of expression in the presence of inducer, and an induction scheme that does not otherwise alter the physiology of the cell. The basal transcriptional activity of all promoters can be increased by the presence of an "enhancer" sequence. Although the mechanism is unclear, certain defined enhancer regulatory sequences are known, to those familiar with the art, to increase a promoter's transcription rate when the sequence is brought in proximity to the promoter.
The creation of a transformed cell requires that the DNA be physically placed within the host cell. Current transformation procedures utilize a variety of techniques to introduce DNA into a cell. In one form of transformation, the DNA is microinjected directly into cells through the use of micropipettes. Alternatively, high velocity ballistics can be used to propel small DNA associated particles into the cell. In another form, the cell is permeabilized by the presence of polyethylene glycol, thus allowing DNA to enter the cell through diffusion. DNA can also be introduced into a cell by fusing protoplasts with there entities which contain DNA. These entities include minicells, cells, lysosomes or other fusible lipid-surfaced bodies.
Transformed cells, those containing the DNA inserted into the host cell's DNA, can be selected from untransformed cells if a selectable marker is included as part of the introduced DNA sequences. Selectable markers include genes that provide antibiotic resistance (e.g. G418) or herbicide (e.g. kanamycin, hygromycin) resistance. Alternatively, conventional techniques like restriction enzyme digestion and Southern blot are generally used for the molecular analysis of events such as HR. However, in certain cases where genomic DNA of transformed cells is available in very low quantities, analysis by these conventional methods can make selection of transgenic cells unperformable. Amplification of targeted DNA sequence by polymerase chain reaction (PCR) allows detection in a sensitive and highly selective manner of this DNA fragment. PCR is an alternative method which has been used to reveal HR events in eukaryotic cells (Zimmer et al., 1989, Nature, 338:150). HR analysis by PCR which gives a desired response is an indication that introduced DNA construct is integrated in the targeted sequence of the host cell's DNA. All the transformation techniques described above have the limitation that they result in rare inserted copies, and result in foreign DNA insertions in very small number or cells, most particularly in gametes and zygotes. Therefore the proportions of transgenic organisms is low too.
The present invention enables the increase of integration of a foreign DNA fragment in the host cell's genome, while it allows to the targeting of a length of DNA to a specific repeated site. Presumably the selected targeted site will also allow the inserted gene to produce its protein production an amount sufficient to produce the desired effect.
In one preferred embodiment, the introduced DNA consists of combination in tandem arrangement of a promoter region linked to a gene or interest flanked by partial of total half-cutted or repeated DNA fragments homologous to a sequences existing in the host cell's DNA. The length of the homologous fragments can vary from 2 to 10 thousands base pairs (bp).
The first element of the invention involves the use of a DNA fragment identical to a specific repeated site in the host cell's genome to flank the DNA costruct to introduce. Targeting can be carried out via homologous recombination. Homologous recombination is a reaction between any pair of DNA sequences having a similar sequence of nucleotides (homologous sequences, where the two sequences interact (recombine) to form a new recombinant DNA species. The frequency of homologous recombination increases as the number of copies and the length of the shared nucleotide DNA sequence increases, and is higher with linearized plasmid molecules than with circularized plasmid molecules. Homologous recombination can occur between two DNA sequences that are less than identical, but the recombination frequency declines as the divergence between the two sequences increases.
Introduced DNA sequences may be targeted via homologous recombination by linking the DNA of interest to sequences sharing homology with endogenous sequences of the host cell. Once the DNA enters the cell, the two homologous sequences can interact to insert the introduced DNA at the site where the homologous genomic DNA sequences were located. Therefore, the choice of homologous sequences that contain the introduced DNA will determine the rate and site at which the introduced DNA is integrated. For example, in the goal to produce transgenic animals, if the DNA of interest is linked to DNA sequences sharing homology to a single copy gene of the host eukaryotic cell, the DNA sequence of interest may be inserted via homologous recombination in a very low proportion of manipulated cells. However, if the DNA sequence of interest is linked to DNA sequences sharing homology to a multicopy DNA sequence of the host eukaryotic cell, then the DNA sequence of interest can be inserted in many specific sites where a copy of the genomic DNA sequence is located. Preferably, the predetermined host DNA site of insertion is a non-essential endogenous gene or other genomic DNA sequence present in high copy number, such as a DNA satellite sequence. Alternatively, the homologous region flanking the gene(s) of interest could exists in only two copies in the host cells DNA.
DNA can be inserted into the genome by a homologous recombination reaction involving either a single reciprocal recombination (resulting in the insertion of the entire length of the introduced DNA) or through a double reciprocal recombination (resulting in the insertion of only the DNA located between the two recombination events). A single homologous recombination event may then result in the entire introduced DNA sequence being inserted into the genomic gene. Alternatively, a double recombination event can be achieved by flanking each end of the DNA sequence of interest (the sequence intended to be inserted into the genome) with DNA sequences homologous to the targeted genomic sequences. Although introduced sequences can be targeted for insertion a specific genomic site via homologous recombination, in higher eukatyotes, homologous recombination is a relatively rare event compared to random insertion events. In plant cells, foreign DNA molecules find homologous sequences in the cell's genome and recombine at a frequency of 0.5 to 4.2×10 -4 (the number of targeted events divided by the number of random integration events), while in animal one homologous recombination occurs against 10 2 to 10 5 random recombinations. Thus the efficiency or production of transgenic plant or animal can be potentially increased by flanking a transgene with repeated host cell's DNA sequences.
One way to control the activity of the transgene product is to link it to an inducible promoter. Inducible promoters include any promoter capable of increasing the amount of gene product produced, by a given gene, in response to exposure to an inducer. Inducible promoters are known to those familiar with the art and a variety exist that could conceivably be used to drive expression of the transgene.
Two preferred inducible promoters are the heat shock promoter and the glucocorticoid system. Promoters regulated by heat shock, such as the promoter normally associated with the gene encoding the 70-kDa heat shock protein, can increase expression several-fold after exposure to elevated temperatures. The heat shock promoter could be used as an environmentally inducible promoter for controlling transcription. The system consists of a gene encoding glucocorticoid receptor protein (GR) which in the presence of a steroid hormone forms a complex with the hormone. This complex then binds to a short nucleotide sequence (26bp) named the glucocorticoid response element (GRE), and this binding activates the expression of linked genes.
As shown in FIG. 1, the transformation construct can also include a polylinker region located in the genomic DNA sequence. The addition of a polylinker region promotes the ease of constructing unique DNA molecules. Through the use of specific nucleotide restriction enzymes, gene cassettes and other DNA sequences can be inserted into the polylinker region. Any DNA sequence inserted into the polylinker can then be flanked with identical sequences of the host genome to improve insertion into a host cell's DNA via site specific recombination. Typically all the genes contained on the introduced DNA will be linked to a regulatory sequences capable of expression the gene's product in a eukaryotic cell.
As shown in FIG. 1, constructs can be physically linked to additional sequences to form a circularized DNA molecule (a plasmid). These additional sequences would contain a gene's cassette encoding a bacterial selectable marker and a bacterial origin of replication. This plasmid is useful in generation large amounts of the DNA constructs. The procedure consists of using this plasmid to transform bacterial cells, growing the bacterial cells under selection for the presence of the plasmid and then finally isolating the plasmid from the replicated bacterial cells. In order to prevent integration of unnecessary plasmid DNA that is outside the site-specific recombination sequences, the plasmid will also contain restriction endonuclease sites that allow the removal of the plasmid sequences prior to transformation.
The present invention will be more readily understood by referring to the following example which is given to illustrate the invention rather than to limit its scope.
EXAMPLE I
Recombination of Foreign DNA with Homologous Terminating Ends Following Microinjection into Bovine Embryos
The annealing pathway of homologous recombination (HR) appears to be functional in a number of higher eukaryotic systems, including mammalian embryos. In accordance with this Example, the efficiency of the process in fertilized bovine oocytes was studied. The possibility of improving HR transgene incorporation reported by Brinster and colleagues was examined (1989, Proc. Natl. Acad. Sci. USA, 86:7087) in flanking the 3' only or both ends of the foreign marker DNA with halves of a bovine Satellite DNA. This centromeric sequence was estimated as existing in at least a thousand copies in the genome. A high frequency of recombination during the S phase was observed in centromeric regions of Drosophila genomes.
Gene targeting in the bovine satellite DNA sequences was performed by microinjection in interphasic zygotes (Gagne et al., 1995, Mol. Reprod. Dev., 41:184-194) for the following reasons: 1) to improve transgenesis' efficiency in bovine species, 2) to prevent mosaisism resulting from transgenes introduced by microinjection into eggs that are not usually represented in the germ line of the first generation: 3) to drive the integration of foreign DNA in such a way to control the influence of the regions around the integration site and to prevent the alteration of a vital gene by insertion: 4) to allow selection of embryos showing site specific integration by the PCR technique before transfer into recipient cows.
Preparation of Bovine Oocytes
Bovine ovaries were obtained from a local slaughterhouse. Cumulus-oocyte complexes were aspirated from antral follicles (1-5 mm in diameter) with a hypodermic needle (18 G), selected for a compact and complete cumulus, and then washed three times in tyrode-Hepes medium supplemented with 3 mg/ml fatty acid free bovine serum albumin (BSA), 0.2 mM pyruvate, 50 μg/ml gentamicin, 5 mM glucose, and pH adjusted to 7.4 before use.
Oocyte Maturation (IVM) and Fertilization (IVF)
Maturation of groups of 10 cumulus-enclosed oocytes per 50 μl drop of culture medium was carried out in 60-mm petri dishes for 25 h at 38.5° C. in 5% CO 2 and air with water-saturated atmosphere. Oocyte maturation medium consisted of TCM 199 supplemented with 10% heat-treated fetal calf serum (FCS: Gibco Lab, NY), 2.2 mg/ml NaHCO 3 , 5 μg/ml of oLH, NIADDK (National Institute of Diabetes and Digestive and Kidney Diseases), 0.5 μg/ml NIADDK oFSH-17, 1 μg/ml estradiol-17β (Sigma Co, MO), 0.2 mM pyruvate, and 50 μg/ml gentamicin. In vitro fertilization was carried out as follows. Two μl of swim-up-separated semen was added to the oil-covered fertilization drops containing five matured oocytes for a final concentration of 1×10 6 cells/ml. Fertilization medium consisted of tyrode lactate medium supplemented with 0.6% BSA, 0.2 mM pyruvate, 2 μg/ml heparin, and 50 μg/ml gentamicin. Fertilization was performed at 38.5° C. in 5% CO 2 in water-saturated atmosphere. The same procedure can be applied to in vivo matured oocytes or alternatively zygotes can be obtained after fertilization in vivo.
DNA Constructs and Microinjection
Construction were performed according to standard DNA recombination procedures (Maniatis et al., 1982, Molecular Cloning, Cold Spring Harbor). FIG. 2 illustrates the construct synthesis, where PCR amplified bovine satellite sequence (1.3 kb) was integrated in a Sma I (S) digested pPoly III vector (2.1 kb). A Sal I (Sa) fragment (215 bp) was removed from the plasmid pPIII-BS(3.5 kb), and the resulting Sal I pPIII-BS (3.285 kb) was directly injected as one-sided homologous DNA. For the other construct, a Pvu II (P) fragment of the Neo r gene (620 bp) was ligated to the Stu I (St) cleaved pPIII-BS. The fragment BS-Neo (1.54 kb) was obtained by digestion of the plasmid pPIII-BS-Neo-620 with Ban II (B).
Bovine satellite sequences (BS) were used as the homologous region. Bovine genomic DNA was extracted, purified and the 1.3 kb BS sequence was amplified by PCR. Oligonucleotide primers are shown in FIG. 3. The PCR product was electrophoresized on a 1% agarose gel, and extracted from the gel by electrodialysis. The amplified BS sequence was introduced in the plasmid vector pPoly III (2.1 kb) digested at the Sma I site located in the polylinker. The resulting pPIII-BS plasmid vector (3.4 kb) was opened in the BS sequence at the unique Stu I site (near the center of the sequence), or at the Sal I site (located at the 3' end of the BS sequence). The Sal I cleaved pPIII-BS plasmid was used directly for microinjection. A segment of 620 bp of the Neo r gene (Neo-620) was isolated from the plasmid pMCl-Neo (Stratagene, La Jolla, Calif., USA) by digestion with restriction enzyme Pvu II. The Pvu II Neo-620 fragment was than ligated with the Stu I digested pPIII-BS plasmid. The BS-Neo fragment (1.532 kb) was finally excised from the pPIII-BS-Neo-620 construct by digestion with Ban II. The linearized Sal I pPIII-BS and the BS-Neo fragment were injected into one of the bovine oocytes pronuclei between 17 and 19 h post-insemination (hpi). This timing was chosen because this is the point at which the chromatin replication process is at its maximum rate and the embryos are most resistant to microinjection (Gagne et al., 1995, Mol. Reprod. Dev., 41:184-194). DNA fragments were injected at concentrations of 0.1, 0.5, 1.0 and 2.0 ng/μl, diluted in a T 10 E 0 .5 (Tris 10 mM, EDTA 0.5 mM, pH 7.4) buffer. It was verified whether this plasmid had any effect on the normal development of embryos by comparing with results of injection of the pRGH-527 plasmid which does not contain homologous regions at 2 ng/μl.
In Vitro Development and Culture of Embryos
In vitro development of embryos took place in 50 μl drops of TCM-199, supplemented with 10% FCS, 0.2 mM pyruvate, and 50 μg/ml gentamicin, under oil, at 38.5° C., 5% CO 2 , and air with a water saturated atmosphere. Embryos were co-cultured with bovine epithelial oviductal cells as described before (Gagne at al., 1991, Mol. Reprod. Dev., 29:6). Culture medium was replenished after 2 days by adding 50 μl of fresh medium. After 5 days of culture, the development of embryos was assessed on the basis of morphological criteria.
DNA Amplification
After 5 days of culture, whole embryos were extracted from zona pellucida by dissection with a 25 G needle in PBS (Ca 2+ -Mg 2+ free), washed once taking care of changing the pipette at each manipulation. The embryonic cells were placed in a 100 μl sterile reaction mixture consisting of 10 mM Tris-HCI, pH 8.3, 50 mM KCl, 1.5 mM MgCl 2 and 20 mM of each deoxynucleotide. For the first amplification, a set of primers (FIGS. 2-3) was chosen to detect the homologous recombination. For the pPIII-BS plasmid (one side homology), one primer started at the 3' end of the pPIII sequence (oligo pPIII-1), and in the case of the BS-Neo fragment (two sides homology), one primer started at the 3' end of the Neo sequence (oligo Neo), and the complementary primer for both amplifications started at the 3' end of the genomic BS sequence (oligo BS). A control set of primers was used to identify the genomic DNA by amplifying a 320 bp targeted sequence of the Kappa-casein gene (oligos kappa 1 and 2). A second amplification set to detect the presence of the complete pPIII-BS-Neo-620 or uncleaved pPIII-BS plasmids (which could allow amplification and thus give a false HR positive response) was carried out on 10 ul of each resulting PCR product. Amplification with primers pPIII-2 and -3 should give a band of 420 bp on the gel if one of the plasmids is present in the samples.
Oligonucleotide primer sequences:
PIII-1 (SEQ ID NO:1) 5═-GGGTATCACGAGGCCGGAT-3'
pPIII-2 (SEQ ID NO:2) 5'-GGCACCTATCTCAGCGAT-3'
pPIII-3 (SEQ ID NO:3) 5'-GGAGGACCGAAGGAGCT-3'
Neo (SEQ ID NO:4) 5'-CCGCCTGGGTGGAGAGGCTATT-3'
BS (SEQ ID NO:5) 5'-CCGTCATCGCAAGATGAAGCCCT-3'
KC-1 (SEQ ID NO:6) 5'-CCTGCCCAAATTCCTCAATGG-3'
KC-2 (SEQ ID NO:7) 5'CTGCGTTGTCTTCTTTGATGTC-3'
The complete plasmid pPIII-BS-Neo-620 was used to determine the appropriate amplification conditions. Before adding 2.5 units of Taq DNA polymerase (Perkin-Elmer Cetus), the samples were heated for 10 min at 100° C. The solution was covered with 100 μl of mineral oil, and amplification was carried out using a Perkin-Elmer Cetus thermal cycler. The procedure consisted of 40 cycles of denaturation at 93° C. for 30 sec., annealing at 59° C. for 30 s and extension at 72° C. for 90 sec. To avoid false-positive detections, which result mainly from contamination of the sample with the final amplification product, we used several measures including physical isolation of the PCR preparation from the final products and use of positive displacement pipettes (Gilson, Villiers-Le-Bel France). Following amplification, 20 μl of each sample were submitted to electrophoresis on a 1% agarose gel. Statistical analysis was carried out by Chi-square test.
Effects of Microinjected Constructs pPIII-BS and BS-Neo on the In Vitro Development of Embryos
Linearized pPoly III plasmid vectors were injected in 18 hpi bovine oocytes. They were flanked at the 3' end by a 1.3 kb bovine satellite (BS) sequence, and a 620 bp fragment of the Neo gene flanked at each side respectively by 5' and 3' halves of the BS sequences. A group of untreated zygotes was kept as control and a group was injected with the Bgl II linearized plasmid pRGH-527 as foreign DNA without homologous sequences (nHS). From the present experiments, we observed that injection of the nHS plasmid significantly affected (p<0.005) embryo development: 12% (n=53) of treated embryos and 23% (n=278) of controls developed to morula stage (>16 cells). Surprisingly, when injected foreign DNA was flanked by homologous sequences on one or both sides, embryo development was even more impaired. Zygotes in which 0.1, 0.5, 1.0 and 2.0 ng/μl of pPIII-BS (one-sided homology) were injected reached the morula stage in proportions of 9% (n=77), 6% (n=116), 4% (n=95), and 1% (n=75) respectively. Embryos in which BS-Neo (two-sided homology) was injected, have developed to morula stage in proportions of 11% (n=92), 4% (n=104), 6% (n=104), and 0% (n=88) respectively. The harmful effects of homologous sequences on embryo development was significantly higher (p<0.01) at concentrations as low as 0.5 ng/μl than in nHS pRGH-527 plasmid at concentrations of 2 ng/μl.
Evidence of Genomic Insertion with One-Side and Bilateral Homologous Transgene
The basic strategy used here was to select primers such that amplification could occur only when homologous recombination had taken place. As illustrated in FIG. 3, primers pPIII-1 and Neo were chosen from the region unique to the injected constructs and primer BS from genomic DNA sequence in the targeted gene but outside of the region used for the HR constructs. Amplification products should be produced only when a construct carrying homologous extremities has been incorporated in its chromosomal homologous sequence and the primers pPIII-1 and Neo sequences have thus been integrated in continuity with the primer BS genomic sequence; no exponential amplification products should appear when the HR constructs have failed to be integrated or have been integrated at a random genomic site.
If integration of injected pPIII-BS and BS-Neo DNA had occurred at the homologous genomic sequences, we should have detect the 1.5 kb and 750 bp fragments respectively on the agarose gels. The genomic control kappa-casein (KC) primers should give a fragment of 320 bp. PCR assay to detect the one-sided HR was performed on 11 embryos developed beyond the 12-cell stage. Of the 11 embryos tested, 3 were found PCR positive for the HR event because of the presence of the 1.5 kb product. When homologous sequences were presented at both sides of the foreign DNA, which was the case for the BS-Neo fragment, the 750 bp band specific to HR was detected in 12 embryos (lanes 3, 5, 6, 9, 10, 11, 14, 17, 18, 22, 23 and 26) out of 26 developed beyond the 12-cell stage.
We are well aware that positive PCR response for HR of injected DNA could be due to the presence of uncleaved and contaminant plasmid constructs, which before digestion contain the annealing sequence of the primer BS, and might allow amplification of the targeted HR sequences. Further analysis was conducted on the PCR reaction mixture following amplification to identify whether the PCR HR-products were due to a contaminating whole plasmid. Amplification was performed with primers pPIII-2 and -3 specific to a pPolyIII region (420 bp). A band of 320 bp specific to the KC gene was present in all samples, including uninjected embryos, but not in the negative and plasmid controls, thus indicating that genomic DNA from embryos was present. However, the targeted sequence of pPolyIII was not detected in 10 of the 12 PCR samples that were HR-positive from the previous amplification. In the other two samples, some weak unspecific bands were observed, including one at 420 bp.
Conclusion
Conventional techniques like restriction enzyme digestion and Southern blot are generally used for the molecular analysis of events such as HR. However, it was previously observed (Gagne et al., 1991, Mol. Reprod. Dev., 29:6) that there is not enough genomic DNA in a single bovine embryo to perform these methods. In addition, it was not possible to use the expression of a foreign gene as a recombination marker since it was also observed (Gagne et al., 1994, Transgene, 1:293) that the transcription of the E coli lacZ gene driven by the 5' flanking region of the chicken β-actin gene could be supported by embryonic cells without being integrated. PCR is an alternative method which has been used to reveal HR events in eukaryotic cells (Zimmer and Gruss, 1989, Nature, 338:150).
Current recombination models require the presence of homology between two DNA sequences on both sides of a recombining site to initiate a recombination reaction. The observation that the frequency of DNA integration is increased by addition of homologous sequence on one side in mammalian cells (Adair et al., 1989, Proc. Natl. Acad. Sci. USA, 86:4572) supports our results. In the case of the two-sided homologous construct, 38 percent of embryos retained (beyond the 12-cell stage) enabled amplification of the 750 bp fragment used to identify the HR event.
In conclusion, the molecular approach is critical in attempts to produce transgenic domestic animals. The data presented here supports that transgenesis via homologous recombination by using a highly repeated genomic sequence is possible in bovine embryos. The results demonstrates that transgenesis efficiency by homologous recombination is potentially high. Once embryonic cells are increasingly transformed by homologous recombination with repeated sequences, they can be selected by PCR to know if the inserted DNA fragment is integrated to the genome.
While the invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modifications and this application is intended to cover any variations, uses, or adaptations of the invention following, in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice within the art to which the invention pertains and as may be applied to the essential features hereinbefore set forth, and as follows in the scope of the appended claims.
__________________________________________________________________________# SEQUENCE LISTING- (1) GENERAL INFORMATION:- (iii) NUMBER OF SEQUENCES: 7- (2) INFORMATION FOR SEQ ID NO:1:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 19 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#= "oligonucleotide primer /desc PIII-1"- (iii) HYPOTHETICAL: NO- (iv) ANTI-SENSE: NO- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:1:# 19 GAT- (2) INFORMATION FOR SEQ ID NO:2:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 18 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#= "oligonucleotide primer /desc pPIII-2"- (iii) HYPOTHETICAL: NO- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:2:# 18 AT- (2) INFORMATION FOR SEQ ID NO:3:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 17 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#= "oligonucleotide primer /desc pPIII-3"- (iii) HYPOTHETICAL: NO- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:3:# 17 T- (2) INFORMATION FOR SEQ ID NO:4:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 22 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#= "oligonucleotide primer Neo"c- (iii) HYPOTHETICAL: NO- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:4:# 22CTA TT- (2) INFORMATION FOR SEQ ID NO:5:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 23 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#= "oligonucleotide primer BS"sc- (iii) HYPOTHETICAL: NO- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:5:# 23AAGC CCT- (2) INFORMATION FOR SEQ ID NO:6:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 21 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#= "oligonucleotide primer /desc KC-1"- (iii) HYPOTHETICAL: NO- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:6:#21 AATG G- (2) INFORMATION FOR SEQ ID NO:7:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 22 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#= "oligonucleotide primer /desc KC-2"- (iii) HYPOTHETICAL: NO- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:7:# 22ATG TC__________________________________________________________________________
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The present invention relates to DNA constructs provided to improve transgenesis or genomic integration of DNA fragment of interest into nuclear DNA of eukaryotic cell. The DNA constructs of the present invention allow a more efficient procedure by increasing the rate of genomic integration of a DNA fragment. After integration into host cell's DNA, the DNA constructs may provide a mean of screening transgenic cells. An increasing integration means, as well as a method for screening transgenic cells with said DNA construct are disclosed.
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This is a contination-in-part of application Ser. Nos. 439,895, filed Nov. 8, 1982, now abandoned, and 494,569 filed May 13, 1983, now Pat. No. 4,480,854.
This invention relates to an improvement in the seat belt apparatus described in the aforementioned patent applications which disclose a slideable tip assembly on the seat belt which has a tongue or tip for releasable connection to a buckle.
The present invention will be described in connection with its preferred usage in which a seat belt retractor is connected to one end of the belt and is located adjacent a vehicle door, either on the floor or in the roof rail, to exert a tension or pulling force on its connected belt end. A tip assembly is carried on the belt and includes the tongue plate which the vehicle passenger grasps and inserts into looking engagement with a seat belt buckle. The buckle is usually located inboard of and along the seat where the occupant is to sit. The other end of the belt is usually connected to an anchor. In this buckled configuration, the span of the belt from the tip assembly to the anchor defines a lap belt portion extending over the lap of the seat occupant; while another portion of the belt extending upwardly from the tip assembly defines a shoulder-engaging portion extending across the chest and shoulder of the seat occupant to a hanger or the seat belt retractor located above the passenger's shoulder.
If the slideable tip assembly is freely slideable on the lap belt it has a tendency to allow additional belt to pass from the shoulder portion into the lap portion during movement of the passenger. After a time, such movements could result in the lap portion becoming loose on the passenger's lap. This condition is undesirable as it could happen that the passenger could possibly slide under the lap portion in what is called a "submarine" movement. Hence, it is preferred to have the lap-engaging span of the seat belt reasonably tight and incapable of being extended without releasing the tip assembly and rebuckling it. This thereby securely holds the occupant in the seat should an accident occur. On the other hand, it is commonly preferred to have the shoulder-engaging span of the belt webbing slightly loose to allow the occupant to move forward in the seat freely while yet not being outside the protective confinement of the seat belt apparatus.
If the tip assembly is fixed in its position on the belt at the time of belt retraction, which is done automatically, the tip assembly is carried upwardly to a relatively high position up near the roof rail. It is preferred that the tip assembly be located at a lower and more easily accessible position near the seat for easy grasping by the user. Thus, it is preferred that the tip assembly be capable of freely sliding down the vertical belt portion to the desired location when the belt is retracted.
In normal non-emergency operations, it is preferred that the seat belt be held reasonably tight to prevent slippage of any of the looser shoulder belt into the lap belt. But at times of emergencies, it is desirable to remove some of the slack from the shoulder belt and transfer it into the lap belt. This transfer resulting in restraining the chest and head to less forward movement and less pivoting than will occur if there is no seat belt transfer from the shoulder belt into the lap belt at times of emergency. Thus, the present invention is directed to providing a slideable tip assembly that is free falling and which grips the belt to prevent transfer of belt from the shoulder portion into the lap portion during normal useage but which, at high loads or emergencies, allows transfer of some of the shoulder belt into the lap belt to make the shoulder belt more taut at the time of shoulder restraint.
A general object of the invention is to provide a new and improved seat belt apparatus having a slideable tip assembly which allows seat belt movement from the shoulder belt into the lap belt at predetermined loads applied to the apparatus.
These and other objects and advantages of the invention will become apparent from the following detailed description taken in connection with the accompanying drawings in which:
FIG. 1 is a schematic illustration of seat belt apparatus showing the belt with the tip assembly thereon;
FIG. 2 is an enlarged view of the tip assembly illustrated in FIG. 1 in its buckled condition;
FIG. 3 is a view similar to FIG. 2, except that it illustrates the tip assembly in an unbuckled, stored condition;
FIG. 4 is a perspective view of components, including a frame and a snubber slide, used to form the tip assembly disclosed herein, the components being disassembled just prior to assembly;
FIG. 5 is an elevation view of the snubber slide of FIG. 4;
FIG. 6 is an end view of the snubber slide of FIG. 4, inverted from its FIG. 2 and 3 orientation, with the seat belt shown in cross section; and
FIG. 7 is a perspective view of the plastic insert that provides the slot liner shown in FIG. 4.
FIG. 8 is a sectional view showing deflection of the belt gripping edge at high loads to allow some belt sliding from the shoulder portion into the lap portion.
FIG. 9 is a diagrammatic view of the deflection of the belt gripping portion.
DETAILED DESCRIPTION OF THE INVENTION
As shown in the drawings for purposes of illustration, the invention is embodied in a seat belt apparatus 12 mounted in a vehicle having a seat 10 upon which the passenger will sit. A seat belt 15 is connected at one end to a seat belt retractor 26 which is located outboard of the vehicle seat adjacent the vehicle door. Herein, the retractor is mounted on the floor but in other installations the retractor is mounted at the vehicle roof rail in the general location where a turning loop 22 is located in the illustrated configuration. The seat belt 15 has a vertical run 24 between the retractor and the turning loop 22 over which the belt freely slides as the passenger grasps a tip assembly 28 on the belt and pulls the belt from the retractor to connect the tip assembly 28 to a seat belt buckle 30. The belt portion extending between the turning loop 22 and a floor anchor 20 is divided into a lap portion 42 and a shoulder portion 44 by the tip assembly, as will be explained in greater detail.
In normal use of the illustrated seat belt apparatus 12 the occupant grasps the tip assembly 28 and moves it laterally away from the belt run 18 to cause the belt 15 to be extended by drawing the same off the retractor 26 until sufficient belt has been withdrawn from the retractor to allow the tip assembly 28 to be engaged with the buckle 30. As best seen in FIG. 2, the buckle 30 typically has a receiving opening 32 into which a tongue 34 formed on the tip assembly 28 is inserted, and a locking pawl 36 that is spring biased to a locking condition and is adapted to ride over the tongue 34 and to snap into the locking opening 38 in the tongue 34 to thereby latch the tip assembly to its buckle. A release button 40 typically further is associated with the buckle to disengage the locking pawl 36 from the tongue opening 38 to release the tip assembly from confined securement with the buckle 30.
In the buckled condition, the lap-engaging span or portion 42 of the belt 15 is defined between the tip assembly 28 and a floor anchor or securing bracket 20; and the shoulder-engaging span or portion 44 of the belt is defined between the tip assembly 28 and the turning loop 22.
In normal usage, i.e. at non-emergency times, of the seat belt apparatus illustrated herein, there is a tight securement of the lap-engaging portion 42 across the lap of the occupant, while yet allowing some looseness in the shoulder-engaging portion 44, thereby allowing the occupant some slight freedom of upper body movement. In normal useage, the looseness in the shoulder-engaging portion 44 should not be allowed to work its way through the tip assembly 28 and ultimately allow the lap-engaging portion 42 to become loose. This is undesirable because if the vehicle suddenly stops, it is possible that the occupant could submarine under the lap-engaging portion 42 of the belt and be injured.
However, at emergency times, the situation becomes different and the reverse is true in the sense that is desirable to allow some of shoulder portion to be transferred to the lap portion after the lap portion is experiencing heavy loading. At the time of significant deceleration of the vehicle, the seated person's body slides forward on the seat and pulls with significant force on the lap portion prior to the person's shoulder and head pivoting about the person's waist. At this time, it is desirable to transfer some slack in the shoulder belt portion into the lap belt portion which may allow a slight increment more of forward travel of the person's hips while allowing greater restraint of the shoulders and head.
The tip assembly 28 is formed inexpensively with only the frame 50 and the snubber slide 60 constituting the operating parts. Although the frame 50 could be formed as a unitary piece of stamped rigid material, such as steel, in the preferred embodiment, the frame consists of a rigid frame body 101 and a molded liner 100 (FIG. 7) which is joined to the body by a snap fit and which is formed of material, e.g., plastic, formed to provide smooth, sliding surfaces that relieve friction and wear as the belt webbing slides thereagainst. Alternatively, a liner 100 could be molded onto the body 101, the tip assembly 28 is completed merely by sliding the slide 60 across the frame beginning at the front tip of the tongue 34 until a detent means 74 on the interior of the snubber slide 60, which is deflected during assembly, snaps into a channel 53a in the frame 50 and is positioned for locking engagement with the frame 50.
Turning now to a more detailed description of the invention, the tip assembly 28 includes the elongated, generally planar tongue plate or frame body 101 which has a narrowed tongue 34 at its forward end with the locking opening 38 and which further has the opening 52', which helps define the belt receiving slot, formed adjacent the opposite larger width rear end. A pair of stamped ribs 101a flanking the lateral sides of the opening 52' and a stamped rib 101b along the rear of the slot give the frame body 101 additional strength. The channel 53a is a cut out in the frame 50 and extends forwardly from the main rectangular portion of the opening 52' toward the gongue 34. The detent 74 slides in the channel 53a and its forward end will abut a stopping surface 53b at the front end of the channel to hold the snubber slide 60 against sliding forwardly off of the frame 50.
The orientation of the tongue 34 and its weight causes the tip assembly 28 to hang downwardly at the angle shown in FIG. 3 when the belt run 18 is vertical and the slot 52 in the tip body or frame 50 and the opening 63 in the slide 60 are aligned as shown in FIG. 3 providing a vertical belt pathway through the tip assembly 28. Thus, the tip assembly 28 may freely slide down the belt run 18 from an upper position more closely adjacent the turning loop 22 to abut a stop 31 carried on the belt 15 to stop the tip assembly at the height of the stop.
The liner 100 is molded as a unitary piece and includes a flat panel 102 that extends along the under side 105 of the frame body 101 and a lip 104 that extends upwardly along a rectangular insert opening around the interior periphery of the frame body opening 52', defining the belt-receiving slot 52. The liner 100 has a thickened rear portion 106 with a channel 108 for receiving a rear bar portion 56 of the frame body 101 behind the slot opening 52' and has a pair of hollow cylindrical projections 113 in front of the lip 104 that extend through a pair of holes 114 in the body flanking the channel 53a. The lip 104 has a gap 104a in the region of the channel 53a leaving the channel open to the rest of the frame slot 52. The liner 100 is applied to the frame body 101 by slightly deforming the liner and sliding it rearwardly along the under side 105 of the frame body 101 so that the channel 108 engages the bar portion 56 and then snapping the front of the liner upward inserting the projections 113 into the holes 114. The front surface of the rear portion 106 of the liner 100 provides one of the walls 58 along which the belt 15 slides.
The snubber slide 60 is adapted to be fitted over the frame 50 prior to the belt being inserted through the slot 52. The snubber slide 60, as best seen in FIGS. 4 and 5, is a closed, channel-shaped body having the longitudinally extending slot 63 defined by four side walls viz, a top wall 66 and a bottom wall 68 joined to a pair of short side walls 62 at corner sections. The top wall 66 and bottom wall 68 are generally flat, planar and parallel. The top wall 66, the side walls 62 and opposed elongated flanges 124 (FIG. 5) of the bottom wall that extend forward of the rest of the bottom wall, provide channel-shaped regions 122 at the lateral sides of the slide 60 for receiving the lateral edges of the frame body 101 in a sliding engagement. Laterally inwards from the channel-shaped regions 122, an interior portion 123 of the bottom wall 68 is spaced further from the front wall 66 in order to pass below the liner panel 102 when the slide 60 is applied to the frame 50.
In accordance with another aspect of the invention, guide means 140 are provided for keeping the belt webbing centered and from folding onto itself or gathering in one corner of the tip as the webbing passes through the tip assembly 28. That is, it is undesireable that the belt fold or double onto itself or catch in a corner of the tip assembly. It is preferred that the belt track and slide cleanly through the tip. To these ends, in the illustrated embodiment, the guide means 140 consists of a pair of parallel tracks extending upward from the bottom wall 68 of the slide 62. The tracks 140 are laterally spaced apart just slightly more than the width of the belt 15 with inner facing vertical side walls for engaging the belt edges, preventing lateral displacement of the belt edges into an adjacent corner. The guide means 140 are found to substantially eliminate miscentering and subsequent twisting of the belt in its passage through the assembly 28, which may be a problem. The preferred tracks are integrally molded ribs on the inner facing side of the wall 68 of the slide 62.
As an optional means of facilitating the sliding of the belt along the forward surface of the rear wall, the rear wall of the slide 60 has a downwardly extending bead 144 that increases the radius of the surface 144' against which the belt 15 slides. It can be seen in FIG. 3 that when the belt is free to slide through the tip assembly 28, its rearward side 81 contacts two large radii surfaces formed of friction relieving material, i.e., the upper rounded corner 58' of the wall 58 and the rounded surface 144' of the bead 144. The bead 144 also strengthens the slide 60 providing more secure locking of the belt by the tip assembly 28 when the belt is extended across the passenger's lap.
To lock the snubber slide 60 onto the frame 50, a detent 74 projects downward and inward from the wall 66 and is adapted to be snap fitted into the frame slot 52 when the snubber slide 60 is positioned in place over the frame 50. The detent 74 restricts the forward sliding movement of the snubber slide 60 on the frame 50 to prevent disassembly thereof. The preferred detent 74 is an integrally molded narrow protrusion that depends from the center of the upper wall 66 through the slot 52 and into the channel 53a when the snubber slide 60 is in its forward position. The detent 74 is elongated in the sliding direction and has a front surface 148 that serves as a stop against forward-disengaging motion. The stop surface 148 extends through the frame perpendicular to the sliding direction substantially to the level of the lower surface of the frame body 101 and engages the front surface 53b of the channel 53a that is likewise perpendicular to the sliding direction. To assure sufficient locking engagement, the stop surface 148 should extend into the channel 53a to at least about one half of the distance to the under side 105 of the frame body 101 and preferably the full distance through, as illustrated. The stop surface 148 should be at least perpendicular but may angle forward from the upper wall 66, in which case the front channel surface 53b should have a complementary angle. A cross protrusion 149 depending from the rear edge of the upper wall 66 just behind the detent 74 engages the forward edge 150 of the frame slot 52, assisting the detent in stopping forward sliding of the snubber slide 60.
In order to assemble the tip assembly 28, the frame 50 and the snubber slide 60 are first telescoped relative to one another and brought to the position where the detent 74 snaps into the channel 53a. A beveled surface 152 at the rear of the detent 74 facilitates sliding of the slide 60 onto the frame body by camming over the front end of the tongue 34 (and then over the rear edge of the locking opening 38) deforming the upper wall 66 so that the slide can be slid rearward to where the detent 74 snaps into position.
The bottom wall 68 of the snubber slide 60 is very short and almost bar-shaped between its transverse forward edge 72, which abuts the belt when the tip assembly is buckled, as seen in FIG. 2, and a rear transverse edge 71. The forward transverse edge 72 of the bottom wall 68 is located only slightly forward of the upper rear edge 70 of the top wall 66, as clearly shown in FIGS. 2, 3 and 4. The bottom wall 68 is free to slide underneath the rear portion of the frame liner 100 when the tip is buckled.
When the tip assembly 28 has been assembled with the belt 15 fed therethrough, the belt passes through the frame slot 52 and also through the slot 63 in the snubber slide 60. As best seen in FIG. 3, the normal weight inbalance caused by the tongue 34 will cant the tip assembly 28 relative to the vertical belt run 18. The snubber slide 60 has moved forwardly along the frame 50 from the belt-gripping position of FIG. 2, and this allows the tip assembly to slide freely with the edges 70 and 58' on the snubber slide 60 and frame liner 100, respectively, sliding along the forward and rearward sides 80 and 81 of the belt. The unbuckled tip assembly 28 is thereby free to slide downward along the belt run 18 until stopped by some means, such as the detent 74 abutting the front channel surface 53b.
In order to engage the tip assembly 28 operatively with the buckle 30, the occupant merely grasps the tip assembly 28 and moves the same in a lateral direction and slides the tip assembly along the belt until the tongue 34 is brought to latch with the buckle 30, feeding out during this effort sufficient belt webbing to define the lap-engaging span 42 and the shoulder-engaging span 44. The extending belt is being pulled through the turning loop 22 and initially into the shoulder-engaging span 44 while the tip assembly 28 slides freely along the belt during this buckling operation. When the tip assembly 28 is engaged with the buckle 30, the pull of the retractor 26 exerts an upward and rightward force on the tip assembly, as viewed in FIGS. 1 and 2 shifting snubber slide 60 in this same direction to the belt-gripping position. (as seen in FIG. 2). In this position, the belt shoulder portion 44 trained about the forward edge 72 of the snubber slide 60 draws the snubber slide upwardly along the frame 50 until the upper grip edge 70 of the snubber slide 60 and the facing grip edge 58' on the frame liner 100 tightly squeeze the interpositioned belt 15. In this position, the tightly pinched belt 15 precludes any further withdrawal of the belt webbing in the direction toward the lap-engaging portion 42 which would tend to enlarge the lap-engaging portion until such time as there is a large deceleration of the vehicles and it is desired to transfer belt from the shoulder portion into the lap portion.
The thickness of the rear portion 106 of the liner 100 is such that it projects upwardly to the level of the top surface the upper wall 66 of the snubber slide 60, and hence, this rear portion and the belt 15 limit the rearward movement of the snubber slide 60 on the frame 50.
In a preferred form of the illustrated tip assembly 28, the frame body 101 is formed of a durable structural material, such as steel, and the snubber slide 60 and the antiwear liner 100 are formed of a durable plastic material. The use of plastic for the slide 60 eliminates metal-to-metal rattling between pieces of the tip assembly. The plastic also provides the resiliency for the wall 66 to allow the detent 74 to be pushed over the top wall 65 of the frame body 101 during the initially assembly of the snubber slide 60 onto the frame 50. However, once the detent 74 has been positioned in the frame opening 52, it interlocks the slide 60 and frame 50 into an assembly 28 that will not fall apart during further assembly operations to insert the tip assembly onto the belt 15. The stiffness of the walls 66 and 68 are such that the snubber slide 60 can not be removed from the frame 50 without the use of a tool to spring the detent 74 upwardly and from the slot 53a in the frame.
A further advantage of a tip assembly 28 which is capable of freely sliding down the vertical belt run 18 is the reduction of the mass which the belt retractor must move during retraction. This allows for the use of a lighter clock-type rewind spring.
The use of a lighter rewind spring results in two end user advantages. Less force is needed to protract the belt, and less pressure will be exerted against the passenger's body if the belt tension is not relieved.
In accordance with the present invention, when the vehicle is decelerating significantly to cause a predetermined tension load, e.g.. 100 lbs. to the lap belt portion 42 some of the shoulder belt portion 44 is allowed to transfer into the lap belt portion. Herein, this is achieved by deflecting the forward edge 72 of the snubber alide 60 upwardly to a position where it is not as effective and causes a release of the gripping action between the upper grip edge 70 of the slide and the facing grip edge 58' on the frame liner 100. In this preferred embodiment of the invention, a pull of 100 pounds on the lap belt portion deflects the center of the forward edge 72 of the snubber slide to be in alignment with or slightly upward of the grip edge 58' on the liner which results in a reduction in the force being applied across the belt width by the grip edge 70. Thus, with these light lap belt loadings, the beam 200 carrying the forward edge 72 deflects sufficiently to reduce the gripping action to allow travel of belt webbing from the shoulder portion into the lap portion which will have initial greater loading thereon as the person's hips travel forwardly on the seat and pull on the taut lap belt while the shoulder belt is not as taut, and may have some slack therein.
To achieve the deflection of the beam 200, the increased cross sectional thickness bead (designated 144 in the aforementioned parent application Ser. No. 494,569) has been eliminated as it provided too great a stiffness to the beam to allow its deflection to the desired amount at the predetermined force loading, e.g. 150 pounds. Also, the amount of deflection of the beam 200 from its very light or non-loaded position to its deflected position shown in FIG. 8 was calculated.
As illustrated in FIGS. 8 and 9 at 150 lbs. loading, the center of the beam has been deflected sufficiently that it is at least parallel to liner grip edge 58' and hence the amount of upwardly pull on the snubber slide 60 will have been reduced significantly so that the shoulder belt portion may slide between the gripping edges 58' and 70.
While a preferred embodiment has been shown and described, it will be understood that there is no intent to limit the invention by such disclosure but, rather, it is intended to cover all modifications and alternate constructions falling within the spirit and scope of the invention. For example, the liner 100 could be eliminated allowing the belt 15 to slide on an upwardly turned rear wall of the metal frame. Also, the belt guiding tracks could be formed elsewhere than on the snubber slide, such as on the frame body or the frame liner.
Various features of the invention are recited in the appended claims.
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An improved tip assembly which includes a tongue plate insertable into a buckle is provided for a safety belt apparatus in which a continuous retractable belt length provides both a lap portion and a shoulder portion. The tip assembly through which the belt passes has a snubber slide engaged with the tongue plate and slidable relative thereto. When the belt is drawn by the passenger over his body, the belt shifts the snubber slide rearward on the tongue plate to where the belt is firmly gripped at normal loads between a surface of the tongue plate and a surface of the snubber slide, whereby that portion of the belt which extends across the passenger's lap cannot expand. At heavy deceleration loads, e.g. 150 lbs on the lap belt, a portion of the snubber slide deflects to decrease the gripping action to allow transfer of belt from the shoulder belt into the lap belt. When the belt is retracted so that a run of the belt is substantially vertical, the weight of the tip assembly causes its front end to tip downward causing the slide to fall forward along the tongue plate releasing its grip on the belt, whereby the tip assembly freely falls to a lower position along the vertical belt run.
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[0001] This application is a divisional application of U.S. application Ser. No. 12/663,187, filed Dec. 4, 2009; which claims priority to, the benefit of and is a 35 U.S.C. 371 filing from PCT Application Serial No. PCT/US2008/007046, filed Jun. 4, 2008; which application claims priority to and the benefit of U.S. Application Ser. No. 60/933,228, filed Jun. 4, 2007; all of the above-identified applications are incorporated by reference in their entireties for all purposes.
1. FIELD OF THE DISCLOSURE
[0002] The present disclosure relates to the real-time modification and control of the electrochemical production of a customized blend of mixed oxidants, reactants or reductants using various prepackaged, or bulk precursor chemical compounds: liquids, gases, solids to generate a unique and customized oxidizing, precipitating, reducing or reactant chemistry environment both in the electrochemical cell itself and/or electrolytic device, and downstream of the cell/device in an adjacent cell/device, or in the water volume passing through the cell/device, or water reservoir to be treated, in both quantity and concentration greater than that which could be produced via current industry electrochemical/electrolytic processes and practice.
2. BACKGROUND
[0003] Electrochemical cells for use in water/wastewater treatment systems are designed to operate by making use of the water electrolysis process wherein, at the anode-water interface, OH—; being present in water due to electrolytic dissociation of water molecules donates an electron to the anode and can be thereby oxidized to oxygen gas which can be removed from the system. As a result, the H+ concentration can be enhanced at the anode-water interface so that H+ enriched acidic water can be produced. In a similar manner, at the cathode-water interface, H+ accepts an electron from the cathode and can be reduced to hydrogen to form hydrogen gas which can be similarly eliminated from the system so that the OH—; concentration can be increased at the cathode-water interface whereby OH—; enriched alkaline water can be generated. Further, when a halogen-containing water (such as, natural water containing sodium chloride or an aqueous solution of sodium chloride) is subjected to electrolysis, halogenated mixed oxidants are generated in the electrolyzed water. This process can be further enhanced by adding selective precursor chemical substances in liquid, gas or solid phase upstream of the electrolytic cell so that upon entering the electrolytic cell they are dissociated or re-combined into tailored amounts of specific oxidants, reductants, or reactants. Ultrasonic treatment when used in conjunction with electrochemical cells can enhance the production of hydroxyl radicals and other oxidants, can keep the cell electrodes free of carbonate, sulfate, sulfide and iron oxide deposits, create a more thorough mixing in the electrochemical volume being treated, reduce the ion boundary layer thickness on each electrode, and either create micro- or nano-bubbles for increased surface area and longer life, or to agglomerate bubbles to enhance flow within the cell. On large water treatment processes electrochemical cells are usually used to treat a side stream of the main flow which is then recombined with the main flow to effect the desired water treatment, or on reduced flow systems the full flow can be directed through the electrochemical cell(s) for treatment.
[0004] Water quality can be defined by measuring the concentrations of oxidants, total hardness, total dissolved solids, total dissolved organics, chemical oxygen demand (COD) biological oxygen demand (BOD), specific contaminants such as heavy metals, pharmaceuticals and/or pathogens, industrial compounds, hormones and other endocrine compounds, dissolved oxygen, conductivity, oxidation-reduction potential (ORP), streaming current potential, and turbidity of the water.
[0005] Drinking water supplies are commonly disinfected with an oxidizer like chlorine. However the organics in the raw water mix with the chlorine used for disinfection to create cancer-causing agents like trihalomethanes (THMs) and haloacetic acids (HAAs). Drinking water and wastewater treatment plants may use on-site electrolytic generators to produce the chlorine used for disinfection and/or ultraviolet light for disinfection and/or as part of an advanced oxidation system for targeted organics destruction. By minimizing the organic content of the water it is possible to reduce the THM/HAA production and create a better quality water supply. Swimming pools, spas, water features such as ornamental fountains and the like are commonly sanitized using either electrolytic chlorination with/without an ultraviolet light clarifier, or ozonation. Each of these technologies has its own distinct advantages and disadvantages.
[0006] Conventional apparatuses used to sanitize water in pools and the like, include electrolytic chlorination systems, or “salt” chlorination systems. These systems utilize an electrolytic cell or “Chlor-alkali” cell, typically comprising a submerged positively charged anode, a negatively charged cathode, and an electrical energy source for applying a current across the gap between the anode and cathode. The anode compartment contains an anolyte including a source of chlorides which, when oxidized, forms chlorine gas. Typically, the chloride source comprises an alkali metal chloride salt such as sodium chloride or potassium chloride, although other sources, such as hydrochloric acid and the like may also be used.
[0007] When current is applied across the anode and cathode gap, the sodium and chloride ions disassociate with chloride ion concentrating in the anolyte solution and the sodium ion concentrating in the catholyte solution. Chlorine and/or oxygen gas is generated on the anode surface and hydrogen gas is generated on the cathode surface which is released back into the flowing water. The dissolved chlorine gas reacts with the water to create hydrochloric acid (HCl) and hypochlorous acid (HOCl). When either ozone or hydrogen peroxide are added as precursor compounds the electrochemical cell, or electrolytic device will produce small amounts of chlorine dioxide in addition to chlorine and other mixed oxidants. At concentrations greater than 1 ppm, hypochlorous acid minimizes or prevents the growth of algae, bacteria, and other microorganisms. When an electrolytic cell is used, the sodium hydroxide and hypochlorous acid recombine to form sodium hypochlorite (bleach) which is the active oxidizer transported back into the main body of water to prevent microorganism growth. Typical examples of salt chlorination systems are disclosed in Kosarek, U.S. Pat. No. 4,361,471, Wreath, et al., U.S. Pat. No. 4,613,415, and Lynn, et al., U.S. Pat. No. 5,362,368, the entire disclosures of which are incorporated herein by this reference.
[0008] One shortcoming of the electrolytic cell is that calcium carbonate or sulfate scale and bio-film build up on the cathode side of the mono- or bi-polar cells with time. The carbonate ion is created from the oxidation of organic matter with the chlorine sanitizer and it combines with the calcium ion in the water to make calcium carbonate salt. Elemental iron in the water is oxidized to iron oxide which coats the electrode surface and provides sites for the hardness scale to attach itself to the electrode. Current electrolytic cell technology reverses the polarity to switch the anode and cathode surfaces on the bipolar plate to dissolve the calcium carbonate scale build up on the alternate side of the plate. Large scale pieces and organic material build up in the electrode pack and usually need to be removed with acid cleaning or via the addition of surfactants.
[0009] Another shortcoming of the electrolytic cell is that it produces a constant chemistry in the cell and so if the water quality changes in the body of water being treated, such as increased bather load, or a slug of organic material enters the water volume (and the ORP changes), then the sanitizer chemistry may be overcome leading to an unsafe condition for human health either temporarily, or for an extended period of time until the sanitizer chemistry catches up with the demand.
[0010] Another shortcoming of the electrolytic cell is that it produces a constant chemistry in the cell that is independent of the type of water being treated and the particular contaminants in that water. For example, the water treatment chemistry required via electrolytic generation for a pool, is very different from the treatment required for remediation of contaminated groundwaters. In each of these cases, additional compounds are added manually to effect the desired treatment. For example, in a pool environment, superchlorination with monopersulphate is required to destroy chloramines.
[0011] Another maintenance problem with electrolytic chlorination systems is that they are not particularly effective on algae reduction and so the addition of algaecides and the like must be included in the maintenance routine for pool operators. This is usually a temporary condition and the algae problem goes away upon treatment.
[0012] Another shortcoming of electrolytic chlorination systems is that amines, such as ammonia, tend to build up in the water over time, binding with the chloride to form chloramines. Since chloramines have strong odors, can irritate the skin and eyes of bathers, are toxic to ingest, cause discoloration and fading of human hair and bathing suits, it is recommended that pool and spa owners periodically superchlorinate or “shock” the water by adding high amounts of chlorine. The increased chlorine breaks down the chloramines by oxidizing the amines to nitrogen gas. Unfortunately, the amount of chlorine required for superchlorination is higher than the safe concentration for swimming or bathing, thus rendering the pool unusable for an extended period.
[0013] Another recommended option for removing chloramines, bacteria, viruses and protozoa from commercial pools and the like is to install an ultraviolet (UV) lamp disinfection system upstream of the electrolytic chlorination system. The UV disinfection system uses low-pressure, high-output mercury lamps or medium-pressure mercury lamps contained in individual quartz sleeve to treat the saltwater flowing through the cell. The UV radiation from the lamp(s) decomposes the chloramines into hydrochloric acid and nitrogen gas. The UV radiation inactivates the microbial DNA of bacteria and algae which makes the microbes more susceptible to chlorination. The UV disinfection system is a relatively high maintenance item, because the quartz sleeve(s) have to be cleaned regularly to prevent particulate build up on the sleeve which would block the UV radiation. Currently, a mechanical-chemical wiper system is used to remove soft scale from the quartz sleeve.
[0014] Conventional apparatus for sanitizing water using ozonation typically comprises a high efficiency ozone generator and a venturi mixer or inductor port that injects ozone gas into the water to oxidize contaminants in the water. Exemplary ozonation systems which have been found to be particularly effective in pools and spas are disclosed in Martin et al, U.S. Pat. No. 6,500,332, Martin et al, U.S. Pat. No. 6,129,850, Martin et al U.S. Pat. No. 6,372,148, and Martin, U.S. Pat. No. 6,331,279. Other ozonation systems are disclosed in Karlson, U.S. Pat. No. 5,855,856, Morehead U.S. Pat. No. 5,451,318, Engelhard, U.S. Pat. No. 5,709,799, and Karlson et al., U.S. Pat. No. 5,518,698. The entire disclosure of each of these patents is incorporated herein by this reference.
[0015] Ozone has been recognized by the FDA to be more than 200 times stronger than chlorine in microbial kill, and can react at higher oxidation levels than can be achieved safely with chlorine. However, dissolved ozone can exist in water for only a very short period before it reacts and is converted back into oxygen gas. Thus, dissolved ozone is not an effective residual sanitizer, in contrast to chlorine which has relatively steady and consistent residual sanitation properties.
[0016] To overcome the short residence time of ozone and the high vapor pressure of chlorine in hot spa water, spa and pool owners have added at sodium bromide salt to the water. Bromine has a very low vapor pressure compared to chlorine, thus, it does not vaporize as readily in aerated hot spa water. Dissolved ozone or sodium hypochlorite will react with the bromide ion to create the hypobromite ion in the water. Hypobromous acid or sodium hypobromite salt will oxidize ammonia to nitrogen gas without creating an intermediate amine compound like the chlorine oxidizer.
[0017] Attempts to combine the favorable properties of chlorination and ozonation are described in Tamir, U.S. Pat. No. 4,804,478 and Gargas, U.S. Pat. Nos. 6,517,713, 6,551,518 and 6,814,877 B2. The entire disclosure of each of these patents are incorporated herein by this reference.
[0018] In the evolution of water treatment it has been identified that organics in the water are undesirable and lead to the formation of carcinogenic compounds when chemically reacted with sanitizers, and disinfecting agents like chlorine, bromine and ozone. For this reason it is desirable to reduce as much as possible the concentrations of organic compounds in the water. For this reason, advanced oxidation processes have been developed to destroy the organic compounds before they can react with the sanitizing/disinfecting agents. Advanced oxidation processes (AOPs) are defined as those processes that optimize the production of hydroxyl radicals (OH) and oxygen species without the addition of metal catalysts. In water treatment, AOPs refer specifically to processes where oxidation of organics by hydroxyl radicals (OH—) occurs specifically through processes that involve ozone (O3), hydrogen peroxide (H2O2) and/or ultraviolet light (UV with .lamda.<300 nm), Fenton oxidation, and sonolysis. All AOP systems generate OH radicals via a pressure (cavitation), chemical reaction, electric field, or photon-based process, or combinations thereof. The ability of an oxidant to initiate chemical reactions is measured in terms of its oxidation potential. The end product of complete oxidation (mineralization) of organic compounds is carbon dioxide (CO2) and water (H2O). The oxidation potential of OH radicals at 2.8V is high relative to ozone at 2.1V and chlorine at 1.4V.
[0019] Depending on the existing oxidants in the water and whether salts, anions, ozone and/or air are added to the water a number of other oxidizers may be generated under AOP conditions including: ozone, peroxomonosulfuric acid, peroxodisulfuric acid, sodium peroxycarbonate, peroxodiphosphate and hydrogen peroxide, all good disinfectants and oxidizers. In general these peroxides can also kill micro-organisms, however these peroxides are very unstable. Perborates are very toxic and peracetic acid (PAA) is a strong acid. PAA can be aggressive in its pure form. Stabilized persulphates can be used to replace chlorine to meet “chlorine-free” disinfection requirements as can electrolyzed water processes.
[0020] AOP systems are designed to treat a wide range of common water pollution problems, for example: total organic carbon (TOC) removal in high purity water systems such as pharmaceutical and semiconductor manufacturing, N-Nitrosodimethylamine (NDMA), a contaminant found in groundwater from liquid rocket fuel production or as by-product of rubber processing, other groundwater pollutants such as Methyl-tert-butyl ether (MTBE), trichlorethylene (TCE), acetone, phenols, benzene, toluene, and xylene. Pesticide removal such as atrazine and 1,4-dioxane from surface or groundwater supplies and bromate removal caused by ozonation of water containing bromide ion are other AOP processes. Dechlorination and dechloramination of process water is another AOP process.
[0021] Conventional AOP technologies are fairly well understood and straightforward to design and implement. Some of the newer AOP technologies such as: TiO2 catalyzed UV oxidation, electro-hydraulic cavitation, electrochemical oxidation, UV/electrochemical oxidation and streaming current electric discharge (SCED) have the potential to deliver greater efficiencies and better performance than conventional treatment processes with the caveat that each contaminant cocktail is different and must be evaluated for the most appropriate treatment alternative.
[0022] In the AOP system the chemical reactions are highly accelerated oxidation reactions that occur when the OH radicals react with organic pollutants to initiate a series of oxidative degradation reactions. However, OH radical inevitably reacts with all kinds of organic and inorganic constituents in water which result in decreasing the efficiency of OH radical for degrading the pollutant of interest. Dissolved iron oxidation uses the OH radical before the oxidation of organics. It is also known that high alkalinity reduces the OH concentration preferentially to generate the carbonate ion. Therefore, the biggest issue of AOP process lies in increasing the OH production yield and directing the reaction pathway where major reactions between OH radical and the pollutants occur.
[0023] There still exists a need for an electrolytic water treatment system that can operate as a combined advanced oxidation process-residual oxidant generator for treatment of a wide range of water qualities and uses. There exists the need to be able to generate a unique oxidant mix (or reductant, or reactant mix) via the addition of precursor compounds and materials upstream of the electrolytic cell such that the resulting electrolytic chemistry contains sufficient numbers of particular and varied oxidizing/reducing species as is necessary to effectively treat the water contaminants. Furthermore there is a need for the addition of precursor chemicals and materials to optimize the electrochemical output of the cells with products that are more useful to the particular water treatment application. Furthermore, there exists a need for such systems which can be manufactured simply and inexpensively, which can easily fit or be retrofitted into a conventional drinking water plant, swimming pool, spa, cooling tower, water feature or the like, and which requires relatively little maintenance.
[0024] There still exists a need for an electrolytic water treatment system that can operate as a combined advanced oxidation process-residual oxidant generator for treatment of a wide range of water qualities that uses an ultraviolet lamp(s) as a virtual anode(s) in an electrolytic cell and a separate wire(s), or a surface of the cell, as the cathode(s). There exists the need to be able to generate a unique oxidant mix, or reductant mix, or reactant mix via the addition of precursor compounds or materials upstream of the UV-electrolytic cell such that the resulting electrolytic chemistry contains sufficient numbers of particular and varied oxidizing/reducing species as is necessary to effectively treat the water contaminants in real time and under changing, generally degrading, water quality conditions. Furthermore, there exists a need for such systems which can be manufactured simply and inexpensively, which can easily fit or be retrofitted into a conventional drinking water plant, industrial treatment plant, swimming pool, spa, cooling tower, irrigation channel, mining process, water feature or the like, and which requires relatively little maintenance.
[0025] There still exists a need for an on-site electrolytic/electrochemical based mixed oxidant and/or sodium hypochlorite generator using only salt, water, electricity and custom prepackaged, or bulk precursor compounds to create custom liquid admixtures for municipal water treatment, industrial water treatment, oil & gas produced water remediation, solution mining, mine wastewater cleanup, cyanide destruction, acid mine drainage cleanup, or like applications. The mining industry currently uses bulk solutions of sodium hypochlorite for solution mining having a single pH value. The flexibility and enhanced process performance afforded the solution mining operation and/or mine wastewater remediation operation with the present invention is significant due to the varied pH and electrolytic chemistries that can be produced at will.
[0026] The present disclosure described embodiments that are directed to overcoming one or more of the above-mentioned shortcomings.
SUMMARY OF THE DISCLOSURE
[0027] The disclosure in at least one embodiment relates to water/wastewater treatment systems and, more particularly, to systems and methods for maintaining the water quality of drinking water supplies, swimming pools, ponds, irrigation waters, aquatic mammal tanks, spas, fountains, cooling towers and the like, and for the destruction of targeted contaminants in wastewater streams such as from municipal wastewater treatment plants, groundwater remediation streams, industrial wastewaters and larger bodies of water such as streams and rivers and for the preparation of lixiviant solutions suitable for solution mining applications.
[0028] Disclosed in at least one embodiment is an apparatus for generating a customized and potentially real-time varied mixed oxidant stream that contains oxidants such as: ozone, hydrogen peroxide and other peroxygen species, hydroxyl radicals, as well as chlorine based oxidants, the quantities and concentrations of each which are determined by the amount and type of precursor compounds that are fed into the electrolytic cell(s). The purpose of the precursor compound feed(s) are to generate both an advanced oxidation process within the pulsed DC-driven electrochemical cell(s) and downstream of the cell(s) in the water reservoir to be treated, and a residual oxidant both in the electrochemical cell and in the water reservoir to be treated, for longer term sanitizing and oxidation of organics. The precursor compound feed stocks are housed in prepackaged cartridges on a carousel type device or the like, or housed in an integrated apparatus housing and may include liquids, dissolvable solids, or compressed gases, or combinations thereof. For all water treatment systems but in particular the larger volume treatment processes there may be a requirement for direct or indirect chemical precursor injection of bulk liquids, gases or dissolvable solids into the electrolytic cell(s).
[0029] Disclosed in at least one embodiment is an apparatus for generating a customized and potentially real-time varied mixed reductant stream that contains reductants such as: ammonia, carbon monoxide, or hydrogen sulfide gases, atomic hydrogen or nitrogen, or sulfide salts, the quantities of each which are determined by the amount and type of precursor compounds that are fed into the electrolytic cell(s). The purpose of the precursor chemical feed(s) is to create a customized reducing environment for effective treatment of specific contaminants that are not destroyed in an oxidation process such as precipitation of heavy metals with the addition of sodium bisulfide. The precursor chemical and material feed stocks are housed in cartridges on a carousel, or integrated apparatus housing and may include liquids, dissolvable solids, or compressed gases, or combinations thereof fed upstream of the electrolytic cell via an injector device, like a mazzei injector. For larger water treatment systems there may be a requirement for bulk supply of precursor agents to the injector system or bulk direct chemical precursor injection of liquids, gases or dissolvable solids into the electrolytic cell(s).
[0030] Disclosed in at least one embodiment is an apparatus for generating a customized water chemistry via the addition of precursor compounds that are changed through electrochemical processes into different chemical agents and/or other chemical precursors that are not affected by electrochemical processes that can also be used to control typical water parameters such as: calcium hardness, total alkalinity, pH, total dissolved solids, and the like infrequently, or in real time based on sensor inputs and controller set points. Chemical precursors to moderate these water quality parameters can be introduced into the treatment apparatus in the form of replaceable cartridges, replaceable bottles, solid blocks, line feeds or other such like chemical and material inputs.
[0031] Disclosed in at least one embodiment is an apparatus that may/may not use ultrasonic emitters in the KHz and/or MHz ranges attached to the electrolytic cell, or series of cells, or different ultrasonic transmitters placed sequentially along the sides of a single electrolytic cell, or a single ultrasonic emitter operating in a sweep frequency mode, to facilitate a thorough mixing of the cell contents for better chemical reaction kinetics, for improved boundary layer circulation at the surfaces of the electrodes, for enhanced OH radical production, for scale removal from the electrodes, for degassing of the electrolytic cell, for bubble agglomeration in the cell, for cavitation of the waters and for micro- and nanobubble formation for enhanced surface area generation and enhanced reaction kinetics. The present invention comprises an apparatus that can utilize UV lamps operated as virtual anodes to create an electrolytic device, or electrochemical cell and so then to use the UV light to both disinfect the water and be used in as advanced oxidation process via direct and indirect photolysis and indirectly via operating as an electrochemical cell.
[0032] Disclosed in at least one embodiment is an apparatus for generating a customized mixed oxidant chemistry via addition of precursor compounds that can be optimized both infrequently, via manual intervention, to treat seasonal water quality fluctuations, or that can be adjusted in real-time to account for daily, hourly or more frequent fluctuations in water quality. This capability is of particular usefulness for municipal water treatment plants where on-site electrolytic hypochlorite generation or electrolytic mixed-oxidant generation for disinfection is practiced. These on-site generators both of which create a uniform 0.8%, or 0.4% disinfection chemistry respectively, are not flexible with respect to oxidant generation since they use a near saturated brine injection into the electrolytic cell(s) as the only feed stock and hence the resulting oxidant quantity and concentration is fixed.
[0033] Disclosed in at least one embodiment is an apparatus that can employ any number or combination of types of electrodes in an electrochemical cell(s) such as, but not limited to: dimensionally-stable electrodes, boron-doped diamond electrodes, titanium-ceramic-Ebonex® electrodes, carbon-glassy, or aerogel electrodes, lead-oxide electrodes, titanium, nickel, platinum, copper-electrodes with specialty coatings, expendable electrodes such as iron or aluminum for electro-coagulation, or silica-based electrodes. The choice of electrode to be used in the present invention depends upon a large number of variables such as, but not limited to: the water treatment process(es) selected, the contaminants of interest, the influent water quality, the desired water quality, the efficiencies of the treatment processes and costs associated with the treatment process.
[0034] Disclosed in at least one embodiment is an apparatus that integrates boron-doped diamond electrodes specifically used for in-situ ozone production in water as the precursor chemical for advanced oxidation processes in electrochemical cells.
[0035] Disclosed in at least one embodiment is an apparatus that integrates boron-doped diamond electrodes specifically for in-situ production of mixed oxidants from the water itself that is fed to an electrochemical cell(s).
[0036] Disclosed in at least one embodiment is an apparatus that integrates boron-doped diamond electrodes specifically for the in-situ enhanced production of mixed-oxidants in water as determined by the selection of precursor compounds feed to the electrochemical cell(s).
[0037] Disclosed in at least one embodiment is an apparatus that can employ any number of different types and combinations of precursor compounds in solid, liquid or gas phase depending upon the water treatment process(es) selected, the contaminants to be treated, the existing water quality, the desired water quality, and other variables.
[0038] Disclosed in at least one embodiment is an apparatus that integrates these different types and combinations of precursor compounds, and materials as solid, liquid or gas phase feed stocks into the treatment apparatus in the form of replaceable cartridges, replaceable bottles, solid blocks, line feeds or other such like chemical inputs and for larger water flows bulk supply of the various feed stocks and precursor feed materials.
[0039] Disclosed in at least one embodiment is an apparatus that integrates precursor compounds that may comprise halogen salts-flourine, chlorine, bromine, iodine, sulphate salts-sodium or potassium or the like introduced as solids, or dissolved in water, or other solvent.
[0040] Disclosed in at least one embodiment is an apparatus that integrates precursor compounds that may comprise liquid feed stocks-ozone, hydrogen peroxide, peroxyacids, brine solutions, chlorine solutions, ammonia solutions, amines, aldehydes, keytones, methanols, chelating agents, dispersing agents, nitrides, nitrates, sulfides, sulfates, and the like, dissolved in water, or other solvent.
[0041] Disclosed in at least one embodiment is an apparatus that integrates precursor compounds that may comprise gaseous feed stocks-ozone, air, chlorine dioxide, oxygen, carbon dioxide, carbon monoxide, argon, krypton, bromine, iodine and the like. Bulk gaseous feeds may be direct to the injector, direct into the electrolytic/electrochemical cell itself, or to the injector system, or electrolytic cells directly via compressed gas cartridges in the chemical precursor carousel.
[0042] Disclosed in at least one embodiment is an apparatus that may use a semi-permeable membrane such as Nafion® or resin impregnated plastic to separate the anode flows from the cathode flows in the electrochemical cell(s). An anionic or cationic membrane can be used to provide one-way transport of ions across the membrane. The membrane can be used to create an acidic or basic solution for downstream water treatment processes by driving a pressure drop across the membrane.
[0043] Disclosed in at least one embodiment is an apparatus that uses ultraviolet (UV) lamps operating as virtual anodes in an electrochemical cell. UV lamps may also include a boron-doped diamond coating and so operate as virtual anodes in an electrochemical/electrolytic cell. Conventional UV mercury lamps can be used to oxidize elemental mercury to mercury oxide for removal as a solid precipitate.
[0044] Disclosed in at least one embodiment is an apparatus that determines the ratio and quantities of precursor compounds to be measured into the electrochemical cell via sensor input(s) and real time monitoring if required, of the various water quality parameters of interest, and the oxidant concentrations of interest either in the electrolytic cell, or in the treated volume of water.
[0045] Accordingly, new customized water treatment apparatus and methods are provided in at least one of the disclosed embodiments. The apparatus is highly effective in destroying organics, select contaminants, bacteria, viruses, protozoa and providing a residual oxidant in the water in a drinking water system, irrigation water, industrial water, pool, spa, fountain, cooling tower, or other reservoir of water and while making the water comfortable and safe for its intended purposes.
[0046] The apparatus can be more effective than chlorine alone in destroying recreational water disease agents such as cryptosporidium and giardia . The apparatus can be highly effective in destroying organic chloramines in a pool environment without the need for superchlorination.
[0047] In at least one embodiment, a water treatment apparatus is provided which generally comprises an inlet line adapted to receive a flow of water to be treated, and an injector assembly, for example a venturi injector, connected to the inlet line and structured and adapted to combine the flow of water with a precursor chemical agent, or agents, for example, liquid hydrogen peroxide and/or an in-situ generated ozone containing water. The injected water having a level of precursor compounds relative to the stream of first water to be treated, is then passed, preferably directly passed, to an electrolytic device, which may include monopolar, membrane or bipolar cell(s) positioned in contact with the flow of water to be treated. The precursor compounds and existing precursor agents in the flow of first water to be treated (sulphates, chlorides, ammonia, for example) react in the electrochemical cell to create a second water, for example water containing a halogen-containing component, such as chlorine, a chlorine-containing component, bromine, a bromine-containing component and the like, ozone, other oxidants, and the like and mixtures thereof. The use of ultrasonic emitters attached to the electrochemical cells results in an enhanced advanced oxidation environment via the production of additional hydroxyl radicals and other oxidants via sonolysis.
[0048] Although the electrochemical cell is sometimes hereinafter referred to as an “electrolytic cell”, or “electrolytic device”, it should be appreciated that the disclosure is not intended to be limited to a conventional electrolytic chlorinator but may be any suitable electrolytic device useful for the purposes and objects described elsewhere herein. It is preferable in many cases, but it is not necessary that the water stream in the inlet line include a salt, such as a halide salt, for example, an alkali metal halide salt, such as sodium chloride, sodium sulfate, sodium bromide and the like and mixtures thereof as the oxidants of interest for water treatment may not include chlorine substances for instances where a “chlorine-free” swimming pool is desirable. The use of certain electrode types such as boron-doped diamond electrodes often will not need halide salt addition in the inlet stream as they can utilize low concentrations of dissolved salts in the water stream itself to generate chlorine disinfectants and the like.
[0049] In at least one embodiment, an outlet line may be provided which is adapted to pass the second water from the electrolytic device to an application for use, for example to a drinking water reservoir, or tank, to a pool, such as a swimming pool and the like, spa, hot tub, fountain, cooling tower, other reservoir and the like. A recirculation line from an agricultural or industrial waste water ponds or irrigation tanks, would pass through the electrolytic device to remove odorous or hardness compounds such as hydrogen sulfide, mercaptans, calcium carbonate, calcium sulphate or organic matter left over from processing. By removing the organic matter from the water, the irrigation water does not spread black leaf mold or provide a breading bed for harmful bacteria to the plant's root system or to animals foraging on the grass or alfalfa. At least one disclosed embodiment can be used on irrigation water to prevent the accumulation of hardness in the root zone by removing the water hardness precipitants prior to irrigation. Precipitations of hardness compounds in the root zone inhibit percolation of water and nutrients to the plants and therefore reduce growth and yield. With higher anode currents bicarbonate ions can be removed from irrigation water as carbon dioxide gas. Reducing the alkalinity in the irrigation water prevents the calcium carbonate build up in the soil. In the extreme, the buildup of salt and hardness compounds will destroy the ability to grow agricultural products. By electrolytically reducing hardness it reduces the hardness build up on sprinkler nozzles. At least one disclosed embodiment can be used to dechlorinate water and/or wastewater for agricultural or reuse purposes. In at least one embodiment, a membrane cell can be used to destroy organic compounds, or disinfect the water on the anode side. Then the anolyte is recycled on the cathode side and injected with a precursor sulphur dioxide to dechlorinate and to restore the reducing state to generate a chlorine-free irrigation water.
[0050] At least one embodiment of the apparatus can be preferably structured to be easily installed into an existing circulation system for the reservoir. Water may be cycled through the apparatus by means of a pump mechanism, located, for example, upstream of the precursor injector.
[0051] In a preferred embodiment, an ozone generator can be provided and can be coupled to the injector to be effective to introduce, for example, inject, an ozone containing water, or gas into the stream of water such that the first water comprises a first ozonated water and the second water comprises a second ozonated water that passes through the electrochemical cell.
[0052] Preferably, the apparatus further includes a control system effective to regulate a quality or property of the water passing through the apparatus. For example, the control system may include one or more sensors and a control unit, for example a microprocessor based control unit, configured to respond to an input signal from the one or more sensors, for example, electronic sensors, and to regulate power output to the electrochemical cell(s), the electrochemical or corona discharge ozone generator, the precursor dispenser solenoids and/or pump in order to maintain or adjust the quality, properties and oxidant/reductant/reactant content of the first or second water, for example, water being passed out of the apparatus and into the reservoir. The microprocessor control prevents wasting energy and matches electrochemical product concentrations for varying treatment loads.
[0053] In some disclosed embodiments, two or more of the components of the system are contained in a common housing. For example, in some embodiments, the ozone generator, precursor cartridges, and the power supply for the electrochemical cell(s), or the ozone generator, the precursor cartridges and the electrochemical cell(s) with or without the power supply are contained within a common housing. In other embodiments, the injector assembly and the electrolytic device are contained within a common housing. In one embodiment, the injector assembly and the electrolytic device are located so as to treat or process water in a main water line of an existing circulation system for the reservoir or the like. In another preferred embodiment the precursor chemical cartridges, an electrolytic boron-doped diamond electrode ozone generator, the injector and electrochemical cell(s) are integrated into a single flow-through system with quick disconnect couplings at both ends to facilitate easy installation on a straight run of pipe.
[0054] In at least one embodiment, the control system may comprise a flow sensor for detecting flow and shutting off power to one or more of the components of the system in the event that a low flow threshold is detected by the sensor. The control system also prevents the destruction of the electrodes under low flow conditions via either a low flow sensor, and/or high thermal cutoff sensor.
[0055] In some embodiments, the control system includes a pH controller configured to maintain both a desired pH level in the first water and/or a desired pH level in the second water. Advantageously, the apparatus may be structured such that the pH of the water passing to the electrolytic device is sufficiently acidic to provide an acid wash, for example, a substantially continuous acid wash, or at least a partially continuous acid wash, to the electrolytic device. For example, in some embodiments of the invention, the water passing to the electrolytic device provides an acid wash, for example, a continuous acid wash to the electrolytic cell plates or precipitation of heavy metal sulfides.
[0056] As a non-limiting example, in some embodiments, the pH controller is structured to be effective to add an agent, for example, hydrochloric acid and/or carbon dioxide gas, to water upstream of the electrolytic device, said agent being effective to provide an acidic wash to the electrolytic cell plates to substantially prevent or at least reduce the buildup of particulate material, for example, calcium carbonate scale, thereon.
[0057] As a another non-limiting example, in at least one embodiment the apparatus may include a mechanism structured to pass the pH adjusting agent from an external storage tank into the stream of water entering the injector or into the first water. In one advantageous embodiment, the pH adjusting agent is drawn substantially directly into the injector assembly, for example, along with the precursor chemical agents. The pH adjusting agent may be released into the water stream at intermittent times, continuously, and/or specifically in response to a signal from the control unit.
[0058] In at least some embodiments, the control unit, upon receiving input from one or more sensors such as oxidation reduction potential (ORP) disposed in the water line, can be programmed to adjust or vary the amount of power being supplied to the electrolytic device as needed to maintain a desired quality of water passed there from. In some embodiments, the control unit is capable of turning power to the electrochemical cell on and off in response to signals received from the sensor or sensors. By varying certain aspects of the power supplied to the electrochemical cell such as voltage, pulse width, amperage draw and the like, the quality, for example, the oxidation reduction potential, of water downstream of the cell can be modified.
[0059] In at least one embodiment, the control system can include a water quality sensor, for example, an oxidation-reduction potential (ORP) sensor. The control system may be structured so that the ORP level in the second water passed from the electrochemical cell is maintained at a specific ORP mV value based on the desired water quality. For pharmaceutical treatment, an infrared spectrometer is used to identify the compound and the intermediate oxidation compounds to verify that the compound has been remove to required levels.
[0060] In at least some embodiments, the apparatus can include both a pH probe and an ORP sensor positioned, for example, to be in contact with water in the inlet line before it contacts the precursor injector. In such embodiments, the control system is preferably structured and configured to control and maintain appropriate ORP level and pH level based on input received from the sensors.
[0061] In at least some embodiments, the control system may be set to accommodate human users of the treated water, for example, bathers, swimmers and the like, with specific needs. For example, for enhancing the comfort of bathers with very dry skin, the ORP may be set to about 600 mV and the pH controller set to about 7.2. For swimmers with suppressed immune systems the ORP might be set at 750 mV.
[0062] In at least some embodiments, the control system may be structured to be effective to control alkalinity of water passing to the electrolytic device, and may include means for adding or removing a substance from the water for regulating the alkalinity thereof.
[0063] For hard water sources for water features and cooling towers, for example, the hardness can be intentionally precipitated on the cathode side of an electrolytic chlorinator cell. Carbon dioxide or bicarbonate salt can be added to maintain alkalinity preferably above 100 ppm but less than 200 ppm to encourage precipitation of calcium or magnesium or other carbonate or sulfate salts on the cathode side of the electrochemical cell. Carbon dioxide can also be used the control the pH of the water. The advantage of carbonate salt precipitation is apparent during a current reversal cycle. When carbonate salt is converted to carbon dioxide gas and dissolved salt, gas pressure builds below the carbonate salt layer, which in turn causes mechanical failure of the adhesion layer, which in turn causes flakes of precipitated carbonated salt to be carried downstream by the flowing water and recovered in the filter for disposal.
[0064] For cooling tower applications and the like, dispersing agents as precursor compounds can be added to control the particle size distribution of the precipitants on the cathode in order to generate seed crystals that will in turn grow to filterable size thereby preventing scale build up on the cooling fin surfaces.
[0065] In at least one embodiment, alkalinity in the water can be maintained between about 100 and about 200 ppm to encourage precipitation of hardness as a carbonate salt, thus reducing the total hardness in the body of water.
[0066] As a non-limiting example, the apparatus can be configured such that a sulfate salt can be added, for example, automatically, to the water on a regular or as needed basis in order to encourage precipitation of hardness as a sulfate salt, thus reducing the total hardness below about 150 ppm in the body of water.
[0067] In at least one embodiment, a collector is located downstream of the electrolytic chlorinator which serves to collect precipitate, for example, flakes of precipitated carbonate and sulfate salts. The collector may comprise a dead space in the flow line located between the electrochemical cell outlet and the inlet to the drinking water supply line, irrigation water supply, pool, cooling tower or other reservoir. A Y-trap plumbing fixture or spin filter may be provided for enabling removal of the precipitate collected in the collector. As dirt and pollution is sucked into the cooling tower, the electro-chemical cell precipitates or agglomerates the solids for more efficient filtering while keeping the evaporation surface area clean.
[0068] When the water hardness must be maintained below about 150 ppm to prevent scale build up due to evaporation on natural or manmade stones or other porous solids, about 8 to about 40 ppm of sodium or potassium sulfate salt can be added, to the water for example, automatically via an appropriate chemical salt precursor cartridge, as determined by means of the control system, in order to encourage precipitation of calcium or magnesium sulfate salt on the cathode side of the electrode. The sulfate ion changes the water solubility of the hardness so that it will precipitate at pH greater than about 7.0-about 7.6. This sodium sulfate salt addition can drop the hardness to below about 50 ppm, to make clear water for fountains and maintain the beauty of the fountain or other water feature, by preventing unsightly tan or white scale buildup in areas of high evaporation. When hardness is dropped below about 120 ppm, care must be used to prevent leaching the calcium carbonate from any mortar exposed to the water. When dust or rain storms blow lots of lawn debris or dirt into the water feature, potassium peroxymonosulfate can be added, for example, automatically via the apparatus chemical cartridge system, and used as a shock and as a salt to remove the hardness addition from the dissolved dirt.
[0069] For chlorination systems the apparatus can be structured such that chlorine is generated on the anode of the electrochemical cell(s) while other oxidants are generated from a combination of ozone, molecular oxygen, hydrogen or other materials on the cathode. For average flow velocities, low current densities, and low concentrations of ozone-containing water or gas originating from the ozone generator, having an ozone concentration less than about 100 ppm, the bi-polar cathode mostly produces the hydroxyl radical (OH) which immediately reacts with any organic compound or chloramines in the stream. For average flow velocities, low current densities, and air injection with ozone concentrations greater than about 100 ppm, a high ozone concentration will be left in the bubbles and the cathode generated hydrogen will make both hydroxyl radical (OH) and the hydroperoxyl radical (HO2). The hydroperoxyl radical can react with water (H2O) to form the hydroxyl radical (OH) and hydrogen peroxide (H2O2). For high concentrations of ozone-containing water or gas passed into the electrochemical cell, a high ozone concentration residual will be left in the bubbles, and the cathode generated hydrogen will make both hydroxyl radical (OH) and the hydroperoxyl radical (HO2) and some trace chlorine dioxide (ClO2) generated on the anode at high current densities. Some of the ozone and/or HO2 also reacts with the water to make hydrogen peroxide (H2O2).
[0070] In at least some embodiments of the invention, the control system can be configured and structured to control the ozone generator in addition to the precursor chemical cartridges, collectively called the precursor cartridge carousel or bulk feed precursor feed stocks.
[0071] In one non-limiting example, in use in a swimming pool, the control system can be used to create a water stream passing from the pool into the apparatus to achieve a high custom mixed-oxidant concentration in order to cause rapid oxidation of organic loading. As the ORP reading approaches a pre-determined set point, the oxidant matrix and/or concentration can be reduced, or changed to maximize chlorine or hydrogen peroxide residual in the water at a set point turn off. In a membrane cell we can recycle either the anolyte stream or the catholyte stream to enrich the chlorine or hydrogen peroxide output of the cell.
[0072] Preferably, the ozone generator, chemical precursor subsystems, air pump and the electrochemical cell can be coupled in a manner effective to substantially increase or enhance the amount and/or concentration of mixed oxidants, for example, hydroxyl radicals, ozone and hydrogen peroxide produced by the electrochemical cell. For example, the ozone generator, chemical precursor subsystems, air pump and the electrochemical cell are directly coupled together so that the first precursor-laden water flows directly from the injector assembly into the electrolytic device. The conduit or other duct providing water communication between the injector assembly and the electrolytic device may or may not include an effective degassing structure, effective mixing structure, and/or effective mixing and degassing structure located there along. The apparatus is preferably structured such that the stream of precursor-laden water is maintained in an aerated, for example, oxygenated, state when the stream enters the electrolytic device, thereby causing the electrolytic device to produce a stream of water having enhanced concentrations and/or quantities of ozone and other oxidants, for example, hydroxyl radicals.
[0073] The apparatus can be adapted for use in a water reservoir such as a water storage tank, irrigation reservoir, industrial reservoir, water treatment tank, pond, river, pool, spa, cooling tower or the like with or without a circulation system.
[0074] At least in some embodiments, the apparatus can be disposed in a bypass line or a side stream allowing the apparatus to run independently of, or in conjunction with the reservoir circulation system.
[0075] In at least one embodiment, one or more components of the apparatus, for example, the electrolytic device and the chemical precursor subsystem injector assembly, can be mounted substantially in-line with the main conduit of the circulation, or flow-through system. Advantageously, both of these components of the system may be enclosed in a common housing structured to be connectable to a main water line of an existing circulation, or flow-through system.
[0076] Preferably, the chemical precursor injector can be connected substantially directly to the electrochemical cell for example, by a single “short as possible” conduit or duct. In at least one embodiment, the apparatus can include no separate precursor injection device as the injection takes place under pressure directly into the electrochemical cell either into the first section of the cell for a cell under the influence of a single ultrasonic zone, or into individual ultrasonic zones of the electrochemical cell where a mixture of kHz and for MHz frequencies of ultrasonic sound are employed to uniformly distribute cavitation sites throughout the water volume. In this embodiment, MHz frequencies create greater concentrations of hydroxyl radicals are produced in the volume, thereby providing a greater range of contaminant treatment options and greater efficiencies. This hydroxyl generating effect is independent of water quality, salt loading and/or organic loading and indeed can be used on sludges with an aqueous continuous phase, however pulsed DC or AC electrode current is usually used with sludges to maximize the effective treatment with MHz ultrasound.
[0077] The apparatus can include no separate mixing and or/mixing degassing vessel, or contact chamber, located downstream of the chemical precursor injector and upstream of the electrochemical cell.
[0078] In at least one embodiment, the apparatus can include a separate degassing unit to prevent vapor lock of downstream equipment such as pumps, irrigation lines and the like.
[0079] A method of treating water in a reservoir is also disclosed and can comprise the steps of withdrawing a stream of water, for example, a stream of water containing a halogen-containing salt, such as sodium chloride, from the reservoir; injecting precursor chemical(s) into the stream of water; introducing the precursor-laden stream of water into an electrolytic cell, for example, having a variable power supply; returning the mixed oxidant laden and chlorinated stream of water to the reservoir; monitoring the quality of the water in the reservoir; and varying the power supplied to the electrochemical cell as needed to maintain the water quality at a desired level. Advantageously, the step of monitoring the quality of the water comprises monitoring a property, for example substantially continuously and automatically monitoring a property, for instance the ORP, of the water, using an electronic sensor. The output of the sensor can be transmitted to an electronic controller that automatically varies the power, or technical aspects of the supplied power to the electrochemical cell as needed.
[0080] In at least one embodiment of the method, the reservoir can include a circulation system, the circulation system including a main conduit communicating with the reservoir and a primary pump for drawing water through the main conduit, the steps of injecting chemical precursors into the stream of water and introducing the precursor-laden stream of water into the electrochemical cell occur within the main conduit.
[0081] In at least one embodiment, the step of withdrawing a stream of water from the reservoir comprises diverting a stream of water out of the main conduit and into a secondary circulation system, and the steps of injecting chemical precursors into the stream of water and introducing the precursor-laden stream of water into the electrochemical cell can occur within the secondary circulation system. In this embodiment, the secondary circulation system can include a secondary pump independently operable of the primary pump. This allows the water treatment process to be performed substantially continuously, even when the primary pump is not operating.
[0082] The precursor enhanced electrochemical systems and methods describe herein possess numerous differ over prior art systems and methods using electrolytic chlorination alone, such as, but not limited to, by preferably including a custom oxidant/reductant stream that can be adjusted in real time with a programmable logic controller, or the like, to varying water quality parameters and/or treatment requirements. At least one of the described embodiments can be used to generate enhanced concentrations and quantities of specific oxidants/reductants based on specific water quality issues for example, opening a pool or spa in the spring where the water is green with algae might involve adding additional hydrogen peroxide precursor solutions to the electrolytic cell to generate large volumes of hydroxyl radicals for algae destruction. In larger applications a freshwater, or saltwater intake to a water treatment facility experiencing red tides, or other blooms might use a similar hydrogen peroxide precursor feed in volume to oxidize the excess organic matter to reduce trihalomethane (THM) formation post disinfection. At least one of the described embodiments can be fabricated into a low-cost chlorine dioxide (CLO2) generator using a precursor of sodium sulphate plus sodium chlorate on the anode side to generate CLO2 gas on the anode. When used in a pool environment, high concentrations of salt are not required as in a saltwater pool, to generate oxidizing agents. Furthermore, water can be used directly in reverse osmosis (RO) membrane systems because CLO2 does not damage RO membranes. The chloride corrosion on pool equipment and destruction of stone surfaces and pool accessories associated with the use of saltwater pools is minimized via use of at least one of the described embodiments because salt concentrations below 1,500 ppm can be used without using silver and/or copper ionization processes. The residual oxidant(s) produced can be hydrogen peroxide, and/or other micro- or nano-sized oxidants that become thoroughly dispersed within the volume to be treated due to bubble size and that tend to last longer in suspension.
[0083] First, mixed oxidants which have a broader killing range than straight chlorine are created in the electrochemical cell. On the cathode surface, atomic hydrogen (H) combines with molecular ozone (O3) to form the hydroxyl radical (OH) and molecular oxygen (O2). The molecular oxygen from the injected air can also combine with atomic hydrogen to form the hydroperoxyl radical (HO2). Both radicals can oxidize bio-film and other organic particles or compounds suspended in the water or combine with water molecules to make the hydrogen peroxide molecule (H2O2), which is a long half-life sanitizer like chlorine. The amounts and concentrations of mixed oxidants produced via the electrochemical cell can be dramatically increased by use of select precursor compounds.
[0084] With the increased pulsed DC current density provided by the electrochemical cell and in the presence of dissolved ozone, hydrochloric acid (HCl) and hypochlorous acid (HClO) and a very tiny percentage of chlorite acid (HClO2) can form on the anode surface. Typical oxide coatings on pool, cooling tower and spa electrodes are optimized for the production of chlorine with a small production of oxygen for chloride salt concentrations of 2,000-3,500 ppm. With boron-doped diamond-like or iridium oxide coatings on the anode, the electrochemical cell operation can be extended to the salt content approaching those of fresh water. Field experience shows that a voltage pulse is needed to push current across the electrode plate gap while preventing an arc formation when organic matter bridges the gap. As the salt content (TDS) of the water approaches 100 ppm, a tiny amount of ozone and chlorine dioxide can be produced along with the molecular oxygen on the anode surface, particularly of boron-doped diamond electrodes to increase the broadband microbial killing ability of the mixed oxidants produced with the chemical precursor enhanced electrochemical system. With the increased current density of the voltage pulse, the current density can rise between the plates to deliver lethal dose of electrical current to the bacteria or algae cell. The electrical conductivity of the current invention can be enhanced by the addition of carbon dioxide, sulfur dioxide, or gases like argon. This particular embodiment is optimized for the production of hydrogen peroxide via streaming current electric discharge at the anode plate(s).
[0085] In addition, water treated according to at least one described embodiment of the apparatus and/or method is more sanitary due to the generation of mixed oxidants such as: hydrogen peroxide, ozone, chlorine dioxide, hydroxyl radicals, peroxyl radicals, persulphates, percarbonates, and the like than water treated by electrolytic chlorination alone, and it will contain a lower residual chlorine level at an equivalent ORP meter reading.
[0086] For instance, because the bulk of the oxidation and sanitizing is performed by advanced oxidation processes and mixed oxidants, the system requires a smaller electrochemical cell and ozone generator than systems using only electrolytic chlorination or ozone with a salt, for example, a sodium chloride salt or a bromide salt. Accordingly, the total cost of a chemical precursor enhanced electro-chlorination system can be reduced because the potential size of the electrodes, housing size and related power supply can be reduced.
[0087] The addition of certain chemical precursors like ozone and/or anti-scalants upstream to the electrochemical cell also inhibits scale formation in the electrolytic cell. Ozonated air bubbles act like a micro-flocculent attracting tiny particles of calcium carbonate scale, thus keeping the cathode surface reasonably clean even if the calcium ion concentration rises above about 240 ppm in the water. The bubble flow helps remove the flakes of calcium carbonate after a reverse in cell polarity. The ozone and/or air addition also can result in the organic matter that normally combines with the calcium carbonate build up on the cathode is removed by oxidation. This could eliminate the need for the expensive electronic “self-cleaning cycle” that is required by most bipolar electrolytic chlorination systems, but field experience shows that “self-cleaning cycle” may still be useful but the delay time can be extended by a factor about 4 to about 8. Thus, by adding ozone and/or air and reversing the polarity occasionally on the electrolytic cell, the system can become ‘maintenance free’ for the whole swimming season of the pool. For cooling towers and aquatic animal habitats, the amount and/or frequency of maintenance can be reduced, for example, during the annual maintenance cycle. The current embodiment can be useful when using the ultraviolet (UV) lamp version of the electrolytic/electrochemical cell because the cell is generating ozone in the volume which acts to micro-flocculate the hardness compounds and organic compounds which in turn then cannot precipitate, build-up, or foul the surface of the UV lamps (anodes). The micro-flocculated seed crystals reduce the buildup rate of carbonates on cathode surfaces. In at least one embodiment, boron-doped diamond coated quartz sleeves on the UV lamps are used to generate mixed oxidants at the coating surface. The boron-doped diamond coating is deposited on the quartz sleeves in thicknesses ranging from 30 nm to 300 nm to prevent blockage of the UV light.
[0088] The polarity reversal during the “self-cleaning cycle” is destructive to the electrolytic cells themselves, damaging the precious metal oxide, DSA, or boron-doped diamond coatings by reducing a tiny amount of oxide to the precious base metal when the anode surface is switched to the cathode surface. For higher current densities, titanium hydride is created at the coating interface. When the polarity is switched again, the acid created on the new anode surface dissolves the precious base metal until it reaches a new layer of precious metal oxide, thus shortening the life expectancy of the cells. For higher current densities, the titanium hydride is converted to titanium oxide and water vapor which delaminates the oxide coating. The use of the present systems can prevent or greatly reduce the reduction of the oxide coating to base metal by absorbing most of the atomic hydrogen with dissolved oxygen or ozone to create hydroxyl radicals, extending the cell life, and reducing costs associated with replacement parts
[0089] Boron-doped diamond electrodes can also be used in at least one apparatus embodiment to counter the degradation effects of polarity cycling. Extended electrode life of more than 5,000 hours has been witnessed even under frequent polarity reversals.
[0090] Furthermore, the advanced oxidation processes and mixed oxidants that can be formed in at least one embodiment oxidize the urea and ammonia based substances that would otherwise react with chlorine to form chloramines. The advanced oxidation processes and mixed oxidants also oxidize organic matter that would otherwise react down to the chain termination of chlorinated methane. Accordingly, fewer chloramines or chlorinated methanes are formed. Those that are formed are destroyed by the mixed oxidants. Mixed oxidants can also oxidize chlorinated hydrocarbons such as methyl chloride, methylene chloride and chloroform which are stable intermediate oxidation products of chlorine-organic matter reactions. Thus, the need for periodic superchlorination is reduced or eliminated. As a further embodiment the water can be heated to over 140 F degrees to convert all nitrogen compounds: nitrates, nitrites, urea, ammonia, proteins, amino acids and the like, into nitrogen gas and removed from the system.
[0091] Moreover, the ozone component of mixed oxidants imparts surface charges to the suspended organic particles causing them to stick together, thus becoming more filterable. This process, know as “micro-flocculation”, allows ozone to provide clearer water than is possible with chlorine alone. In fact, for water features such as fountains, the water droplets can temporarily bead on the surface, due to the increased surface tension of the clean water, creating unique visual effects for sunlight and artificial night light.
[0092] At least one embodiment can be used to destroy double-bonded carbon compounds to reduce contaminant structure and/or toxicity and/or density and/or molecular weight. An example of this would be the destruction of benzene, or phenol like compounds.
[0093] For the commercial spas, pool-spa combinations, or water features such as spraying fountains or cooling towers, the addition of sodium bromide to the water stream entering the apparatus can reduce the evaporation rate of chlorine from the main body of water. Chlorine or ozone can oxidize the bromide ion to the bromite ion. The hypobromite ion does not decompose like hypochlorite ion when exposed to the ultraviolet light spectrum from the sun or low-pressure mercury lamp, thus bromine sanitizer has a longer half-life in the water.
[0094] Accordingly, new customized water treatment apparatus and methods are provided by the disclosed embodiments. Organic sticky or gelatinous compounds can be partially oxidized into non-sticky carbon-like particles to prevent plugging of macro or ultra-filtration membranes such as filtering Kraft water from a paper pulping process. Hardness salts can be precipitated and smaller organic compounds can be oxidized in front of a nano-filtration membrane to improve the rejection rate of certain cations and increase the production time between wash cycles. Hardness salts can be precipitated and dissolved organic compounds can be oxidized to decrease the SDI index from 5+ to near zero for longer production run times on reverse osmosis membrane desalination systems.
[0095] Both chlorine evaporation and oxidation of the organic compounds cause the pH of the water to rise over time, which in turn requires the manual addition of hydrochloric acid to prevent the precipitation of calcium salts. At least one of the disclosed embodiments can automate this process as the hydrochloric acid or carbon dioxide can be added as a precursor chemical to the precursor chemical subsystem carousel and be controlled via pH sensor input. Calcium carbonate or calcium sulfate usually will precipitate when the pH rises above about 7.9 on the edges where the water splashes against wall or surface of a water feature. The precipitated calcium salts leave ugly white and tan splotches on the surface which has to be removed with scrubbing using a lime removing product. Hydrochloric acid is used to replace the chlorine that evaporated from the water or to combine with the calcium ion to keep it soluble in the water.
[0096] The pH controller may be set to maintain the pH of the water in the reservoir at between about 7.1 to about 7.4 while an acid component, for example, hydrochloric acid, is added to the water stream upstream of the electrolytic cell in an amount effective to maintain concentration of the chloride ion in the water at surfaces of the electrolytic cell plates to provide an acid washed on a regular basis. A chemical precursor enhanced electro-chlorination system can be structured to be substantially ‘maintenance free’ during most of the swimming season and to reduce maintenance costs in cooling tower applications. The pH controller is set to not let the pH drop below about 6.5 downstream of the electrolytic cell to prevent leaching or oxidation of metal pump parts or heat exchangers surfaces.
[0097] Experience shows if the pH drops below about 6.5, copper or stainless steel heat exchangers will dissolve and precipitate on the pool or spa surface changing the color to a light blue-green or light brown-gray respectively. Cooling towers electrolytic cells usually require additional acid washing to remove harden scale buildup. At least one of the described embodiments minimizes the need for acid washing by using the superior properties of boron-doped diamond electrode coatings such as high thermal conductivity, high hardness and chemical inertness, a wide electrochemical potential window in aqueous and non-aqueous media, very low capacitance, a wide pH window, extreme electrochemical stability and resistance to regular polarity reversals.
[0098] In at least one embodiment ultrasound plus the boron-doped diamond electrodes can be used to precipitate silica out of solution in cooling tower applications and the like. This negates or minimizes the need for pressure washing of active surfaces in the cooling tower.
[0099] In addition, the control system preferably included with the chemical precursor enhanced electrochemical systems can allow treatment of the water using chlorine sanitizers to adjust input of compounds and/or the amount of electrolytically-generated chlorine containing agents, as desirable or necessary in response to changing conditions, substantially without need for user intervention. If the acid precursor cartridges or carbon dioxide cartridges are large enough, the pH and ORP controller can prevail over water and organic material additions after a rain, dust or wind storm. For larger water reservoirs the direct feed of the bulk acid and bulk carbon dioxide chemical precursors to the electrochemical cell can be utilized. The immediate treatment of contamination prevents the introduction of resistant strains of black algae and leaf mold growth in porous surfaces of the tile grout, cement, or plaster of the pool, spa, and fountain or on evaporation enhancers in the cooling tower.
[0100] For aquatic animal habitats in the zoo, after the animal feeds or defecates in the water, the ORP meter will detect the organic matter addition to the water. The filter system will strain the large particles from the water while the chemical precursor enhanced electrochemical water treatment system will oxidize the fine fiber particles, bacteria and yeast bodies, and gastric enzymes. The pH controller will then corrected the pH with acid to neutralize the ash left over from the oxidation of organic matter. A small amount of sodium or potassium sulfate salt can be added to the water via the precursor chemical carousel to encourage the precipitation of the ash in the electrochemical cell which is removed by downstream filtering. A slip stream of the zoo habitat water is heated within a separate electrolytic/electrochemical cell to convert the ammonia and urea to nitrogen gas to remove the algae food source from the water. The other option is to convert the ammonia to hydrogen gas on the cathode, electrolytically. By reducing the calcium and magnesium loading in the water via electrochemical precipitation we can prevent the formation of calcium-rich biofilms on aquatic surfaces. This in turn allows for lower concentrations of oxidants to rid the pool of black molds, or other colony-forming species.
[0101] At least one embodiment can be used specifically as a perchlorate reducing and destruct agent or a perchlorate chlorine dioxide generator when the perchlorate ion is used as a precursor compound. In one option, the percholorate stream can be fed to the anode compartment of the electrolytic device or cell(s) to produce chlorine dioxide gas from the perchlorate ion. In another option, there can be a reduction of the perchlorate ion to chlorine by passing the perchlorate ion through the cathode chamber of the electrolytic device or cell(s).
[0102] At least one embodiment can be used as a substitute lixiviant solution in leach mining applications that use cyanide as the lixiviant leaching agent. The cyanide solution as a known contaminant of environmental concern can be treated with a combination of UV photolysis and electrochemical oxidation with or without hydroxyl generating precursors. At least one embodiment can use a UV lamp spectra preferably between 172 nm to 400 nm as a pulsed DC anode either alone, or in combination with DSA, or boron-doped diamond electrodes.
[0103] At least one embodiment can be used in solution mining applications to generate specific pH ranges for effective leaching of precious metals like gold, silver, the platinum group metals: platinum, palladium, rhodium, ruthenium, osmium and iridium and solution mining of uranium using custom precursor mixtures in the electrolytic/electrochemical cell(s), with or without membranes, to create various pH conditions ideal for complexing of the metals in the ore body. At least one embodiment includes the use of ultrasonic transducers attached to the electrolytic cell(s) to better mix the solutions, separate metals from soil particles in solution, and to keep the electrode surfaces free of calcium carbonate and/or calcium sulphate type build-ups which would lead to electrode failure and/or process failure. At least one embodiment is ideally-suited to the onsite generation of mixed-oxidants and/or sodium hypochlorite solutions in electrolytic/electrochemical cell(s) for borehole injection, and subsequent recovery, in the solution mining operation using brine, electricity, water and prepackaged, or bulk precursor compounds to generate the custom pH solutions for the unique requirements of each solution mining application. At least one embodiment can extend to the use of real time monitoring of pH and other solution mining parameters in the ore body and the associated adjustment of the electrolytic process via programmable controller or the like, to generate a modified solution for continuous injection.
[0104] At least one disclosed embodiment can be used in the clean-up of mine wastewaters such as acid mine drainage by using the electrolytic cell(s), ultrasonic transducers and appropriate precursor compounds adjusted in real time to plate out heavy metals on the electrodes in a custom electrowinning process, or to precipitate, separate, change or destroy various waste stream constituents via electrochemical solutions, based on changing metals or other constituent concentrations in the water to be treated, and/or other sensor feedback. Furthermore, complimentary applications extend to acid mine drainage treatment where the mixed oxidant/mixed reductant solutions could be used to kill the microbes that leach heavy metals into the water supplies, or in heap leaching operations the use of the on-site, real-time, electrochemically generated solutions could be used to destroy cyanide waste streams coming from gold leaching operations and the like.
[0105] At least one embodiment comprises an apparatus that represents a major improvement over prior electrochemical or electrochlorination systems for disinfection and/or advanced oxidation processes. Broadly, at least one embodiment provides an improved electrochlorination and electrochemical system for the on-site generation and treatment of municipal water supplies and other reservoirs of water, by using a custom mixed oxidant and mixed reductant generating system for the enhanced destruction of water borne contaminants by creating custom oxidation-reduction-reactant chemistries in real time if necessary. At least one embodiment provides a range of chemical precursors that when acted upon in an electrochemical cell either create an enhanced oxidation, or reduction environment for the destruction or control of contaminants. At least one embodiment, introduces via the chemical precursor injection subsystem those chemical agents that can be used to control standard water quality parameters such as total hardness, total alkalinity, pH, total dissolved solids, and the like infrequently, or in real time based on sensor inputs and controller set points.
[0106] The use of electrochemically-generated mixed oxidants and electrochemically-mediated advanced oxidation processes for disinfection, organics destruction, and contaminant destruction can be substantially superior to electro-chlorination systems for all applications.
[0107] At least one embodiment can use all types of dimensionally stable anodes, boron-doped diamond coatings, sub oxide titanium ceramic, lead-oxide or titanium-oxide coatings, and/or other relevant electrode coatings, in addition to ultrasonic treatment at varying frequencies to generate specific treatment zones within the electrolytic cell(s). However, the use of ultrasonic treatment is not required, but preferred because the cell is then self-cleaning.
[0108] At least one embodiment can extend to the use of UV lamps operated as virtual anodes to create an electrolytic cell and/or electrolytic device thereby using the UV lamps for multiple simultaneous purposes: disinfection, photolysis, and advanced oxidation processes such as oxidation of elemental mercury to insoluble mercury oxide. At least one embodiment can relate to the use of ultrasonic treatment to prevent scaling or fouling of the UV lamp quartz sleeves and the electrodes and to generate OH radicals specifically, and other mixed oxidants such as: ozone, peroxomonosulfuric acid, peroxodisulfuric acid, sodium peroxycarbonate, peroxodiphosphate, and hydrogen peroxide to destroy organic compounds in water at the surface of the UV lamps when operated as virtual anodes, and/or coated with a boron-doped diamond coating. When the UV lamps are operated as virtual cathodes, metals are reduced to elemental state, hardness ions are precipitated, and free radicals are created from hydrocarbons, cyanide, hydrogen sulfide, and ammonia. The combination of ultrasonic and ultraviolet light can be used to reduce the molecular weight of brown humic acid to make amber fulvic acid, which is a direct absorbing plant fertilizer. Utilizing UV lamps in electrolytic reactors relates also to the ability to determine and generate the customized blends of oxidants/reductants and/or reactants in real time that may be required by the various water treatment processes based on feedback sensors in the water to be treated and the modulation of UV output to effect the most efficient process.
[0109] At least one embodiment preferably uses individual ultrasonic transducers each operating at different frequencies, and/or in sweep frequency mode in either the 12-70 kHz range, or 0.1-1 MHz range to create individual zones of electrochemical treatment within the electrochemical cell, or cells.
[0110] At least one embodiment can be a significant innovation over current electrochemical on-site oxidant generation practice where a near saturated brine, water and electricity are used to generate a fixed concentration of sodium hypochlorite solution and/or mixed oxidant solution in a side stream process for the disinfection of municipal drinking water supplies, cooling tower treatment and the like, or in swimming pool and spa applications where chlorides in the pool water and/or ozone gas are used as precursors to a standard electrochemical cell to produce sodium hypochlorite and more hydroxyl radicals since in the present invention, there is a potential suite of precursors that can be drawn upon in real time to produce the exact concentrations and amounts of varying electrochemical products such as: ozone, peroxomonosulfuric acid, peroxodisulfuric acid, sodium peroxycarbonate, peroxodiphosphate, and hydrogen peroxide that are needed by the water to be treated based on sensor feedback to a system controller to create a dynamic, not fixed, electrochemical treatment process. At least one embodiment relates to the use of ultrasonic treatment to prevent scaling or fouling of the electrodes, to improve mixing and to generate OH radicals specifically along with other oxidants within the electrochemical cell or device. It is known to water treatment professionals that water quality is constantly changing and so in the typical water treatment process, the tendency is towards overdosing of chemicals to effect the possibility that all changes in water quality have been addressed, particularly organics destruction, however this often leads to the production of unwanted byproducts which are known carcinogens such as trihalomethanes (THM), or haloacetic acids (HAAC). In the present example, at least one embodiment can be used to destroy more of the organic compounds in the water by the production of enhanced quantities and concentrations of hydroxyl radicals (OH) that will react more quickly than the chlorine compounds produced in the electrochemical cell so that reduced amounts of THMs and HAACs can be expected over traditional electrochemical processes as described earlier in this paragraph.
[0111] At least one embodiment can be used to generate enhanced amounts and concentrations, and customized chemistry of mixed oxidants, or reductants, or reactants for the enhanced disinfection of water supplies and volumes of water, destruction of dangerous pathogens like giardia and cryptosporidium , destruction of biological agents, precipitation of heavy metal salts or calcium, barium, or magnesium hardness and enhanced destruction of organic compounds such as pharmaceuticals, endocrine compounds, pesticides, industrial compounds, and enhanced destruction of inorganic compounds such as hydrogen sulfide and mercaptans in aqueous solutions in full flow and side stream applications.
[0112] At least one embodiment can be used specifically in arsenic removal systems as a pretreatment step in front of the ion-exchange resins to oxidize arsenic III to arsenic V at an ORP of approximately 700 mV and to precipitate hardness ions that compete with the absorption on the resin beds. At least one embodiment presoftens the water prior to reaching the resin beds.
[0113] At least one embodiment can be used to modify water quality chemistry in real time based on sensor feedback and subsequent injection of water quality adjusting agents such as for pH, alkalinity, total dissolved solids, turbidity and disinfection into the electrolytic device for electrochemical transformation into the active agent, or via injection of integrated precursor material feed stocks, or bulk feed stocks into the electrolytic device for distribution to the water volume being treated.
[0114] At least one embodiment can also be used to produce hydrogen electrolytically using ammonia as the precursor chemical, for example from a sewage digestor, overcoming much of the cost and limitations of deriving pure hydrogen for on-site power generation for fuel cell applications. At least one embodiment can convert ammonia electrolytically directly into nitrogen gas avoiding the usual biological conversions required to take ammonia to nitrate and nitrate to nitrogen gas.
[0115] At least one embodiment can be used in solution mining applications to generate specific pH ranges for effective leaching of precious metals like gold, silver, and the platinum group metals: platinum, palladium, rhodium, ruthenium, osmium and iridium, as well as uranium, through the use of custom precursor mixtures in the electrolytic/electrochemical cell(s), with or without membranes, to create various pH conditions ideal for complexing of the metals in the ore body under treatment.
[0116] At least one embodiment can be for the use of enhanced electrolytic/electrochemical cells operating in an on-site generation mode using only salt, water, electricity and custom precursor chemical mixtures, either prepackaged, or in bulk, to generate custom solutions which are injected into boreholes for the dissolution of the materials to be mined. At least one embodiment can envision a real time monitoring of the underground solution process parameters of interest such as pH and concentration of the lixiviant solution, and the modification of the associated injected solution parameters via chemical precursor addition and/or air to effect the desired changes in solution chemistry. At least one embodiment may include the use of ultrasonic transducers attached to the electrolytic cell(s) to better mix the solutions, separate metals from soil particles in solution, and to keep the electrode surfaces free of calcium carbonate and/or calcium sulphate type build-ups which would lead to electrode failure and/or process failure.
[0117] At least one embodiment can be used in the clean-up of mining wastewaters by using the electrolytic cell and appropriate precursor compounds adjusted in real time, to plate out heavy metals on the electrodes in a custom electrowinning process, or to precipitate, separate, change or destroy various waste stream constituents via electrochemical solutions, based on changing metals or other constituent concentrations in the water to be treated, and/or other sensor feedback. Furthermore, complimentary applications can extend to acid mine drainage treatment where the mixed oxidant/mixed reductant solutions could be used to kill the microbes that leach heavy metals into the water supplies, or in heap leaching operations the use of the on-site, real-time, electrochemically generated solutions could be used to destroy cyanide waste streams coming from gold leaching operations and the like.
[0118] Many of the envisioned applications for one or more of the described embodiments can extend specifically to water and wastewater treatment, perchlorate treatment, chlorine dioxide generation, solution mining operations, irrigation water treatment, industrial water treatment, oil & gas produced water treatment, treatment of rivers, ponds and reservoirs and groundwater remediation processes.
[0119] Additional aspects and advantages of the described or disclosed embodiments invention are set forth in the following description, figures, and claims
BRIEF DESCRIPTION OF THE DRAWINGS
[0120] FIG. 1 is a schematic diagram showing a water treatment apparatus according to the disclosure applied to a side stream of the main water flow where the precursor compounds are supplied from the precursor chemical carousel due to the smaller volume of precursors required, and this implies in general a smaller volume of water to be treated such as a private pool, or spa, water feature, industrial process and the like;
[0121] FIG. 1( a ) is a schematic diagram showing a top view of the precursor chemical carousel device that holds cartridges, bottles, or compressed gas cylinders as feed stocks to the electrochemical cell(s);
[0122] FIG. 1( b ) is a schematic diagram showing a profile view of the electrochemical cell that demonstrates that the electrochemical cell can be either composed of various types of electrodes, or composed of ultraviolet (UV) lamps operated as virtual anodes and related rods or the sides of the treatment chambers acting as cathodes, to constitute an electrolytic device and an electrochemical cell;
[0123] FIG. 1( c ) is a schematic diagram showing a profile view of the virtual anode and cathode configuration of a UV lamp cluster to demonstrate how multiple UV lamp can be configured and operated so as to both disinfect and be used as an advanced oxidation process generator;
[0124] FIG. 2 is a schematic diagram showing a water treatment apparatus according to another embodiment of the disclosure applied to a side stream of the main water flow where external chemical precursors either introduced as gases, or liquids are required in volume, due the types and larger volumes, or bodies of water to be treated such as a commercial pool for example, water park, drinking water treatment plant and the like;
[0125] FIG. 3 is a schematic diagram showing yet a further embodiment of the disclosure applied to the full flow of water and where the precursor compounds are supplied from the precursor chemical carousel due to the smaller volume of precursors required, and this implies in general a smaller volume of water to be treated such as a private pool, or spa, water feature and the like;
[0126] FIG. 4 is a schematic diagram showing another water treatment apparatus in accordance with the disclosure applied to the full flow of water where external chemical precursors either introduced as gases, or liquids are required in volume, due the types and larger volumes, or bodies of water to be treated such as a commercial pool for example, water park, industrial treatment process, irrigation water treatment, drinking water treatment and the like;
[0127] FIG. 5 is a schematic diagram showing yet a further embodiment of the disclosure applied to the full flow of water and where the precursor compounds are supplied from the precursor chemical carousel, directly into the electrochemical cells and not upfront of the electrochemical cells, due to the smaller volume of precursors required, and this implies in general a smaller volume of water to be treated such as a private pool, or spa, water feature and the like;
[0128] FIG. 6 is a schematic diagram showing another water treatment apparatus in accordance with the disclosure applied to the full flow of water and where volume precursor compounds are supplied in bulk as gases directly into the electrochemical cells and not upfront of the electrochemical cells, where due the types and larger volumes, or bodies of water to be treated such as a commercial pool for example, water park, drinking water treatment plant and the like;
[0129] FIG. 7 is a schematic diagram showing another water treatment apparatus in accordance with the disclosure applied to the full or partial flow of water and where precursor compounds are supplied to the flow to treat mid to high TDS water;
[0130] FIG. 8 is a schematic diagram showing another water treatment apparatus in accordance with the disclosure applied to the full or partial flow of water and where precursor compounds are supplied to the flow to treat high TDS water;
[0131] FIG. 9 is a schematic diagram showing another water treatment apparatus in accordance with the disclosure applied to the full or partial flow of water and where precursor compounds are supplied to a single electrolytic/electrochemical cell with a proton exchange membrane and prill-resin for treatment of low TDS water;
[0132] FIG. 10 is a schematic diagram showing another water treatment apparatus in accordance with the disclosure applied to the full or partial flow of water and where precursor compounds are supplied to a single electrolytic/electrochemical cell with a proton exchange membrane and prill-resin for treatment of low TDS water;
[0133] FIG. 11 is a schematic diagram showing another water treatment apparatus in accordance with the disclosure applied to the full, or partial flow of water and where precursor compounds are supplied to a zero gap electrolytic/electrochemical cell with a proton exchange membrane (PEM) for ultrapure water oxidation;
[0134] FIG. 12 is a schematic diagram showing another water treatment apparatus in accordance with the disclosure applied to the full, or partial flow of water and where precursor compounds are supplied to a zero gap electrolytic/electrochemical cell with a proton exchange membrane (PEM) for oxidation treatment of high organic concentrations in water or wastewater; and
[0135] FIG. 13 is a schematic diagram showing another water treatment apparatus in accordance with the disclosure applied to the full, or partial flow of water and where precursor compounds are supplied to a electrolytic/electrochemical cell with a proton exchange membrane (PEM) as an advanced treatment process for non-aqueous phase liquid (NAPL) contaminants or other groundwater remediation processes and/or subsurface contaminant treatment process.
DETAILED DESCRIPTION
[0136] With reference to the figures, the preferred embodiment and other embodiments will now be described as it may be applied to specific configurations of electrolytic/electrochemical cell(s) for water and/or wastewater treatment. Referring now to FIG. 1 , a water treatment apparatus 10 is shown and can be adapted for use in a water reservoir 40 , such as a swimming pool, spa, irrigation water treatment, industrial water treatment, groundwater remediation treatment, solution mining application, river, pond, aquatic mammal tank, fountain, drinking water plant, or the like. Water can be circulated through the reservoir 40 by a circulation system including, without limitation, a main conduit 11 and a primary pump 12 . In the embodiment shown, a secondary circulation system, or side stream, including a secondary supply conduit 13 and a secondary return conduit 14 , can be provided for diverting at least a portion of a stream of water, initially traveling in the direction shown by arrow A, from the main conduit 11 through the water treatment apparatus 10 , in the direction shown by arrow B, and subsequently returning the treated water back to the main conduit in the direction shown by arrow C. A check valve 15 may be used to prevent backflow of treated water from conduit 14 to conduit 13 .
[0137] Apparatus 10 generally includes, without limitation, a housing 16 having an inlet opening 17 coupled to the secondary supply conduit 13 and an outlet opening 18 coupled to the secondary return conduit 14 . An inlet line 19 passes a water stream from inlet opening 17 through a secondary pump 20 , which draws water through the apparatus 10 . Downstream of pump 20 can be an injector assembly 21 comprising a venturi injector 22 having a water inlet port 23 for receiving water ejected from pump 20 , and an inlet 25 for receiving precursor compounds, for example, an oxygen containing and/or ozone containing gas, or aqueous oxidant solution and hydrogen peroxide liquid. Apparatus 10 may further include, without limitation, an electrolytic, or corona discharge ozone generator 26 for producing ozone and a precursor-laden water outlet 24 which releases a stream of water containing precursor compounds, air, or other gases and/or being substantially aerated, into a duct 36 connected to an inlet end 27 of an electrochemical cell 28 .
[0138] In a preferred embodiment, electrochemical cell 28 can be fed via a plumbed manifold 45 to venturi injector 22 with ozone from ozone generator 26 , and/or chemical precursors from the chemical precursor carousel 29 , and/or air drawn in via a small air pump 31 from outside 32 of apparatus housing 16 . In a preferred embodiment, electrochemical cell 28 can comprise a bipolar cell (having electrochemical zones 91 - 93 as depicted in FIG. 1 ), or multiple bipolar cells arranged in series, each of which may, or may not, have a separate ultrasonic transducer 33 attached. Electrochemical zones 91 , 92 , 93 are defined by their respective ultrasonic zones of influence. In FIG. 1 . there are three ultrasonic transducers 33 attached to electrochemical cell(s) 28 and therefore there are three individual and unique water or water treatment zones within the electrochemical cell, or series of cells. Each of these ultrasonic transducers may be operated at discrete frequencies, or combinations of frequencies, in the kHz and MHz ranges, or in sweep frequency mode in the kHz or MHz range in the current invention. There could be any number of such unique treatment zones employed in the current invention. For simplicity three zones are shown in FIG. 1 . Electrochemical cell 28 can be connected to an energy source, preferably a variable power supply 34 . After the water passes through electrochemical cell 28 , the water contains mixed oxidants, for example: chlorine, chlorine dioxide, ozone, hydrogen peroxide, and hydroxyl radicals although the hydroxyl radical oxidation effect is short lived. This highly effective sanitizing stream then passes through outlet 35 which communicates with the housing outlet 18 , allowing the treated water to be passed to the main supply conduit 11 via the secondary return conduit 14 and to an application for use, for example a pool, spa, fountain cooling tower, drinking water treatment supply, or other reservoir requiring or benefited by sanitized water.
[0139] Preferably, chemical precursor injector 22 and electrochemical cell 28 are coupled in a manner effective to substantially increase or enhance the amount and/or concentration of mixed oxidants, for example, hydroxyl radicals, that are produced by electrochemical cell 28 . For example, apparatus 10 is preferably structured such that the stream of precursor-laden water leaving chemical precursor injector 22 is maintained in an aerated state when the stream enters electrochemical cell 28 . This will allow or cause the electrochemical cell to produce a useful stream of water having hydroxyl radicals and other mixed oxidants that are useful in sanitizing a variety of microorganisms, including resistant organisms like cryptosporidium and giardia , for example.
[0140] In a preferred embodiment, chemical precursor injector 22 can be substantially directly connected, preferably by single duct 36 , to electrochemical cell 28 . In this embodiment, apparatus 10 preferably includes no mixing vessel or contact chamber effective to contain and mix precursor-laden water passed to electrochemical cell 28 . It has been found that by directly connecting chemical precursor injector 22 and electrochemical cell 28 as shown, and providing a substantially continuous flow of aerated water into electrochemical cell 28 during operation of apparatus 10 , the apparatus 10 will produce a variety of hydroxyl radicals that would not be produced if the water was degassed prior to entering electrochemical cell 28 , for example, by first passing the water through a mixing chamber, degassing chamber, contact chamber or the like prior to entering electrochemical cell 28 .
[0141] Ozone generator 26 , chemical precursor injector 22 , and electrochemical cell 28 may be of any suitable type known in the art. For instance, the components of ozone generator 26 may be similar in structure and function to those disclosed in Martin, U.S. Pat. No. 6,500,332, the entire disclosure of which is incorporated herein by this specific reference, or an electrolytically generated ozone using for example, boron-doped diamond electrodes. Electrochemical cell 28 , where chlorine is a desired byproduct, may be similar to any of those disclosed in Kosarek, U.S. Pat. No. 4,361,471, Wreath, et al., U.S. Pat. No. 4,613,415, and Lynn, et al., U.S. Pat. No. 5,362,368, the entire disclosure of each of which is incorporated herein by this specific reference. The most useful applications for electrochemical cell 28 will be where the cell is used to generate mixed oxidants such as: ozone, hydroxyl radicals, hydrogen peroxide and peroxygen species in addition to chlorine species.
[0142] Preferably, electrochemical cell 28 can be substantially smaller, for example, about 25%-50% smaller, than prior art electrochemical cells, particularly if boron-doped diamond electrodes are used in the making of the electrochemical cell as the maximum current loading for diamond electrodes is up to 6.times. higher than conventional RuO coated titanium electrodes. The pulse width and amplitude of the DC current is used to modify the composition and concentration of the mixed oxidants or reductants generated on the electrodes. For example, in one embodiment, pump 20 is a relatively small, for example a 1/15 horsepower pump. The size and low power requirements of this embodiment allow the apparatus to be economically operated on a substantially continuous basis, or for an extended period of time, thereby providing long term, continuous water treatment of water in a pool, spa, fountain, water supply or other water feature.
[0143] The small size of electrochemical cell 28 , which is made possible by the fact that much oxidizing and sanitizing activity is performed by enhanced amounts and concentrations of mixed oxidants brought about via the injection of precursor compounds and generated by electrochemical cell 28 , is particularly advantageous in that all of, or substantially all of, the components of apparatus 10 can be packaged in a small, compact housing 16 that can conveniently be mounted by the side of the pool, spa, fountain, irrigation reservoir, industrial reservoir, water treatment reservoir, or the like.
[0144] In a preferred embodiment, apparatus 10 can further comprise a control system including sensors 37 , 41 , 42 and a control unit 38 . Sensors 37 , 41 , 42 may comprise any suitable sensors, preferably a quality electronic sensor, effective to monitor and/or measure a property of the water in contact therewith. Control unit 38 may comprise a microprocessor based control unit effective to regulate a property of the water passing through the apparatus based on a signal received from any of sensors 37 , 41 , 42 . As a non-limiting example, control unit 38 may be operatively coupled to a component, for example, electrochemical cell power supply 34 and/or ultrasonic power supply 39 , and/or ozone generator 26 , and/or pump 20 , and may be responsive to regulate the component in response to an input signal from sensor 37 .
[0145] As a non-limiting example, sensor 37 may comprise a flow sensor mounted upstream of the chemical percursor injector 22 . Control unit 38 may be configured to shut off or regulate power to pump 20 , ozone generator 26 and/or electrochemical cell power supply 34 when sensor 37 indicates that flow has dropped below a predetermined level.
[0146] Apparatus 10 may further comprise a pH controller (not depicted) for example, integrated into control unit 38 , configured to maintain a desired pH level in the water flowing through apparatus 10 . As a non-limiting example, the pH controller unit can be configured and located to release carbon dioxide gas, hydrochloric acid or other suitable agent from the precursor chemical carousel 29 into injector 22 by means of manifold system 45 . The pH controller unit may also include a pH sensor 48 , and be structured to regulate the addition of acid, for example, for maintaining a comfortable effective pH of about 7.2 in reservoir 40 being treated and preventing the downstream pH from dropping below about 6.5. With pH above about 6.5, wetted metal parts downstream of electrochemical cell 28 are not subject to a destructive corrosion rate.
[0147] The pH controller unit (preferably integrated into control unit 38 ) may be configured to be effective to create a continuous acidic wash in duct 36 , the wash having a pH effective to reduce or eliminate scale buildup on the electrodes of electrochemical cell 28 .
[0148] Water treatment apparatus 10 can be structured such that with sufficient precursor chlorides chlorine is generated on the anode of electrochemical cell 28 while other oxidants are generated from a combination of ozone or molecular oxygen and hydrogen on the cathode. For average flow velocities, low current densities, and with the injection of chemical precursors such as ozone containing gas, or water from ozone generator 26 having an ozone concentration less than 100 ppm, the bi-polar cathode of cell 28 mostly produces the hydroxyl radical (OH), which immediately reacts with any organic compound or chloramines in the stream. For average flow velocities, low current densities, and air/water injection with ozone concentrations greater than 100 ppm, a high ozone concentration will be left in the water and the cathode-generated hydrogen will make both the hydroxyl radical (OH) and the hydroperoxyl radical (HO2). The hydroperoxyl radical can react with water (H2O) to form the hydroxyl radical (OH) and hydrogen peroxide (H2O2). For high concentrations of ozone-containing water or gas passed into electrochemical cell 28 , a high ozone concentration residual will be left in the water, and the cathode-generated hydrogen will make both the hydroxyl radical (OH) and the hydroperoxyl radical (HO2) and some trace chlorine dioxide (ClO2) generated on the anode at high current densities. Some of the ozone also reacts with the water to make hydrogen peroxide (H2O2).
[0149] As a non-limiting example, in use in a swimming pool, control unit 38 can be used to create a water stream passing from the pool into apparatus 10 to achieve a high mixed oxidant concentration in order to cause rapid oxidation of organic loads. As the ORP reading approaches a set point, the chemical precursor volume and/or concentrations can be reduced to maximize chlorine residual in the water at a set point turn off. Control unit 38 may also be coupled to water quality sensor 41 for monitoring the quality of water in reservoir 40 . Control unit 38 may include a regulator (not depicted) for automatically varying power to electrochemical cell 28 as needed to maintain the water quality at a desired level. Water quality sensor 41 may be, for instance, an ORP sensor for measuring the oxidizing activity of the water. Other sensors suitable for measuring or monitoring properties such as the pH or chlorine concentration of the water could also be used instead of, or in addition to, an ORP sensor.
[0150] Referring now to FIG. 1 a ., a top view of precursor chemical carousel 29 used in water treatment apparatus 10 of FIG. 1 is depicted, and any number of precursor compounds can be stored as replenishable cartridges 60 in the body of apparatus 10 as liquids, gases or dissolvable solids. Cartridges 60 may include any and all precursor compounds to be used for enhancement of water quality, for enhancement of advanced oxidation processes, and for enhanced disinfection and organics destruction. Accordingly, precursor chemical cartridges 60 could contain, for example, hydrogen peroxide, hydrochloric acid, peroxyacids, halogen salts, ozone, sulphate salts, oxygen, nitrogen, ammonia, sodium bisulfide and bisulfite salts, bicarbonate salts, sulfur dioxide and the like.
[0151] FIG. 1 b . depicts a schematic of electrochemical cell 28 , as depicted in FIG. 1 , composed of either various electrodes 71 , for example boron-doped diamond sheets, or ultraviolet (UV) lamps operated as virtual anodes 72 with the housing acting as a cathode surface 73 in its simplest form as a monopolar cell. The pulse width and amplitude of the DC current is used to create the virtual cathode or anode charge on the lamp surface. In this embodiment, the pulsed direct current can be passed through an electrolytic coating (such as boron-doped diamond, iridium oxide, titanium sub-oxide, doped aluminum oxide, doped silicon oxide, platinum metal, silica carbide, and tantalum carbide) deposited directly on the UV lamp's quartz surface to generate an anode charge on the surface whereupon the low pH condition that exists at the surface of the UV lamp prevents scaling or fouling of the UV lamp. The UV light is then used for multiple simultaneous purposes, such as disinfection, photolysis and advanced oxidation. The UV light is used to enhance the reaction rates of aqueous contaminant destruction, to destroy chloramines, to reduce pathogen levels, to convert elemental mercury to mercury oxide, and to generate hydroxyl radicals and other mixed-oxidants. Modulation of the UV output and/or pulsed current through the electrolytic coating can also be included according to the water treatment demands. UV mercury lamps can be used to oxidize elemental mercury to mercury oxide for removal as a solid precipitate.
[0152] FIG. 1 c . depicts the UV lamp-based electrochemical cell 28 referenced in FIG. 1 and the water treatment apparatus 10 , but with a group of UV lamps 80 , rather than a single UV lamp, as would be typical in a larger installation or for treatment of the full flow of water or a significant side flow. FIG. 1 c . depicts the end view of a typical UV reactor 83 , familiar to those skilled in the art of UV system design, that can be operated as an electrochemical cell when UV lamps 80 are operated as virtual anodes and the body 81 of the UV reactor 83 and conductive rods placed within the core 82 of the reactor 83 constitute the cathode(s) of electrochemical cell 28 . Megahertz ultrasound can be used to enhance the photochemical reactions.
[0153] FIG. 2 shows another water treatment apparatus 110 . Except as expressly described herein, apparatus 110 is similar to apparatus 10 , and features of apparatus 110 which correspond to features of apparatus 10 are designated by the corresponding reference numerals increased by 100. In this FIG. 2 embodiment, the water treatment apparatus can be designed to be used for treatment of larger volumes of water, or more complicated treatment processes where larger volumes of precursor compounds are required and it is not practical to feed the electrochemical cell 28 from the chemical precursor carousel 129 . In this embodiment the precursor compounds can be fed from bulk storage feed stocks such as bulk gases 150 via an automatic valve 153 controlled by the system controller 138 , and/or bulk liquids 151 which may include use of a pump 152 controlled by system controller 138 into the chemical precursor manifold 145 for transport to the injection system 122 . Bulk gases for example could include argon, nitrogen, ozone, oxygen, nitrogen, sulfur dioxide, carbon dioxide, carbon monoxide, ammonia, and the like. Bulk liquids for example could include concentrated brine, chelating agents, liquid ammonia, chlorine, hydrogen peroxide, hydrochloric acid, peroxyacids, halogen salts, sulphate salts, ammonia, sodium bisulfide and bisulfite salts, bicarbonate salts and the like.
[0154] FIG. 3 shows another water treatment apparatus 210 . Except as expressly described herein, apparatus 210 is similar to apparatus 10 , and features of apparatus 210 which correspond to features of apparatus 10 are designated by the corresponding reference numerals increased by 200. In this embodiment, the bypass lines ( 13 and 14 of FIG. 1 ) have been eliminated, and a chemical precursor injector 222 and an electrochemical cell 228 are mounted directly in the main conduit 211 of the reservoir 240 circulation system. Water, powered by a pump 212 in line 211 , enters the injector housing 221 through inlet 223 , and enters the chemical precursor injector 222 . Water passing through chemical precursor injector 222 enters electrochemical cell 228 via the precursor-laden water inlet 237 . The mixed oxidants produced in electrochemical cell 228 then exit electrochemical cell 228 through the cell water outlet 235 , and continue toward reservoir 240 via main conduit 211 . As in the previous embodiment, a flow sensor 237 may be provided upstream of the chemical precursor injector 222 for monitoring flow through the system and shutting off power to the electrolytic chlorinator (electrochemical cell 228 ) when the flow drops below a predetermined level. In this embodiment there may be a separate housing 258 for sensors 237 , 248 , 242 and the precursor injector housing 221 and electrochemical cell 228 complete with ultrasonic transducers 233 depending on the proximity of system control unit 238 to main conduit 211 . The electrochemical zones 291 , 292 , 293 are defined by their respective ultrasonic zones of influence. The pulse width and amplitude of the DC current is used to modify the composition and concentration of the mixed oxidants or reductants generated on the electrodes. In FIG. 3 , there are three ultrasonic transducers 233 attached to electrochemical cell(s) 228 and therefore there are three individual and unique water or water treatment zones within the electrochemical cell 228 . Each of these ultrasonic transducers may be operated at discrete frequencies, or combinations of frequencies, in the kHz and MHz ranges, or in sweep frequency mode in the kHz or MHz range. There could be any number of such unique treatment zones employed. For simplicity three zones are shown in FIG. 3 .
[0155] Chemical precursors for the chemical precursor injector 222 are supplied through a precursor manifold 245 leading from an ozone generator 226 and/or the precursor chemical carousel 229 , and/or air via the air pump 231 that takes in outside air at inlet 232 . Ozone generator 226 is replaced by an atomic nitrogen, sulfur dioxide, atomic hydrogen, or amogen generator, or the like for reductive reactions in electrochemical cell 228 .
[0156] Apparatus 210 preferably also includes a control system 238 for example, contained within housing 216 for controlling various aspects of the water treatment system. For instance, control unit 238 is preferably coupled to both flow sensor 237 and power supply 234 of electrochemical cell 228 , causing electrochemical cell 228 to shut off automatically when the flow falls below a predetermined or safe level.
[0157] Control unit 238 may also be coupled to a water quality sensor 241 for monitoring the quality of water in reservoir 240 . Control unit 238 may include a regulator (not depicted) for automatically varying power to electrochemical cell 228 as needed to maintain the water quality at a desired level. Water quality sensor 241 may be, for instance, an ORP sensor for measuring the oxidizing activity of the water. Other sensors suitable for measuring or monitoring properties such as the pH or chlorine concentration of the water could also be used instead of, or in addition to, an ORP sensor.
[0158] FIG. 4 shows a further water treatment apparatus 310 . Except as expressly described herein, system 310 is similar to apparatus 10 , and features of apparatus 310 which correspond to features of system 10 are designated by the corresponding reference numerals increased by 300. In this embodiment, water treatment apparatus 310 can be designed to be used for treatment of larger volumes of water, or more complicated treatment processes where larger volumes of precursor compounds are required and it is not practical to feed electrochemical cell 328 from the chemical precursor carousel 329 . In this embodiment the precursor compounds can bee fed from bulk storage feed stocks such as bulk gases 350 via an automatic valve 353 controlled by the system control unit 338 , and/or bulk liquids 351 which may include use of a pump 352 controlled by system control unit 338 into the chemical precursor manifold 345 for transport to the injection system 322 . Bulk gases for example could include argon, nitrogen, ozone, oxygen, ammonia, and the like. Bulk liquids for example could include concentrated brine, chelating agents, liquid ammonia, chlorine, hydrogen peroxide, hydrochloric acid, peroxyacids, halogen salts, sulphate salts, ammonia, sodium bisulfide and bisulfite salts, bicarbonate salts and the like.
[0159] FIG. 5 shows another water treatment apparatus 410 . Except as expressly described herein, apparatus 410 is similar to apparatus 10 , and features of apparatus 410 which correspond to features of apparatus 10 are designated by the corresponding reference numerals increased by 400. In this embodiment, the bypass lines ( 13 and 14 of FIG. 1 ) have been eliminated, the chemical precursor injector ( 322 of FIG. 4 ) has been eliminated, and an electrochemical cell 428 is mounted directly in the main conduit 411 of the reservoir 440 circulation system. In this embodiment the precursor compounds are injected via pump 459 into the electrochemical cell zones 491 - 493 directly. The electrochemical zones 491 , 492 , 493 are defined by their respective ultrasonic zones of influence. The pulse width and amplitude of the DC current is used to modify the composition and concentration of the mixed oxidants or reductants generated on the electrodes in each respective zone. Electrochemical cell zone 491 may be used to precipitate metals, salts, hardness, organics and the like which are then removed from the cell at exit point 494 . Electrochemical cell zone 493 may also be configured as a UV polishing zone for the treatment process. In FIG. 5 there are three ultrasonic transducers 433 attached to the electrochemical cell(s) and therefore there are three individual and unique water, or water treatment zones within the electrochemical cell, or series of cells. Each of these ultrasonic transducers may be operated at discrete frequencies, or combinations of frequencies, in the kHz and MHz ranges, or in sweep frequency mode in the kHz or MHz range. There could be any number of such unique treatment zones employed. For simplicity three zones are shown in FIG. 5 . Water, powered by a pump 412 in line 411 , enters electrochemical cell 428 through inlet 427 .
[0160] Precursor compounds originating from chemical precursor carousel 429 , and/or ozone generator 426 , and/or air via the air pump 431 using ambient air inlet 432 are transported along chemical precursor manifold 445 and pumped via pump 459 directly into electrochemical cell 428 . The mixed oxidants produced in electrochemical cell 428 then exit electrochemical cell 428 through the cell water outlet 435 , and continue toward reservoir 440 via main conduit 411 . As in the previous embodiment, a flow sensor 437 may be provided upstream of electrochemical cell 428 for monitoring flow through the system and shutting off power to electrochemical cell 428 when the flow drops below a predetermined level. In this embodiment there may be a separate housing 458 for the sensors 437 , 448 , 442 and electrochemical cell 428 complete with ultrasonic transducers 433 , depending on the proximity of control unit 438 to main conduit 411 .
[0161] Control unit 438 may also be coupled to a water quality sensor 441 for monitoring the quality of water in reservoir 440 . Control unit 438 may include a regulator for automatically varying power to electrochemical cell 428 as needed to maintain the water quality at a desired level. Water quality sensor 441 may be, for instance, an ORP sensor for measuring the oxidizing activity of the water. Other sensors suitable for measuring or monitoring properties such as the pH or chlorine concentration of the water could also be used instead of, or in addition to, an ORP sensor.
[0162] FIG. 6 shows a further water treatment apparatus 510 . Except as expressly described herein, system 510 is similar to apparatus 10 , and features of apparatus 510 which correspond to features of system 10 are designated by the corresponding reference numerals increased by 500. In this embodiment, water treatment apparatus 510 can be designed to be used for treatment of larger volumes of water, or more complicated treatment processes where larger volumes of precursor compounds are required and it is not practical to feed the electrochemical cell 528 from the chemical precursor carousel 529 . In this embodiment the precursor compounds can be fed from bulk storage feed stocks such as bulk gases 550 via an automatic valve 553 controlled by the system control unit 538 , and/or bulk liquids 551 which may include use of a pump 552 controlled by system control unit 538 into the chemical precursor manifold 545 . Bulk gases for example could include argon, nitrogen, ozone, oxygen, ammonia, and the like. Bulk liquids for example could include concentrated brine, chelating agents, liquid ammonia, chlorine, ozone, hydrogen peroxide, halogen salts and the like. Individual electrochemical treatment zones are designed into the current invention for precipitation, flocculation, oxidation, or reduction processes.
[0163] In this embodiment the precursor compounds are injected via pumps 559 into the electrochemical cell zones 591 - 593 directly. Electrochemical zones 591 , 592 , 593 are defined by their respective ultrasonic zones of influence. In FIG. 6 there are three ultrasonic transducers 533 attached to the electrochemical cell(s) 528 and therefore there are three individual and unique water or water treatment zones within the electrochemical cell 528 , or series of cells. The electrochemical zones 591 - 593 are separated to enhance the desired reaction within cell 528 . Each of these ultrasonic transducers 533 may be operated at discrete frequencies, or combinations of frequencies, in the kHz and MHz ranges, or in sweep frequency mode in the kHz or MHz range. There could be any number of such unique treatment zones employed. For simplicity FIG. 6 shows three such zones. Water, powered by a pump 512 in line 511 , enters electrochemical cell 528 through inlet 527 .
[0164] Precursor compounds originating from the bulk storage feed stocks such as bulk gases 550 via automatic valve 553 controlled by system control unit 538 , and/or bulk liquids 551 which may include use of a pump 552 controlled by the system control unit 538 , and/or the ozone generator 526 , and/or air via air pump 531 using ambient air inlet 532 are transported along chemical precursor manifold 545 and pumped via pump 559 directly into electrochemical cell 528 . The mixed oxidants produced in electrochemical cell 528 then exit electrochemical cell 528 through the cell water outlet 535 , and continue toward reservoir 540 via main conduit 511 . As in the previous embodiment, a flow sensor 537 may be provided upstream of electrochemical cell 528 for monitoring flow through the system and shutting off power to electrochemical cell 528 when the flow drops below a predetermined level. In this embodiment there may be a separate housing 558 for the sensors 537 , 548 , 542 and electrochemical cell 528 complete with the ultrasonic transducers 533 depending on the proximity of control unit 538 to main conduit 511 .
[0165] Control unit 538 may also be coupled to a water quality sensor 541 for monitoring the quality of water in reservoir 540 . Control unit 538 may include a regulator for automatically varying power to electrochemical cell 528 as needed to maintain the water quality at a desired level. Water quality sensor 541 may be, for instance, an ORP sensor for measuring the oxidizing, or reducing activity of the water. Other sensors suitable for measuring or monitoring properties such as the pH or chlorine concentration of the water could also be used instead of, or in addition to, an ORP sensor.
[0166] Apparatus 510 can be structured to be highly effective in producing an aqueous mixture having an increased or enhanced biocidal activity, for example, relative to an identical apparatus without the inclusion of precursor compounds. Without wishing to be limited by any particular theory of operation, by oxygenating the water passed to electrochemical cell 528 via the injection of air/oxygen from inlet 532 and substantially maintaining the water in the oxygenated state while the water is introduced to the electrolytic device, the electrolytic activity in the water causes increased chemical reactions in the water that more effectively produce biocidally active materials or species, for example, higher concentrations of one or more oxidants, and/or more varieties of different oxidants, than are produced without the water being oxygenated and substantially maintained in the oxygenated state. Ozone generator 526 is replaced by an atomic nitrogen, atomic hydrogen, sulfur dioxide, or amogen generator, or the like for reductive reactions in electrochemical cell 528 . The addition of a salt, for example, a halite salt, for example, sodium chloride and/or sodium bromide, to the water in apparatus 510 , further enhances the production of biocidally active materials.
[0167] In some embodiments, the method includes utilizing a tank 551 to inject an acidic component or carbon dioxide gas 550 into the water in an amount effective to produce an acidic wash for electrochemical cell 528 and/or a super-oxidant level in the water exiting electrochemical cell 528 .
[0168] The steps of withdrawing the stream from reservoir 540 and returning the stream to reservoir 540 may consist of simply pumping the stream through main conduit 511 of the reservoir's preexisting circulation system, or they may comprise diverting the stream from main conduit 511 into a secondary circulation system communicating with the pre-existing circulation system. In the former case, the steps of injecting chemical precursors into the stream and directing the stream through electrochemical cell 528 to generate mixed oxidants are performed within main conduit 511 itself. In the latter case, the steps of injecting chemical precursors into the stream of water and introducing the precursor-laden stream of water into electrochemical cell 528 occur within the secondary circulation system. The secondary circulation system including a secondary pump operates independently of the primary pump of the reservoir's circulation system, thus allowing 24-hour operation of the water treatment apparatus. Electrochemical cell zone 591 may be used to precipitate metals, salts, hardness, organics and the like which are then removed from the cell zone at exit point 594 . Electrochemical cell zone 593 may also be configured as a UV polishing zone for the treatment process.
[0169] FIG. 7 shows a further water treatment apparatus 600 in accordance and in the present example, for use with single or multiple cells, with proton exchange membranes (PEMs) 601 , to treat a water with mid to high total dissolved solids (TDS) levels. In the current embodiment, the precursor feeds 611 are injected into the anoltye chamber 602 and catholyte chamber 603 of the electrolytic/electrochemical cell 615 via inlets 607 in addition to the water to be treated 609 . Upon treatment in cell 615 the water exits cell 615 at out separated outlets 608 and then can be recycled 612 back through the anolyte chamber 602 or catholyte chamber 603 as desired to further treat the water stream 609 . Electrolytic cell 615 further comprises ultrasonic tranducers 604 , anode 605 , and cathode 606 .
[0170] FIG. 8 shows a further water treatment apparatus 700 and similar to that of FIG. 7 , and in the present example, for use with single or multiple cells, without membranes, to treat a water with high total dissolved solids (TDS) levels. In the current embodiment, the precursor feeds 711 are injected into the electrochemical treatment chamber 713 of the electrolytic/electrochemical cell 715 in addition to the water 709 that is to be treated at inlet 707 . Upon treatment in cell 715 , the water 710 exits cell 715 at outlet 708 and then can be recycled 712 back through the electrochemical chamber 713 as desired to further treat water stream 709 . Electrolytic cell 715 further comprises ultrasonic tranducers 704 , anode 705 , and cathode 706 .
[0171] FIG. 9 shows a further water treatment apparatus 800 and similar to that of FIGS. 7 and 8 , and in the present example, for use with single or multiple cells, with membranes 801 (PEM), to treat a water with low TDS levels and where a conductive prill-resin electrolyte 814 must be used. In the current embodiment, the precursor feeds 811 are injected into the anoltye chamber 802 and catholyte chamber 803 of the electrolytic/electrochemical cell 815 in addition to the water which is to be treated 809 . Upon treatment in cell 815 , the treated water 810 exits cell 815 at separated outlets 808 and then can be recycled 812 back through the anolyte chamber 802 or catholyte chamber 803 as desired to further treat water stream 809 . Electrolytic cell 815 further comprises ultrasonic tranducers 804 , anode 805 , and cathode 806 .
[0172] FIG. 10 shows a further water treatment apparatus 900 and similar to that of FIGS. 7-9 , and in the present example, for use with single or multiple cells, without membranes, to treat a water 909 with low TDS levels and which contains a conductive prill-resin electrolyte 914 . In the current embodiment, the precursor feeds 911 are injected into the electrochemical treatment chamber 913 of electrolytic/electrochemical cell 915 in addition to the water 909 that is to be treated at inlet 907 . Upon treatment in cell 915 the treated water 910 exits cell 915 at outlet 908 and then can be recycled 912 back through the electrochemical chamber 913 as desired to further treat water stream 909 . Electrolytic cell 915 further comprises ultrasonic tranducers 904 , anode 905 , and cathode 906 .
[0173] FIG. 11 shows a further water treatment apparatus 1000 , a zero gap electrolytic/electrochemical cell, and in the present example for use with single or multiple cells, with a proton exchange membrane (PEM) 1001 , to treat an ultrapure water with very low to no total dissolved solids (TDS), where complete disinfection of the treated water 1010 is required, and where a residual disinfectant is required to inhibit algae, or bacteria, or biofilm growth in the ultrapure water piping. At least one embodiment is ideal for use in the semiconductor industry where ultrapure water is required for quality manufacturing. In the current embodiment, the precursor feeds 1011 are injected into the anoltye chamber 1002 and catholyte chamber 1003 of the electrolytic/electrochemical cell 1030 in addition to the water 1009 that is to be treated via inlet 1007 . Upon treatment in cell 1030 , the treated water 1010 exits cell 1030 at separated outlets 1008 for use. At least one embodiment can be used in ultrapure applications as it can use a pure water closed loop 1015 which is constantly recycled through catholyte chamber 1003 to build up the concentration of hydrogen peroxide in tank 1016 . Make up water 1018 to the pure water closed loop 1015 is first treated to a very high quality via the electrodeionization (EDI) cell 1019 . Air, or oxygen, 1017 as a precursor material is injected into catholyte chamber 1003 to enhance the production of hydrogen peroxide in loop 1015 . The produced hydrogen peroxide can be used 1020 as a precursor feed stock to anolyte chamber 1002 or for residual disinfection of the treated water 1010 post electrochemical treatment. Electrolytic cell 1030 further comprises ultrasonic tranducers 1004 , BDDE/PbO perforated-porous anode 1005 , and BDDE/Noble metal cathode 1006 .
[0174] FIG. 12 shows a further water treatment apparatus 1100 (similar to apparatus 1000 of FIG. 11 with corresponding parts having a reference number increased by 100), a zero gap electrolytic/electrochemical cell 1130 and in the present example, for use with single or multiple cells, with a proton exchange membrane 1101 , to treat a water or wastewater stream with a total dissolved solids (TDS) range of approximately 500-4,000, where oxidation and disinfection of the treated water 1110 is required, and where a residual disinfectant is required to inhibit algae, or bacteria growth.
[0175] At least one embodiment can be used in the water and wastewater industry where a membrane cell is used and cathode 1106 does not scale up or require constant acid washing. In the current embodiment, precursor feeds 1111 are injected into anoltye chamber 1102 and catholyte chamber 1103 of electrolytic/electrochemical cell 1130 in addition to the water 1109 that is to be treated. Upon treatment in the cell 1130 , the treated water 1110 exits cell 1130 at separated outlets 1108 for use. At least one embodiment can be used in water wastewater treatment applications in that it can use a pure water closed loop 1115 which is constantly recycled through catholyte chamber 1103 to build up the concentration of hydrogen peroxide in tank 1116 . Make up water 1118 to pure water closed loop is first treated to a very high quality via EDI cell 1119 . Air, or oxygen, 1117 as a precursor material is injected into catholyte chamber 1103 to enhance the production of hydrogen peroxide in loop 1115 . The produced hydrogen peroxide can be used 1120 as a precursor feed stock to anolyte chamber 1102 or for residual disinfection and oxidation of treated water 1110 post electrochemical treatment. Electrolytic cell 1130 further comprises ultrasonic tranducers 1104 , BDDE/PbO perforated-porous anode 1105 , and BDDE/Noble metal cathode 1106 .
[0176] FIG. 13 shows a further water treatment apparatus 1200 (similar to that of apparatus 1100 of FIG. 12 with corresponding parts having a reference number increased by 100), a zero gap electrolytic/electrochemical cell 1230 and in the present example, for use with single or multiple cells, with a proton exchange membrane (PEM) 1201 , to treat a groundwater 1228 remediation stream where oxidation/reduction of the water 1209 is required. At least one embodiment can be used in oil and gas produced water cleanup and for ground water remediation projects where a membrane electrolytic/electrochemical cell is used to generate on-site oxidants/reductants to treat a contaminated stream and the membrane separated cathode does not scale up or require constant acid washing. In the current embodiment, precursor feeds 1211 are injected into anoltye chamber 1202 and catholyte chamber 1203 of electrolytic/electrochemical cell 1230 in addition to the water 1209 that is to be treated. Upon treatment in cell 1230 , treated water 1210 exits cell 1230 at separated outlets 1208 for use. At least one embodiment can be used in water and wastewater treatment applications in that the current invention can use a pure water closed loop 1215 which is constantly recycled through catholyte chamber 1203 to build up the concentration of hydrogen peroxide in tank 1216 . Make up water 1218 to pure water closed loop 1215 is first treated to a very high quality via the electrodeionization (EDI) cell 1219 . Air, or oxygen, 1217 as a precursor material is injected into catholyte chamber 1203 to enhance the production of hydrogen peroxide in loop 1215 . The produced hydrogen peroxide can be used 1220 as a precursor feed stock to anolyte chamber 1202 or for residual disinfection and oxidation of treated water 1210 post electrochemical treatment. EDI pretreatment 1226 is possible on the recycle loop for a fully contained electrochemical groundwater remediation system. Flexibility is afforded by the current implementation whereby varying the incoming chloride content via the use, or non-use of electrodeionization (EDI) it is possible to selectively determine the mixed oxidant composition chemistry ( 03 and/or H2O2 and/or mixed oxidant products from electrolytic/electrochemical cell 1230 depending on precursors and chloride content into cell 1230 ) that is produced in anolyte chamber 1202 . This custom mixed oxidant or mixed reductant solution is further conditioned by pH adjustment 1222 , surfactant addition 1223 , or air injection 1224 prior to being pumped 1225 below ground 1227 into treatment zone 1228 . Contaminated groundwater 1209 to be remediated is pumped 1225 out of the treatment zone 1228 and is either sent once through EDI pretreatment process 1226 and on through an EDI cell 1219 and into anolyte chamber 1202 for treatment on a once through basis, or contaminated groundwater 1209 can be recycled any number of cycles through anolyte chamber 1202 . Electrolytic cell 1230 further comprises ultrasonic tranducers 1204 , BDDE/PbO perforated-porous anode 1205 , and BDDE/Noble metal cathode 1206 .
[0177] At least one embodiment is for generating a customized oxidant or reductant mix in an electrochemical cell for treating water or aqueous solutions from a reservoir, said apparatus comprising: (a) an inlet operatively connected to said reservoir by a supply circulation system allowing the transport of said water or aqueous solution from said reservoir to said inlet, a pump for sending said water or aqueous solution through said electrochemical cell, said pump operatively connected to said inlet; (b) an injector assembly comprising a venturi injector, an inlet port operatively connected to said pump, a precursor inlet, and an outlet port, said outlet port operatively connected to a cell inlet of said electrochemical cell; (c) a manifold operatively connecting an ozone source, a source of at least one chemical precursor, and an air source to said precursor inlet of said injector assembly; (d) an variable power supply operatively connected to said electrochemical cell, said electrochemical cell including a cell outlet operatively connected to said supply circulation system; (e) a control system including a control unit in communication with at least one sensor for monitoring and generating at least one signal to said control unit based on at least one property of said water or aqueous solution, said at least one sensor located to operatively monitor said water or aqueous solution, said control unit including a microprocessor configured to regulate said at least one property in real-time response to said at least one signal; and (f) said control unit operatively connected to at least one component selected from the group of said pump, said ozone source, said source of at least one chemical precursor, said air source, and said variable power supply, said control unit configured to selectively regulate the power supplied to and the operation of any component of said at least one component group in real-time response to said at least one signal. The source of at least one chemical precursor may be adjusted to comprise any chemical precursors specifically desired for the treatment of said water or aqueous solution. The source of at least one chemical precursor can include a carousel holding one or more containers, each of said one or more containers holding a chemical precursor, said carousel operative to selectively deliver at least one chemical precursor to said manifold under the control of said control unit. The electrochemical cell can comprise at least one bipolar cell arranged in series. The at least one bipolar cell can include at least one ultrasonic transducer, each of said at least one ultrasonic transducers defining a respective ultrasonic zone of influence within said at least one bipolar cell, and said apparatus further comprises an ultrasonic power supply operatively connected to said at least one ultrasonic transducer and said control unit. The at least one ultrasonic transducer can operate at frequency ranges at or near 12 kHz to 70 kHz for cavitation, degassing, and/or mixing of said water or aqueous solution within said respective ultrasonic zone of influence and at or near 0.1 MHz to 1 MHz for hydroxyl generation within said respective ultrasonic zone of influence. The at least one bipolar cell can include an electrode having a dimensionally stable anode coating. The dimensionally stable anode coating may be selected from the group consisting of boron-doped diamond, iridium oxide, titanium sub-oxide, doped aluminum oxide, or doped silicon oxide. The bipolar cell can include at least one ultraviolet light source operating as a virtual anode. The virtual anode can comprise an ultraviolet light source coated with an electrolytic coating. The water or aqueous solution can be in an aerated state upon leaving said injector assembly and entering said electrochemical cell. The control unit can regulate a pulse width and amplitude of a DC current generated by said variable power supply. The control unit can further comprise a pH controller configured to release any suitable agent from said source of at least one chemical precursor to regulate the pH level in said water or aqueous solution. The at least one sensor can comprise one or more sensors selected from the group consisting of a flow sensor mounted between said inlet and said injector assembly, a pH sensor operatively located at any desired point in the apparatus for monitoring said water or aqueous solution, and a water quality sensor located in said reservoir. The at least one sensor may be selected from the group consisting of: a total dissolved solids sensor, an oxidation-reduction potential sensor, a pH sensor, a UV-visible to near-infrared sensor, and a far-infrared sensor. The electrochemical cell, said injector assembly, and said source of chemical precursors can be integrated into a housing. The precursors can be selected from the group consisting of: air, oxygen, hydrogen peroxide, salts of bromide, iodide or chloride, ammonia, amines, peroxy-carbonates, peroxy-sulfates, and ozone. The precursors can also be gases selected from the group of: air, ozone, oxygen, argon, methane, ammonia, nitrogen, carbon dioxide, chlorine, and hydrogen sulfide. The present invention may also utilize a gravity feed arrangement to feed precursors into said water or aqueous solution, and may also utilize a static discharge device for the precursors that discharges a predetermined amount of precursor based on the rate of flow of the water or aqueous solution.
[0178] At least one embodiment of the method can comprise treating a flow of water or aqueous solution in water treatment applications, said method comprising the steps of: (a) providing at least one electrochemical cell; (b) treating said flow of water or aqueous solution by passing said flow through at least one electrochemical cell and subjecting said flow to an electrolytic process in said at least one electrochemical cell to create a desired customized water chemistry in said flow; (c) generating an oxidation or reduction or precipitation process in said electrochemical cell for treating said flow, said step of generating including operating a cathode and an anode in said electrochemical cell; (d) providing precursor materials that can be selectively injected into said flow; and (e) injecting said precursor materials into said flow prior to said step of treating to adjust said properties of said flow according to said desired customized water chemistry. The method may also include the step of monitoring properties of said flow with at least one sensor located upstream of said electrochemical cell and at least one sensor located downstream of said electrochemical cell. The method may also include the step of sending inputs from said at least one sensor to a control unit. The method may also include the step of controlling said steps of treating, generating, and injecting with said control unit configured to immediately react to said step of monitoring relative to said desired customized water chemistry and relative to fluctuations in said properties of said flow. The method may also include said step of controlling being manually directed. The method may also include said step of controlling comprising automatically reacting in real-time to said inputs by regulating the injection of said precursor materials. The method may also include said step of controlling being performed with a microprocessor adapted to receive and respond to said inputs. The method may also include wherein said anode is a dimensionally stable anode having a coating selected from the group of materials consisting of: boron-doped diamond, iridium oxide, titanium sub-oxide, doped aluminum oxide, doped silicon oxide, platinum metal, or a silica or tantalum carbide. The method may also include the step of disinfecting said flow via use of an ultraviolet light as said anode. The method may also include the step of arranging said at least one electrochemical cell in series. The method may also include the step of arranging said at least one electrochemical cell in parallel. The method may also include using ultrasound for a purpose selected from the following group consisting of: improving the rate of reaction in said step of generating, cleaning precipitated hardness from said cathode, degassing said flow, and increasing hydroxyl generation in said electrochemical cell. The method may also include said ultrasound being operated in a range from at or near 12 kHz to 70 kHz for said purposes of improving and cleaning and degassing, and in a range from at or near 0.1 MHz to 1 MHz for said purpose of increasing. The method may also include cleaning said anode with a solid-state electrolytic system. The method may also include said step of cleaning comprising coating said anode with an electrolytic coating and passing a current through said coating to generate an acidic layer on said coating where said coating is in contact with said flow. The method may also include said step of treating comprising removing arsenic, said step of generating further comprising placing an ion-exchange resin-impregnated membrane separating said flow between said anode and said cathode, and oxidizing arsenic III to arsenic IV. The method may also include said step of injecting comprising adding ammonia as a precursor reducing agent in said flow. The method may also include said step of controlling being configured to regulate said step of injecting such that said flow falls within desired pH ranges effective for leaching metals in solution mining applications. The method may also include said step of injecting further comprising adding at least one precursor selected from the group consisting of sulfide, carbonate, phosphate or sulfate ions to said flow to promote the precipitation of metals in said electrochemical cell for improving the leaching of metals in mine effluent. The method may also include the step of injecting said flow into boreholes in the ground for dissolution of metals in the ground after said steps of treating and generating. The method may also include said step of monitoring including the pH and concentration of said flow, and said step of injecting includes chemical compounds and air. The method may also include said step of injecting comprising reductants to create a reducing environment in said electrochemical cell for the treatment of contaminants not neutralized by an oxidation process. The method may also include said step of treating further comprising precipitating water hardness contributors at said cathode in said flow. The method may also include using a closed-loop ultrapure water circuit to continuously prevent materials from precipitating on said cathode and to increase the reaction rates in said generating step, wherein said flow at said cathode produces hydrogen peroxide for reinjection to said flow. The method may also include said step of controlling being configured to destroy organic contaminants in said flow. The method may also include said step of generating comprising providing said anode and said cathode in separated compartments and creating desired pH ranges in said compartments to separate precious metals from said flow. The method may also include said step of generating further comprising the use of an anionic or cationic membrane for generating higher pH concentrations in said compartments. The method may also include catalyzing oxidation or reduction reactions in said electrochemical cell by generating free radicals from organic or inorganic compounds in said flow by using an ultraviolet light source as an anode. The method may also include said step of injecting comprising increasing the pressure of said flow by super-saturating said flow with said precursor materials, said precursor materials being in gaseous form, wherein said flow is pressurized to a level in a range of at or near 10 to 200 psi greater than the operating pressure of said electrochemical cell, said level depending on the concentration required for the stoichiometry of said step of generating an oxidation or reduction or precipitation process in said electrochemical cell. Said step of treating may further comprise recirculating said flow through said electrochemical cell until said level is reached. Said step of treating may further comprise passing said flow through multiple electrochemical cells until said level is reached. Said precursors include gases selected from the group consisting of: air, ozone, oxygen, argon, methane, ammonia, nitrogen, carbon dioxide, chlorine, and hydrogen sulfide.
[0179] At least one embodiment can also be directed to an anode for use in an electrochemical cell, said anode comprising an ultraviolet light bulb and an automatic solid-state cleaning system. This aspect may also include said automatic solid-state cleaning system comprising an electrolytic coating. This aspect may also include said electrolytic coating being deposited on the surface of said bulb. This aspect may also include a quartz surface on said bulb with said electrolytic coating deposited on said quartz surface. This aspect may also include said quartz surface comprising a quartz sleeve adapted to slide over and be in contact with said bulb. This aspect may also include said electrolytic coating comprising a material selected from the group consisting of: boron-doped diamond, iridium oxide, titanium sub-oxide, doped aluminum oxide, doped silicon oxide, platinum metal, silica carbide, and tantalum carbide. This aspect may also include said electrolytic coating having a thickness in the range of at or near thirty to two hundred nanometers. At least one embodiment may also be directed to a method of cleaning an ultraviolet light anode comprising an automatic solid-state system. This aspect may also include said automatic solid-state system comprising passing a direct current through an electrolytic coating on said anode. This aspect may also include said step of passing a direct current comprising pulsing said direct current. This aspect may also include said pulsing of said direct current occurring in a range from at or near 400 Hz to 300 kHz. The power source can use automatic frequency modulation from 10 kHz to 300 kHz to hold the time averaged virtual anode current constant on the lamp or sleeve surface as aqueous solution conductivity changes or as precipitants build up on the return cathode surface between cleaning cycles. The direct current pulse voltage can be used to control the maximum instantaneous current load on the surface to prevent premature coating failure or to meet the required minimum current loading in aqueous phase to kill pathogens. This aspect may also include said ultraviolet light anode emitting ultraviolet light in the range of at or near 172 to 260 nanometers. At least one embodiment may include a UV anode that does not use an external connection to said electrolytic coating. Rather, an increased level of current comes from within said UV lamp and is passed through said electrolytic coating from said lamp. The electrodes in the lamp may be increased in size to handle the additional current for anode protection of the surface of the lamp. An additional ballast is used to supply the additional current to the lamp when the lamp supplies the current for the anode protection. The current return for the additional ballast comes through a submerged electrode in the treated water. The additional ballast output is controlled with a simple dimmer circuit.
[0180] At least one embodiment is further directed to a method of cleaning an ultraviolet light anode in an electrochemical cell including an aqueous solution, said anode comprising an ultraviolet light bulb and an electrolytic coating, said method comprising the step of passing a direct current through said electrolytic coating sufficient to generate an anode charge on said coating, said direct current including an external connection to said electrolytic coating. This aspect may also include said step of passing a direct current comprising pulsing said direct current. This aspect may also include said pulsing of said direct current occurring in a range from at or near 400 Hz to 300 kHz. This aspect may also include ultraviolet light from said ultraviolet light anode being used to catalyze oxidation or reduction reactions in said electrochemical cell by generating free radicals from organic or inorganic compounds in said aqueous solution. This aspect may also include said ultraviolet light bulb emitting ultraviolet light in the range of at or near 172 to 260 nanometers.
[0181] All locations, sizes, shapes, measurements, amounts, angles, voltages, frequencies, component or part locations, configurations, temperatures, weights, dimensions, values, percentages, materials, orientations, applications, uses, etc. discussed above or shown in the drawings are merely by way of example and are not considered limiting and other locations, sizes, shapes, measurements, amounts, angles, voltages, frequencies, component or part locations, configurations, temperatures, weights, dimensions, values, percentages, materials, orientations, applications, uses, etc. can be chosen and used and all are considered within the scope of the disclosure.
[0182] Dimensions of certain parts as shown in the drawings, if any, may have been modified and/or exaggerated for the purpose of clarity of illustration and are not considered limiting.
[0183] Unless feature(s), part(s), component(s), characteristic(s) or function(s) described in the specification or shown in the drawings for a claim element, claim step or claim term specifically appear in the claim with the claim element, claim step or claim term, then the inventor does not considered such feature(s), part(s), component(s), characteristic(s) or function(s) to be included for the claim element, claim step or claim term in the claim for examination purposes and when and if the claim element, claim step or claim term is interpreted or construed. Similarly, with respect to any “means for” elements in the claims, the inventor considers such language to require only the minimal amount of features, components, steps, or parts from the specification to achieve the function of the “means for” language and not all of the features, components, steps or parts describe in the specification that are related to the function of the “means for” language.
[0184] In the above description, numerous specific details are set forth in order to provide a thorough understanding of the present arrangements and teachings. It will be apparent, however, to one skilled in the art that the present arrangements and teachings may be practiced without limitation to some or all of these specific details.
[0185] Although illustrative embodiments of the present teachings and arrangements have been shown and described, other modifications, changes, and substitutions are intended. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the disclosure, as set forth in the following claims.
[0186] While the disclosure has been described in certain terms and has disclosed certain embodiments or modifications, persons skilled in the art who have acquainted themselves with the disclosure, will appreciate that it is not necessarily limited by such terms, nor to the specific embodiments and modification disclosed herein. Thus, a wide variety of alternatives, suggested by the teachings herein, can be practiced without departing from the spirit of the disclosure, and rights to such alternatives are particularly reserved and considered within the scope of the disclosure.
[0187] While the foregoing written description of the embodiments enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiments, method, and examples herein. The invention should therefore not be limited by the above described embodiments, method, and examples, but by all embodiments and methods within the scope and spirit of the disclosure as claimed. Any feature or combination of features described herein is included within the scope of the disclosure provided that the features of any such combination are not mutually inconsistent.
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An electrochlorination and electrochemical system for the on-site generation and treatment of municipal water supplies and other reservoirs of water, by using a custom mixed oxidant and mixed reductant generating system for the enhanced destruction of water borne contaminants by creating custom oxidation-reduction-reactant chemistries with real time monitoring. A range of chemical precursors are provided that when acted upon in an electrochemical cell either create an enhanced oxidation, or reduction environment for the destruction or control of contaminants. Chemical agents that can be used to control standard water quality parameters such as total hardness, total alkalinity, pH, total dissolved solids, and the like are introduced via the chemical precursor injection subsystem infrequently or in real time based on sensor inputs and controller set points.
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BACKGROUND OF THE INVENTION
The present invention relates generally to movable structure support mechanisms, and more particularly relates to apparatus for supporting a structure for tilting and swiveling or rotating motion.
Supporting devices having tilting and rotating capabilities are commonly employed to support structures such as a CRT display device in any one of a number of positions, to permit such a display device to be shifted from one position to another to enable it to be used by more than one person of differing height, and to enable a particular display of information to be developed on a terminal display by one person and to be shifted without undesired tilting movement to be shown to another person. The latter use finds particular application, for example, when a salesman, stock broker or bank loan officer calls up data on a display screen representing a product or situation and wishes to show it to a customer seated near him, by imparting a rotational movement to the supported CRT display. One problem which has been experienced with certain supporting devices is that when rotational movement is imparted to them, the frictional force between the various elements is lessened sufficiently that an undesired tilting movement also takes place. In extreme cases, the tilting motion may be of such magnitude as to cause the CRT display to shift downwardly so that the display is no longer readily viewable. Similarly, when it is desired to tilt, but not rotate, the CRT display, an inadvertent rotational movement may result.
SUMMARY OF THE INVENTION
The present invention provides an apparatus in which a structure is supported for both tilting and rotational movement, in which one type of movement may be achieved without also causing the other type of movement, if desired, and in which a combination of tilting and rotational movement may also be achieved, if desired.
In accordance with one embodiment of the invention, apparatus for supporting a structure for tilting and rotating motion comprises first means attachable to said structure and having a convex lower portion and a projection extending downwardly therefrom; socket means with respect to which said first means may move in tilting motion, having a concave portion complementary to the convex portion of said first means and being slotted to receive said projection and also having a peripheral bearing surface; second means attached to said projection for maintaining a predetermined frictional relationship between said first and second means and said socket means; base means having a base surface and also having a bearing surface for cooperating with the peripheral bearing surface of the socket means for rotational movement; and retaining means attached to said socket means for retaining said socket means in said base means.
It is accordingly an object of the present invention to provide a supporting structure for tilting and rotating motion.
A further object is to provide a tilt and swivel support structure in which one type of movement can be achieved without also causing the other type of movement.
A further object is to provide a tilt and swivel support structure in which separate cooperating surfaces are provided for enabling the two types of movement to take place.
With these and other objects, which will become apparent from the following description, in view, the invention includes certain novel features of construction and combinations of parts, a preferred form or embodiment of which is described with reference to the drawings which accompany and form a part of this specification.
BRIEF DESCRIPTON OF THE DRAWINGS
FIG. 1 is an exploded sectional view of the tilt and swivel support structure of the present invention.
FIG. 2 is a plan view of the structure shown in FIG. 1.
FIG. 3 is a sectional view taken along line 3--3 of FIG. 2.
FIG. 4 is a sectional view taken along line 4--4 of FIG. 3.
FIG. 5 is a sectional view taken along line 5--5 of FIG. 3.
FIG. 6 is a fragmentary sectional view taken along line 6--6 of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, the structure 10 shown there includes a base 12, a socket 14 which is rotatable within the base 12, a retainer 15 which retains the socket 14 in assembled relationship to the base 12, a tilting ball 16 having a convex surface which is disposed within a complementary surface of the socket 14, and tensioner 18 which maintains the ball 16 in assembled relationship to the socket 14 and which can provide a desired amount of frictional force between the ball 16 and the socket 14. The tilting ball may be secured to a display or other terminal 20, shown in phantom outline.
The base 12 has an upper flat portion 17, a peripheral wall 19 and an extended flat lower surface 22, and is shown in FIG. 2 as being of generally rectangular shape for stability, though other shapes could be employed if desired. The base 12 includes an upstanding annular wall 24, an annular flange 26 disposed internally of said wall at the lower portion thereof, and another annular wall 21 extending downwardly from the flange 26. Internal reinforcing ribs 23 (FIG. 3) strengthen the base 12. Corner fittings 25 at the ends of certain of the ribs 23 are adapted to receive feet 27 of rubber or other suitable material to hold the base 12 against shifting when placed on a table or desk. The inner surface of the wall 24 and the upper surface of the flange 26 form bearing surfaces for engagement with complementary surfaces of the socket 14, as will be subsequently described in greater detail. An upstanding projection 28 on the flange 26 cooperates with a slot 46 in the complementary surface of the socket 14 to limit relative movement between the socket 14 and the base 12, as will also be described in greater detail.
The support structure 10 of the present invention is used most frequently in supporting an electronic terminal or display device 20 which requires at least one cable associated therewith in order to function. If such a cable extends in plain view from the terminal or display, it is unsightly and may interfere with efficient use of the terminal by becoming entangled with the support or with other items placed on the table or desk adjacent to the support structure. For these reasons, it is desirable that the cable should enter the base and extend upwardly internally through the support structure to its connection to the terminal. Accordingly, it will be seen that cables 30 and 32 enter the base 12 via an aperture 34 on the left side, as viewed in FIGS. 1 and 3, are bent around the central opening defined by the wall 21, and then extend upwardly to the terminal 20. A clamp 36 (FIGS. 3 and 5) cooperates with the aperture 34 to retain the cables 30, 32 in position at their point of entry to the base 12. Screws 38 or other suitable fastening means may be employed to hold the clamp 36 in place. Cable ties 40 extend through openings 42 in the wall 21 and flange 26 and around the cables 30, 32 to retain them in circumferential position around the central opening of the base 12. If desired, the cables 30, 32 could also be retained in a circumferential position by other means such as clamps or other additional part of parts in the base 12, which would eliminate the need for cable ties.
The socket 14 includes a cylindrical outer wall 44 which has a height and an outside diameter of suitable dimensions to fit within the opening defined by the wall 24 of the base 12, and to rest upon the flange 26 of said base for rotational movement of the socket 14 with respect to said base. The projection 28 on the flange 26 engages a discontinuous slot 46 in the bottom of the wall 44 to limit the relative movement of the socket 14 and base 12 to approximately 180 degrees, which prevents damage to the cables 30 and 32 from excessive winding.
The upper surface 48 of the socket 14 is ofgeneraly concave configuration to accommodate the hemispherical lower portion of the ball 16, as will be subsequently described. A lower surface 49 of the socket 14 is generally convex in configuration to provide a generally uniform wall thickness between the surfaces 48 and 49. A raised annular portion 50 on said upper surface provides a bearing surface on which said hemispherical portion of the ball 16 may move in tilting motion. An elongated slot 52 is centrally disposed in said upper surface 48, and terminates in curved portions at either end. Four bosses 54 extend downwardly from the other side of the upper surface 48, and are internally threaded to receive screws 56 which serve to attach the retainer 15 to the bosses 54, so that the flange 26 is positioned between the bottom surface of the wall 44 and the retainer 15, thus retaining the socket 14 against removal from the base 12. In order to provide the desired low coefficient of friction on the bearing surface 50 and on the external and bottom surfaces of the cylindrical outer wall 44, the entire socket 14 may be fabricated from a suitable low-friction material, such as "Valox" plastic, manufactured by General Electric Company. The use of two different materials at bearing points reduces or eliminates sticking and galling of the cooperating elements.
As noted above, the ball 16 has a lower generally hemispherical surface 60 which fits within the upper surface 48 of the socket 14, and bears on the annular surface 50. An upper surface 58 of the ball 16 is concave in configuration to provide a generally uniform wall thickness between the surfaces 58 and 60. A projection 62 having an aperture 64 therethrough extends downwardly from the surface 60 and fits within the slot 52 in the socket 14 to limit and define the tilting movement of the ball 16 with respect to the socket 14. Threaded bores 66 in the projection 62 are adapted to receive adjusting screws 68 which also pass through apertures 70 in the tensioner 18. The tensioner 18 is provided with a central stepped aperture 72 and an upper angled annular surface 74 which is configured to engage the lower surface 49 of the socket 14. By adjustment of the screws 64, the force with which the surfaces 60 and 74 engage the surfaces 50 and 49 can be varied, to adjust the force by which a particular angle of tilt is maintained.
The ball 16 may be secured by any suitable means to the display or terminal 20 which it supports. In the illustrated embodiment, a plurality of screws 77 extending through apertures 76 in a flange 78 of the ball 16, in combination with a tongue 80 integral with said flange, are employed. The screws 77 may enter threaded apertures 79 in the terminal for engagement therewith after the tongue 80 has been inserted in a complementary slot 81 in the terminal 20. Also, in the illustrated embodiment, the flange 78 is comprised of two angled surfaces 82 and 84, to mate with the corresponding lower surfaces of the terminal 20. However it will be understood that the upper portion of the ball 16 could be configured as a single plane, or in any other suitable configuration, to match the mating surface or surfaces of the terminal 20.
As previously mentioned, the cables 30 and 32 enter the base 12 through the aperture 34 and are passed upwardly through the interior of the support 10. Apertures 72, 52 and 64 in the tensioner 18, socket 14 and ball 16, respectively, are provided for this purpose.
In operation, it will be seen that the rotating and tilting movements of the structure 10 are separate and distinct. Thus rotation is accomplished by relative movement of the socket 14 with respect to the base 12 and tilting is accomplished by relative movement of the ball 16 with respect to the socket 14. Either one of a tilting or a rotational movement can be carried out without in any way affecting the other, so that, for example, rotation of the terminal 20 from one viewing position to another does not produce an undesired accompanying tilting movement, which might result in a "drooping" of the terminal 20 out of optimum viewing position.
While the form of the invention shown and described herein is admirably adapted to fulfill the objects primarily stated, it is to be understood that it is not intended to confine the invention to the form or embodiment disclosed herein, for it is susceptible of embodiment in various other forms within the scope of the appended claims.
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A tilt and swivel apparatus supports a structure such as a CRT display device above a stable base. Separate tilt and swivel mechanisms are provided to improve the stability of the apparatus. Stop elements limit the extent of tilting and rotation which is permitted. An internal passage is provided for cable connections to the supported structure.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to the manufacture of mesoporous materials.
BACKGROUND OF THE INVENTION
[0002] Ordered mesoporous materials, such as and usually mesoporous silica (SiO 2 ), consist of arrangements of pores with uniform diameter and structure. The size of these mesopores, and the spacing between the pores can range between a few to tens of nanometers. The preparation of mesoporous materials, both powders and thin films, can usually be described as being template assisted. In a typical process surfactant molecules, ionic or non-ionic, which aggregate in aqueous solution to form micelles and/or various liquid crystal phases can be used as templates for forming mesoporous elemental oxides. Under the correct conditions a suitable inorganic compound (which can be described as a precursor as it supplies the cations into the inorganic mesoporous framework) is hydrolysed and condensed around the organic surfactant template to form an inorganic-organic hybrid material. Careful removal of the organic component, by calcination and/or chemical extraction, results in a mesoporous inorganic elemental oxide material with high surface area. To prepare mesoporous thin films the mixture of inorganic precursor and organic template is applied to a substrate prior to condensation of the elemental oxide. Careful calcination yields a solid mesoporous film.
[0003] Silica (SiO 2 ) is the easiest material to prepare in both powder and film form. In preparing SiO 2 films great care has to be taken over the process variables, such as choice of precursor (the source of cations in the mesoporous framework) materials, reactant concentrations, reaction temperatures, reaction time, application method and conditions, thickness of applied film, drying temperature, drying time, calcination temperature, calcination time etc., to produce stable materials exhibiting high pore order within the film. Preparing mesoporous films of other materials, for example silica doped with other cations such as titania (TiO 2 ), zirconia (ZrO 2 ), ceria (CeO 2 ), and hafnium oxide (HfO 2 ) is difficult compared to powders due to the rapid hydrolysis of the oxide precursors and crystallisation of the films as a poorly defined agglomeration of particles with no long range ordered mesoporosity.
[0004] For many commercial applications of mesoporous films, processing the inorganic precursor material as a highly thermal stable coating or thin film is essential. However, the thermal treatment typically employed to remove organic components and importantly densify the poorly defined inorganic walls surrounding the organic template can lead to a total collapse of the templated ordered mesoporous network. This is particularly true for ordered mesoporous material synthesis of solids other than silica.
[0005] It is advantageous to make mesoporous titania thin films due to their application in photochromic and photovoltaic cells, photo-catalysed bio-degradation surface coatings, gas sensors and photonic band gap materials amongst others. However, attempts to prepare mesoporous titania materials using simple hydrolysis and condensation reactions have resulted in products of low thermal robustness. As a result, attempts have been made to increase the thermal stability of mesoporous titania materials using several post-synthesis calcination methods. For powder synthesis, the most thermally stable materials seem to have been produced by Cassiers et al [1] who reported that the post-treatment of uncalcined mesoporous titania powder with ammonia resulted in the formation of mesoporous crystalline titania with thermal stability up to 600° C. However, it is not clear in their work that the materials produced have significant long range order. The most stable films made to date were synthesised by Sanchez and Grosso et al [2] who employed the evaporation-induced self-assembly (EISA) method for the preparation of high-quality mesoporous TiO 2 thin films. This involved synthesizing a film followed by low temperature calcination (500° C.) and then applying a short post-synthesis treatment involving short time exposure to 730° C. which they described as “delayed rapid crystallization”. This resulted in materials that were claimed to have long term thermal stability to temperatures of 500° C. However, the products have only limited long range order as they are formed by partial collapse of a long-range ordered mesoporous structure.
[0006] There is therefore a need for an improved process for manufacturing mesoporous thin film materials which will address these problems.
STATEMENTS OF INVENTION
[0007] According to the invention there is provided a process for preparing a mesoporous material comprising the step of preparing a sol and treating the sol material under supercritical fluid conditions. The treatment under supercritical fluid conditions forms an ordered mesoporous material.
[0008] In one embodiment the mesoporous material is a mesoporous film. In this case the process may comprise applying the sol to a substrate to form a mesoporous film and subsequently treating the film under supercritical fluid conditions.
[0009] In another embodiment the mesoporous material is a mesoporous powder. In this case the process may comprise directly treating the sol under supercritical fluid conditions to form a mesoporous powder material.
[0010] In one embodiment the sol material is treated under supercritical fluid conditions in the presence of a silating agent. The silating agent may be selected from a silicon containing material which can be decomposed to form silica during the supercritical fluid treatment. The silating agent may be a silicon alkoxide or an organic silane. The silating agent may be tetramethyloxysilane or tetramethylsilane.
[0011] In one embodiment the sol material is treated under supercritical fluid conditions in the presence of a titanating agent. The titanating agent may be selected from a titanium containing material which can be decomposed to form titania during the supercritical fluid treatment. The titanating agent may be a titanium alkoxide. The titanating agent may be titanium tetra isopropoxide or titanium tetra isobutoxide.
[0012] In another embodiment the supercritical fluid is selected from any one or more of carbon dioxide, propane, ethane, butane, pentane, hexane, ammonia and water.
[0013] The process may be carried out at temperatures up to 500° C. in the presence of a silating agent or titanating agent or similar inorganic compound. The supercritical fluid treatment may be carried out at a pressure greater than the critical pressure of the fluid and the temperature is less than 20° C. less than the critical temperature of the fluid.
[0014] In one embodiment after treatment with supercritical fluid, the mesoporous material is calcined in air or air-ozone mixtures at temperatures between 200 and 1000° C.
[0015] In one embodiment the sol comprises a surfactant template, a elemental oxide precursor inorganic compound, a catalyst, and a solvent. The precursor inorganic compound may be a hydrolysable compound as the source of cations in the final mesoporous oxide framework. The precursor compound may be a compound selected from any one or more of of Si, Al, Ti, Zr and W. The precursor compound may be an alkoxide or a chloride. The precursor compound may also include an alkoxide or chloride of boron, lanthanum, yttrium and hafnium.
[0016] In one case the solvent is an alcohol which may be selected from one or more of ethanol, methanol, 1-propanol, 2-propanol and 1-butanol.
[0017] In one embodiment the catalyst is an acid catalyst. The acid may be selected from one or more of hydrochloric, nitric, sulfuric, phosphoric, hydrofluoric, acetic and citric acid. In another embodiment the surfactant is selected from the group consisting of triblock copolymers of polyethylene (PEO), polypropylene (PPO), polyalkyloxide materials, polyoxyethylene alkyl ethers and anionic or cationic surfactants consisting of alkyl chains and ionic head groups such as cetyl trimethyl ammonium bromide.
[0018] In one embodiment the sol is a prepared by heating a sol mixture to a temperature between −4° C. and 80° C. for up to 2 hours.
[0019] The process may comprise cooling the sol and controlling the amount of water to a temperature between −4° C. and 25° C. to effect the production of a partially hydrolysed product prior to adding a secondary inorganic precursor compound to effect cross condensation processes.
[0020] In one embodiment the prepared sol is allowed to stand for a period at a temperature between 0° C. and 80° C.
[0021] The sol material may be applied to a substrate by spin or dip coating. The film may be dried in defined stages at temperatures between 20 and 200° C.
[0022] The surfactant may be selected to control the pore size of the mesoporous material. The pressure of the supercritical fluid and the temperature thereof may be selected to control the pore size of the mesoporous material.
[0023] The invention provides an ordered mesoporous material whenever prepared by a process of the invention. The material may be an ordered mesoporous film material or an ordered mesoporous powder material.
[0024] In another aspect the invention provides a mesoporous material having an ordered array of pores. The pore diameter may be from 1 to 30 nm, preferably between 1 and 15 nm and generally between 1 and 5 nm.
[0025] The ordered mesoporous material may be in the form of a film or in the form of a powder. The mesoporous material may be formed by an elemental oxide.
[0026] The invention provides an easy and reproducible process to prepare high-quality elemental oxide films of elemental oxides (including silica, titania, zirconia, doped silicas and many other elemental oxides) on substrates by spin-coating and post-treatment of the film in supercritical carbon dioxide (sc-CO 2 ) carbon dioxide. With the synthesis method of the invention it is possible to prepare crystalline and amorphous films of elemental oxides with enhanced thermal robustness. We have shown that thermally stable long range ordered mesoporous films stable in air to temperatures of up to 600° C. may be prepared. Further, well-defined mesoporous films with less well-defined order and thermally stable to 850° C. may also be prepared.
[0027] The present invention provides a method for forming a porous elemental oxide film having an ordered array of pores whose diameter is between 1 and 30 nm, usually 1 to 15 nm, and generally 1 to 5 nm. The porous elemental oxide formed exhibits increased thermal stability compared to conventionally prepared mesoporous films. By careful control of the reaction conditions and the amount and type of surfactant used, the pore size and structure of the mesoporous layers may be predetermined.
[0028] The invention provides well-ordered thermally stable ordered mesoporous films showing significantly less macroscopic cracking than more conventionally processed materials. The invention is particularly suited to the preparation of thermally stable films of elemental oxides which, because of their chemical properties, are difficult to form or are prone to pore collapse at low temperatures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The invention will be more clearly understood from the following description thereof, given by way of example only, with reference to the accompanying drawings, in which:
[0030] FIG. 1 is a flow diagram illustrating a process according to the invention;
[0031] FIG. 2 is a graph showing PXRD (powder x-ray diffraction) patterns of (A) (left) untreated and (B) (right) supercritical carbon dioxide (sc-CO 2 )/TMOS-treated mesoporous titania thin films calcined at various temperatures for a duration of one hour each;
[0032] FIG. 3 are transmission electron microscopy (TEM) images of the sc-CO 2 /TMOS-treated titania films after calcination at (A) temperatures below 600° C. and (B) temperatures above 600° C.;
[0033] FIG. 4 is a scanning electron microscopy (SEM) image of the sc-CO 2 /TMOS-treated titania films after calcination at 750° C. No physical cracking of the surface can be seen;
[0034] FIG. 5 is a graph showing PXRD (powder x-ray diffraction) patterns of sc-CO 2 /TMOS-treated mesoporous silica films calcined at various temperatures for duration of one hour each;
[0035] FIG. 6 is a graph showing Low-angle XRD patterns of (a) mesoporous zirconia thin film post-treated by sc-CO 2 /TMOS (treated at 150° C.) and those then calcined at (b) 450, (c) 750, (d) 850, and (e) 950° C. after the post-treatment. As can be seen porosity is maintained to temperatures of 850° C.;
[0036] FIG. 7 are TEMs of (a) mesoporous zirconia thin film treated by sc-CO 2 /TMOS and those then calcined at (b) 450, and (c) 750° C. after the post-treatment. (d) high resolution electron micrograph of (c) showing the crystalline grains of tetragonal zirconia; and
[0037] FIG. 8 is a graph showing the IR spectra of a stearic acid layer as a function of time under UV illumination at a wavelength of 254 nm.
DETAILED DESCRIPTION
[0038] FIG. 1 is a flow diagram showing a process in accordance with the present invention, illustrating a general method of forming ordered mesoporous elemental oxide films. First, a elemental oxide sol is prepared as illustrated by block 1 . The sol-gel is then deposited onto a substrate to form a film, as illustrated by block 2 . Then, as illustrated in block 3 , the as-deposited film is dried and densified. The film is processed in a supercritical fluid and in the presence of a secondary precursor material such as a silating, titanating or similar agent (block 4 ) to yield an ordered mesoporous thin film with robust pore structure. Finally, as illustrated in block 5 , the film is calcined to create an organic free mesoporous oxide film.
[0039] FIG. 2 illustrates the beneficial effect of the sc-CO 2 /TMOS treatment. Low angle powder x-ray diffraction (PXRD) data at angles between 0 and 5 degrees 2 theta are an indication of mesoporosity as ordered mesoporous samples show a well-resolved feature in this range. If a sample of substrate coated material prior to the sc-CO 2 treatment is compared to a similar sample after the sc-CO 2 treatment, the additional thermal robustness of the sc-treated film is easily observed. In the untreated film pore collapse is initiated at 350° C. (as indicated by the loss of intensity and movement of the peak) and completed by 450° C. when the XRD feature is absent. The sc-CO 2 /TMCS treated sample shows no structural change until heated to temperatures in excess of 600° C. some 250° C. higher than the untreated sample. There is some structural change above this temperature that is explained by coalescence of some of the pores, but significant porosity is retained to thermal processing at 850° C. The sample retains mesoporosity when heated to 800° C. for 48 hours.
[0040] FIG. 3 displays TEM images which show the mesoporous structure of the titania film produced is highly ordered until thermal processing temperatures of 600° C. ( FIG. 3A ). Above this process temperature the pore restructuring leads to a less ordered phase with larger pores ( FIG. 3B ).
[0041] FIG. 4 shows a secondary electron microscope image of the films as described herein. The film is free of any macroscopic cracks due to sc-CO 2 /TMOS process which prevents film shrinkage and the stresses associated with crack formation during synthesis.
[0000] Terminology
[0042] We define an ordered mesoporous structure as one in which the pores are arranged in an ordered arrangement with symmetry described as hexagonal, cubic or lamellar arrangement. In this way an ordered mesoporous structure is not the same as a random mesoporous formed from tortuous mesopores resulting for example from trapped volumes between particles in a solid. The ordered mesoporous structures formed here are similar to materials previously described using the acronyms MCM [Mobil Composition of Matter] or SBA [Santa Barbara]. We define the organic template as a defined regular structural arrangement originating from the assembly of surfactant molecules in a solvent as defined by the solvent-surfactant interactions. The organic template can also be described as a structural directing agent (SDA). A typical surfactant is a triblock copolymer of polyethylene (PEO) and polypropylene (PPO) with a chemical formula of PEO 60 PPO 20 PEO 60 . The inorganic precursor is a chemical compound that can be reacted with other chemical compounds to produce an oxide material. The oxide material will form around the organic template structure to form an inorganic oxide skeleton which will survive treatments to remove the organic component. The inorganic element, or elements of the precursor may be from the Main Group or the Transition series of the Periodic Table. Typically, these may be silicon, boron, titanium, zirconium, hafnium, or cerium. The most likely (but not necessarily the only) precursor is a suitable elemental alkoxide compound such as tetraethyl orthosilicate or titanium tetra isopropoxide or elemental halides such as silicon tetrachloride or titanium tetrachloride. The precursor (in the presence of surfactant and solvent and other materials) is treated with water and a hydrolysis catalyst to yield molecules and molecular assemblies containing hydroxide groups. These hydroxyl group containing species react by eliminating water or HX (X=OR or halide) to produce -M-O-M- (M representing a cation and O and oxygen ion) bonds, by what is known as a condensation reaction. The product of the condensation reaction is a poor chemically, structurally and stoichiometrically defined solid or gel containing elemental oxide, hydroxide and inorganic-organic bonds. Cross-condensation is a term which implies that two different cations are components of a gel joined through chemical bonds. A dilute gel which flows easily on pouring is termed a sol. A supercritical fluid is defined as an element, compound or mixture above its critical temperature (T c ) or critical pressure (P c ) below which state changes can be effected by changes in temperature and/or pressure. We describe a silylating agent as a silicon containing compound under which, under the conditions used in our experiments, may act as a precursor to SiO 2 or react with Si—OH bonds. Calcination is defined as the removal of the organic template by thermal treatment in air. As an alternative, mixtures of air and ozone may be used for organic template removal.
[0043] The surfactant used may be, but is not limited to, one of the following: triblock copolymers of polyethylene (PEO), polypropylene (PPO), polyalkyloxide materials, triblock neutral surfactants having the general formula PEOxPPOyPEOz (e.g. Pluronic Materials from BASF, P127, P123, P65), diblock neutral copolymers having the general formula PEO x PPO y and polyoxyethylene alkyl ethers, e.g. C x H 2x+1 —O—(CH 2 —CH 2 O) 2 H e.g. Brij materials, Brij56, Brij55 available from Uniquema).
[0044] The alcohol-type solvent used may be, but is not limited to, one of the following, methanol, ethanol, propanol, butanol.
[0045] A suitable silating agent may be, but is not limited to, one of the following: tetraethoxysilane (TEOS), tetramethoxysilane (TMOS), tetrapropoxysilane (TPOS), and tetrabutoxysilane (TBOS), tetramethysilane, tetraethysilane.
[0046] A suitable titanating agent may be, but is not limited to a titanium alkoxide such as but not necessarily titanium tetra isopropoxide or titanium tetra isobutoxide.
[0047] The elemental oxide source used to prepare the sol may be, but is not limited to, an alkoxide or chloride of boron, lanthanum, and yttrium, titanium, or zirconium, silicon, tungsten, hafnium.
[0048] In one case the solution is deposited onto a substrate by spin coating the solution, which has been diluted with ethanol. Optimally, the solution is diluted to 50%, but may be diluted to other concentrations depending on the desired thickness of the final film. Ideally, the solution will be spin coated for 10 seconds at 100 rpm, then for 50 seconds at between 1000 and 5000 rpm, ramping the speed over 5 seconds. The result is a transparent, evenly coated film with no visible cracks ( FIG. 4 ).
[0049] In another case dip coating can be used to coat the chosen substrate. Dip coating is normally carried out with an undiluted solution, where the substrates are immersed and withdrawn at 0.2 to 2 cm per minute. Optimally, the substrates are immersed and withdrawn at 0.5 cm/min. The solution can also be diluted with ethanol or another suitable solvent to control the thickness of the final film.
[0050] Control of the surfactant concentration used in the preparation of the elemental oxide mesoporous film allows the resulting pore structure of the film to be predetermined. Hexagonal and lamellar structures have parallel arrangements of pores and porous surfaces respectively. Cubic structures have channels running through the entire film that allow transport to and from the surface. This may be a desirable characteristic for a porous films used in adsorbent, catalysis or sensor devices and applications. Elemental oxide ordered mesoporous films are prepared in several stages and these are represented schematically in FIG. 1 .
[0051] Step 1: In the first step a sol is prepared from a suitable chemical compound. This is a precursor to the inorganic framework of the mescoporous material. This compound must be hydrolysable so that a hydroxide species is formed. This hydroxide species should condense to form element-oxygen-element bonds. The precursor is mixed with the following ingredients: a suitable solvent which in most cases in an alcohol, a mixture of structural directing agents (surfactant templates), an acid hydrolysis catalyst, and controlled amounts of water. The sol may be prepared at temperatures between −5 and 80° C. The sol should be clear and free from any visible particles to produce high quality films. Of importance is the use of partial hydrolysis to make mesoporous materials of mixed cation composition. The amount of water and the temperature may be used to yield partially hydrolysed precursor compounds of one of the cations. Secondary precursors are then added to allow cross condensation and so produce mixed elemental oxide mesoporous materials. Adding a secondary alkoxide to the cooled solution allows the reaction of the secondary precursors to form a cross condensate via reactions such as:
—Al—OH+OH—Si— —Al—O—Si—+H 2 O
This means that the element, for example, aluminium, is incorporated directly into the pore wall, which increases the mechanical strength and adhesion of the resulting mesoporous film.
[0052] Step 2: The sol produced in step 1 is allowed to stand for a period of time. This may be from one minute to several days and may be undertaken at temperatures between 0 and 80° C. The purpose of this process is to change the viscosity of the sol to allow film processing. The viscosity of the sol increases with time and temperature because of solvent evaporation and cross-linking of the inorganic polymer chains during the condensation processes. The sol may be diluted in a suitable alcohol to control the thickness of the film produced. The film may be most conveniently applied to substrates such as silicon, glass, alumina, silica etc. by spin or dip coating. For spin coating a measured drop of sol is placed at the centre of the substrate and spinning speeds of 50 to 10,000 revs min −1 can be used. For dip coating the sample can be placed in the sol and removed at rates from 0.5 mm s −1 to several cm s −1 . The sol is normally applied at temperatures between 0 and 40° C.
[0053] Step 3: The as spun or dipped film may require further treatment to allow densification of the inorganic walls and/or ordering of the inorganic-organic surfactant assembly (structural direction). This may involve secondary thermal processing of the as-coated films prepared as described in step 2. Solvent may be removed by drying for several hours or days at temperatures between 20 and 80° C. In cases where the sol does not have an ordered structure, during the evaporation of the solvent, the concentration of surfactant and inorganic constituents may become high enough to induce assembly of the ordered porous structure. Higher temperature treatments may or may not be required in a secondary stage. This allows pore walls to densify so that films survive the supercritical fluid treatment described below in step 4 and also to promote adhesion to the substrate. This treatment normally consists of heating at temperatures between 60° C. and 200° C.; the temperature should not be high enough to affect decomposition or degradation of the organic surfactant molecule.
[0054] Step 4: This is the supercritical fluid treatment and is responsible for achieving films or powders of very high thermal stability and exhibiting high degrees of ordered mesoporosity. The films described in step 3 are placed in a high pressure cell together with a controlled amount of a silating, titanating or similar agent and exposed to a fluid such that the pressure and temperature of the fluid are above the critical values. The sample may be heated to effect reaction at temperatures of up to 500° C. during this treatment. We believe that the high thermal stability of the supercritical fluid treated films can be ascribed to the dispersion of Si and its interactions with the mesoporous matrix. During the supercritical fluid silating treatment, the additional silicon species from the silating agent can penetrate into the rnesoporous wall structure of the films and occupy both surface and near-surface sites due to the high penetrating power of sc-CO 2 under high pressure. The interaction of Si species with mesoporous wall oxo-hydroxo oligomers will consequently lead to a compact and highly condensed wall which can resist further structural contraction when the film is calcined at a relatively high temperature. Thus, the densified wall of the post-treated film exhibits high thermal stability with no significant contraction of the pores during the high-temperature treatment.
[0055] Step 5: The substrate and films are removed from the supercritical fluid process conditions and further calcined at temperatures between 200 and 1000° C. for periods of a few minutes to several days in air or air/ozone mixtures to provide a films which consists of open pores (i.e. no organic surfactant present) and all the cationic species have been converted to oxides.
[0056] The invention will be more clearly understood by the following examples.
EXAMPLE 1:
Preparation of Mesoporous Titania Films
[0057] To make mesoporous titania films, a precursor solution was prepared using titanium tetra isopropoxide (Ti(i-PrO) 4 , TTIP), a triblock copolymer surfactant of chemical formula given as EO 18 PO 58 EO 18 , hydrochloric acid (HCl), and absolute ethanol (EtOH) with molar ratio of 1.0 TTIP: 0.02 surfactant: 2.0 HCl: 35.2 EtOH. A clear solution was obtained by stirring at room temperature for between 15 min and 3 hrs. The solution was dropped onto a silicon or glass substrate and the substrate was spun at 3110 rpm for 20 s. The resulting film was aged in air at ambient temperature at 60° C. for 24 hrs and then annealed at 150° C. for 48 hrs. For the preparation of treated films, the titania film on the substrate was placed in a 20 cm 3 high-pressure cell with 0.02 cm 3 of teramethyoxysilane (TMOS). The cell was attached via a three-way valve, to a stainless steel reservoir (21 cm 3 ). A high-pressure pump (ISCO Instruments, PA) was used to pump CO 2 through the reservoir in to the reaction cell. The cell was placed in a furnace and heated to 300-500° C. and pressurised to 34.5-48.3 MPa simultaneously. The reaction proceeded at these conditions for about 15 minutes. The films were removed from the cell and calcined in a conventional furnace, in air at various temperatures for duration of one hour each. The surfactant is removed in this process by pyrolysis to yield an ordered mesoporous element silicate film. The resulting film has silicon, incorporated directly into the pore wall, which increases the thermal robustness of the film allowing subsequent process operations to be completed on the film without compromising the film's structural integrity.
[0058] In this preparation, by careful selection of the type and mixture of the surfactants used as well as the amount of each surfactants used, the pore size and structure can be varied.
EXAMPLE 2
Preparation of Mesoporous Zirconia Films
[0059] To make mesoporous zirconia films, a precursor solution was prepared using zirconium propoxide (Zr(PrO) 4 ) as a 70 wt % solution in n-propanol (Pr n OH), a triblock copolymer surfactant of chemical formula given as EO 106 PO 70 EO 106 , hydrochloric acid (HCl), and absolute ethanol (EtOH) with molar ratio of 1.0 Zr(PrO) 4 : 0.0075 surfactant: 3 HCl: 35.2 EtOH: 2.4 Pr n OH. A clear solution was obtained by stirring at room temperature for 3 hrs. The solution was dropped onto a silicon or glass substrate and the substrate was spun at 2500 rpm for 20 s. The resulting film was aged in air at ambient temperature at 60° C. for 12 hrs and then annealed at 150° C. for 24 hrs. For the preparation of treated films, the zirconia film on the substrate was placed in a 20 cm 3 high-pressure cell with 0.02 cm 3 of teramethyoxysilane (TMOS). The cell was attached via a three-way valve, to a stainless steel reservoir (60 cm 3 ). A high-pressure pump (ISCO Instruments, PA) was used to pump CO 2 through the reservoir in to the reaction cell. The cell was pressurised to 48.3 MPa and then placed in a furnace and heated to 100° C. The reaction proceeded at these conditions for about 15 minutes. The films were removed from the cell and calcined in a conventional furnace, in air at various temperatures for duration of one hour each. The surfactant is removed in this process by pyrolysis to yield an ordered mesoporous zirconia film. The resulting film has silicon, incorporated directly into the pore wall, which increases the thermal robustness of the film allowing subsequent process operations to be completed on the film without compromising the film's structural integrity.
[0060] In this preparation, by careful selection of the type and mixture of the surfactants used as well as the amount of each surfactants used, the pore size and structure can be varied.
EXAMPLE 3
Preparation of Mesoporous Silica Films
[0061] 1.4 g of the triblock surfactant, indicated as EO 20 PO 70 EO 20 , was added to 15 cm 3 of absolute ethanol and stirred for one hour at 40° C. Then, 0.5 cm 3 of 0.1 molar HCl was added. Following this, 5 cm 3 of tetraethoxysilane (TEOS) and 0.5 cm 3 of distilled water were added with vigorous stirring. These additions took place in about 5 minutes. The solution was stirred at room temperature for 3 hrs. The sol produced was then allowed to stand for 12-15 hours at room temperature to obtain the right viscosity of the sol to allow effective spin-coating. The obtained sol was diluted with an equal volume ethanol and then dropped onto a silicon substrate and then the substrate was spun as 3110 rpm for 20 seconds. The resulting film was aged in air at ambient temperature at 60° C. for 24 hrs and then annealed at 150° C. for 48 hrs. The films thus processed were treated in sc-CO 2 and TMOS as described above. The silica film on the substrate was placed in a 20 cm 3 high-pressure cell with 0.02 cm 3 of tetramethoxysilane (TMOS). The cell was placed in a furnace and heated to 300-500° C. and pressurized to 34.5-48.3 MPa simultaneously. The reaction proceeded at these conditions for about 15 minutes. The films were removed from the cell and calcined in a conventional furnace, in air at various temperatures for duration of one hour each. The surfactant is removed in this process by pyrolysis to yield an ordered mesoporous silica film. FIG. 5 illustrates the mesoporous structure of the film as a function of calcination temperature (used for pyrolysis) as indicated by PXRD. To temperatures of 750° C. the film exhibits a well-ordered mesoporous structure as indicated by the intense diffraction feature between 1.5 and 2° (two theta). It is only on heating to temperature of 850° C. does the film begin to show pore collapse. This degradation temperature is some 300° C. higher than for a non supercritical/TMOS treated sample.
[0062] The sol used to spin coat the substrate may be prepared in the following manner. 7 g of the triblock polymer surfactant indicated as C 16 H 33 (OCH 2 CH 2 ) 10 OH), was mixed directly with 13.5 cm 3 of EtOH, 25 cm 3 of TEOS and 2.5 cm 3 of 0.12 molar hydrochloric acid. This was heated whilst stirring at 45° C. for 15 minutes. The mixture was then cooled in ice to 25° C. which effectively decreases the rate of hydrolysis of the silicon precursor so that the reaction is stable for several hours. 1 g of aluminium sec-butoxide was added and the mixture stirred for 10 minutes at a temperature of 25° C. Following the preparation the sol was allowed to stand for 24 hours at room temperature. Subsequently, a silicon substrate was coated as detailed above and processed with the sc-CO 2 /TMOS treatment. Similar films with similar thermal robustness were prepared in this way. The only difference was that the mesoporous thin film silica had pores which were much closer together than for the triblock polymer surfactant prepared films. In this case, the change in pore-to-pore distance is related to the properties of the surfactant and not the process conditions.
EXAMPLE 4
Preparation of Mesoporous Titania Films
[0063] Mesoporous titania films were prepared exactly as defined in example 1 but were pre-treated using sc-CO 2 and titanium tetra isopropoxide (TTLP) and were demonstrated to have high photocatalytic activity. The films had very similar physical and structural properties as sc-CO 2 TMOS treated films but exhibited much better photocatalytic properties. The photocatalytic activity of the sc-CO 2 and TTIP pre-treated TiO 2 thin films was evaluated based on the decomposition of stearic acid in the following way. A 0.02 M solution of stearic acid in methanol was first coated on the titania-coated silicon wafers by a process of spin-coating. The silicon wafer was spun at 3100 rpm for 20 s at room temperature. The films were illuminated under UV light at a wavelength of 254 nm for various time intervals. The process of photocatalysis was evaluated by measuring the absorbance of the C-H vibration band of stearic acid in the wavelength range from 3100 to 2700 cm −1 . In this wavelength range stearic acid exhibits two strong and easily observed features. A sc-CO 2 /TMOS treated film as prepared in example 1 was calcined at 550° C. for 1 hour prior to the photocatalysis experiment. IR spectra in the wavenumber range between 3100 and 2700 cm −1 collected as a function of time during UV light irradiation and these show photodegradation of stearic acid by the sc-CO 2 /TTIP treated thin film ( FIG. 8 ). The C-H vibration band of stearic acid progressively disappears during illumination with UV light and after approximately 75 minutes the C-H peaks completely disappeared suggesting the total degradation of stearic acid. This degradation period is much faster than that observed from a similar titania film prepared without sc-CO 2 and TTIP pre-treatment.
[0064] In general, the invention involves forming an ordered mesoporous elemental oxide film using a supercritical fluid treatment. The invention provides a process to prepare films with greater thermal robustness than conventionally prepared materials and in certain cases alleviates significant experimental difficulties in the synthesis of the materials. The process is simple and can be widely applied. The process is not limited to particular surfactants or mixtures thereof and so the synthesis allows the control of the pore size and structure of the mesoporous film to be predetermined. Mesoporous films may be consistently formed by the process of the invention. The process may be used to prepare mixed mesoporous (i.e. containing more than one cation) oxide films using mixtures of precursors in the synthesis steps.
[0065] The mesoporous materials such as mesoporous thin films may be exploited as catalysts, including photocatalysts, absorbents and as dielectric materials in the semiconductor industry. Additionally, mesoporous thin films have potential applications as material components in highly specific chemical sensors, opto-electronic devices, chromatography support materials, thin-films for the glass sector, photovoltaics and fuel cells.
[0066] The present invention may be implemented with various changes and substitutions to the illustrated embodiments. For example, the present invention may be implemented on many different kinds of substrates other than silicon, such as, glass, quartz, sapphire, and alumina.
[0067] Although specific embodiments, including specific equipment, parameters, methods, and materials have been described, it will be readily understood by those skilled in the art and having the benefit of this disclosure, that various other changes in the details, materials, and arrangements of the materials and steps which have been described and illustrated in order to explain the nature of this invention may be made without departing from the principles and scope of this invention.
[0068] The invention is not limited to the embodiments hereinbefore described which may be varied in detail.
REFERENCES
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2. Grosso, D.; Soler-Illia,, G. J. de A. A.; Crepaldi, E. L.; Cagnol, F.; Sinturel, C.; Bourgeois, A.; Brunet-Bruneau, A.; Amenitsch, H.; Albouy, P. A. and Sanchez, C. Chem. Mater. 2003, 15, 4562.
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A process for preparing a mesoporous material comprises the step of preparing a sol and treating the sol material under supercritical fluid conditions. The treatment under supercritical fluid conditions forms an ordered mesoporous material. The sol may be applied to a substrate to form a mesoporous film and subsequently treating the film under supercritical fluid conditions. Alternatively the process may comprise directly treating the sol under supercritical fluid conditions to form a mesoporous powder material.
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BACKGROUND OF THE INVENTION This invention relates to loaders used in earth-moving service and the like and, more specifically, to means for reducing the width of the front portion of a loading bucket to facilitate dumping of the bucket's contents into a separate receptacle such as a dump truck, for example.
It has proven desirable to provide earth-loading buckets with relatively wide entrances, as defined by the front edge and side walls of said buckets, in order to allow the greatest possible amount of material to be loaded into the bucket as the front edge of the bucket loosens and lifts said material as the bucket travels over the terrain to be cleared.
However, relatively wide buckets are difficult to unload when the width of the receptacle is insufficient to accommodate all the falling debris and earth material. This may occur even though the width of the receptacle is greater than the width of the bucket as material falling from a bucket has the tendency to spread outwardly from the sides of the bucket, resulting in loss of material over the front or rear of the receptacle. This is especially inconvenient when the receptacle is a truck without a protective cover for the operator's station at the front of the vehicle.
It has been determined that if the ratio of the width of the receptacle to the width of the bucket is less than about 1.4 to 1, the bucket must be positioned substantially centrally of the receptacle to avoid spillage of material over the sides of the receptacle when emptying the bucket. This is a disadvantage, as centering of a loader with respect to the receptacle may be impractical due to space and time limitations.
When the length of the truck bed (measured from the operator's station to the rear of the bed), or other receptacle, is only slightly greater than the width of the bucket opening, spillage problems may occur even if the bucket is centered with respect to the receptacle. This situation arises in cases where relatively short dump trucks are utilized in material-moving operations.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a new and improved loader for use in earth-moving operations and the like. More specifically, it is an object of the invention to provide a loader, the bucket of which has a relatively wide opening that may be narrowed when the bucket is moved to its dumping position so as to provide a relatively narrow dumping opening which will effectively result in a dumping area of reduced size.
An exemplary embodiment of the invention achieves the foregoing object in a loader having a gate mounted on one of the sides of the bucket of said loader for movement between a first position wherein the gate extends forwardly from a side of the bucket and does not obstruct the dumping opening of the bucket, and a second position wherein the gate extends inwardly from a side in order to partially obstruct the dumping opening.
One version of the above embodiment includes a hydraulic cylinder mounted on the top of the bucket and connected to a pivot arm of the gate to effect movement of the gate between its first and second positions.
Another embodiment of the invention comprises a loader with a gate mounted on the rear of the loader's bucket in close proximity to a side of the bucket for rotation between a first position wherein the gate extends forwardly from the rear of the bucket and is disposed against the bottom of the bucket, and a second position wherein the gate extends upwardly and forwardly of its mounting point on the rear of the bucket, thereby partially obstructing the dumping opening thereof.
In one preferred embodiment of the invention, the above gate comprises a rigid member which includes a rear lever portion which extends rearwardly from the bucket for abutment against a lifting arm of the loader, thereby serving to move the gate between its first and second positions as the lift arm is moved between its lower and upper positions.
One highly preferred embodiment of the invention comprises the above loaders with a second gate mounted at the opposite side of the bucket.
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 side elevational view of a loader used in earth-moving or loading operations and embodying the invention;
FIG. 2 is a view of the loader taken along line 2--2 of FIG. 1;
FIG. 3 is an enlarged, fragmentary side elevational view of a modified embodiment of the invention;
FIG. 4 is an enlarged, fragmentary side elevational view of the embodiment of FIG. 3 in dumping position;
FIG. 5 is a view of the bucket of FIG. 4 taken substantially along line 5--5 of FIG. 4; and
FIG. 6 is a perspective view of one of the gates shown in FIGS. 3-5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, an exemplary embodiment of a loader made according to the invention includes a wheeled vehicle frame, generally designated 10, provided with lifting arms 12 which are pivotally mounted to the frame 10 by pivots 14. Hydraulic cylinders 16 are mounted to the frame 10 by pivots 18 and to the arms 12 by pivots 20. Operation of the cylinders 16 raises or lowers the arms 12 in a known manner.
As best seen in FIG. 2, a bucket, generally designated 22, is pivotally mounted to the arms 12 by pins 26 which extend through the ends 28 of the arms 12 and through two pairs of arcuate ribs 30 which form rear and bottom supports for the bucket 22.
Referring again to FIG. 1, hydraulic cylinders 32 are pivotally mounted to the frame 10 by pivots 34 and to the bucket 22 by pins 38 located above the pins 26. The pins 38 extend through the ends 40 of the cylinders 32 and through brackets 42 (FIG. 2) which form an integral part of the bucket 22. Operation of the cylinders 32 tilts the bucket 22 on the arms 12, as is well known, thereby allowing material contained in the bucket 22 to fall therefrom into a suitable receptable, such as the bed 48 of dump truck 50.
The bucket 22 has spaced side walls 52 and 54, an arcuate rear and bottom wall 56, and a spill plate 58. A front edge 60, as shown in FIG. 1, is disposed forwardly of the wall 56 and the forward extremities 62 of the ribs 30.
Referring to FIG. 2, the side wall 52 of the bucket 22 is provided with a forwardly extending gate 72 which is pivotally mounted to the side wall 52 by a hinge 74 for movement between a first position shown in dotted lines wherein the gate extends forwardly from side wall 52, and a second position wherein the gate extends forwardly and inwardly from side wall 52, as shown in solid lines in FIG. 2. A similar gate 80 is pivotally mounted to the side wall 54 for movement between a similar first position and second position. Hydraulic cylinders 86 and 88 are mounted on the spill plate 58 by brackets 90 and 92 and are pivotally connected to the gates 72 and 80 by arms 94 and 96 thereon, respectively, as by pins 98 and 100.
Extension of the cylinders 86 and 88 pivots the gates 72 and 80, respectively, from their respective first positions to their second positions, thereby partially obstructing the entrance 66 to the bucket 22 so as to effectively narrow the dumping opening.
Loading of the bucket 22 may be accomplished with the gates 72 and 80 disposed in their first positions, thereby providing the dumping opening 66 with its greatest possible width. When the bucket 22 is in its dumping position (shown in FIG. 1) over the receptacle 48, the operator of vehicle 10 may actuate either or both of the cylinders 86 and 88, thereby moving gates 72 and 80 to their second positions so as to narrow the bucket opening.
Either of the gates 72 or 80 may be operated independently of the other, or simultaneously, at the option of the operator. It may be desirable to operate only one of the gates in situations where there is sufficient clearance between one side of the bucket and the corresponding boundary of the receptacle to avoid spillage of material as it is dumped.
The resultant narrowing of the bucket opening limits the outward spread of material as it is dumped from the bucket 22. This will allow the vehicle's operator to position the bucket 22 in a dumping position over receptacle 48 without positioning the center of the bucket substantially centrally of the receptacle.
In cases where the reaceptacle is only slightly wider than the bucket, spillage problems may occur even if the bucket is centered over the receptacle. This is often the case where relatively short dump trucks are used to receive and transport material. Narrowing of the bucket opening as described above acts to restrict the area into which the dumped material will spread, thereby allowing relatively wide buckets to be used with short receptacles.
FIGS. 3-6 illustrate an alternative embodiment of the invention wherein gates 102 and 104 are pivotally mounted to the side walls 52 ad 54 of the bucket 22 as by pins 106 which extend substantially perpendicularly to the walls 52 and 54.
The gates 102 and 104 each include a wedge-shaped plate 108 which extends forwardly of the respective pivot pins 106 and levers 110 which extend rearwardly of the associated pins through the rear wall 56 and which underlie the arms 12. The plates 108 each include a flat bottom 112 and a tapered upper surface 114. As shown in FIG. 6, the surfaces 114 taper both forwardly from the associated pin 106 and inwardly from the corresponding walls 52 and 54. The plates 108 are substantially heavier than the associated levers 110 so as to normally reside in the position illustrated in FIG. 3 due to the influence of gravity.
The gates 102 and 104 are pivotal on pins 106 between a first position wherein the bottom portions 112 are disposed against the bottom of the bucket 22, and a second position wherein the plates 108 extend forwardly and upwardly of the pivot axes defined by pins 106.
Movement of the gates 102 and 104 from the first position to the second position is effected by the abutment of levers 110 against the undersurface 118 of the arms 12 when the arms are moving toward an elevated position, as shown in FIG. 4.
Tilting of the bucket to a dumping position will cause the gates to move fully to their second position, as shown in FIG. 4.
The gates 102 and 104 serve to narrow the effective dumping width of the bucket 22 when the gates are in their second position. Material positioned between the gates and the rear wall 56 will slide inwardly from the side walls 52 and 54 due to the inward taper of the surface 114 of each gate. Thus, the downward flow of material will be substantially limited to the area between the inner edges 120 and 122 of gates 102 and 104 during dumping.
After dumping, the gates 102 and 104 will return to their first positions simply by means of returning the bucket 22 to its loading position (shown in FIG. 3), as the plates 108 are heavier than levers 110 and will pivot from their second positions to their first positions due to the influence of gravity.
From the foregoing, it may be appreciated that a loader made according to the invention will provide a relatively wide loading width while allowing selective narrowing of the dumping width. As a consequence, the need to center the bucket with respect to the receptacle when dumping will be obviated, resulting in economy of time and reduction of spillage.
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A loader, including a vehicle frame, lift arms mounted on the frame for movement between upper and lower positions, and a bucket having a bottom, a rear and spaced sides, said bottom and sides defining a dumping opening, the bucket being mounted on the lift arms for movement therewith, wherein the improvement comprises a gate pivotally mounted to the bucket for movement between a first position wherein the dumping opening is unobstructed, and a second position wherein the dumping opening is partially obstructed so that the dumping opening may be selectively narrowed when the bucket contents are to be dumped in a restricted area.
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